EXHAUST SYSTEM

TABLE OF CONTENTS
page page

EXHAUST SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PARTICULATE FILTER
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS TURBOCHARGER SYSTEM
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CATALYTIC CONVERTER TURBOCHARGER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DIAGNOSIS AND TESTING -
REMOVAL TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . 24
RIGHT HAND CATALYTIC CONVERTER . . . . . . . . 7 REMOVAL - TURBOCHARGER . . . . . . . . . . . . . . . . . 24
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LEFT HAND CATALYTIC CONVERTER . . . . . . . . . 8 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . . . . . 10 CHARGE AIR COOLER AND PLUMBING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RIGHT HAND CATALYTIC CONVERTER . . . . . . . 11 DIAGNOSIS AND TESTING - CHARGE AIR
LEFT HAND CATALYTIC CONVERTER . . . . . . . . 12 COOLER SYSTEM - LEAKS . . . . . . . . . . . . . . . . . 30
HEAT SHIELDS REMOVAL - CHARGE AIR COOLER . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION - CHARGE AIR COOLER . . . . . . . . 31
MUFFLER MOTOR-BOOST PRESSURE SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL
RESONATOR - 5.7L SERVOMOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SERVOMOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RESONATOR - 6.1L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 EXHAUST SYSTEM
DESCRIPTION
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EXHAUST SYSTEM - V6 SINGLE SYSTEM

1 - BALL FLANGE
2 - CATALYTIC CONVERTER ASSEMBLY
3 - CROSS BRACE
4 - BAND CLAMPS
5 - RH REAR MUFFLER AND RESONATOR
6 - ISOLATORS

The exhaust system consists of two front close coupled catalytic converters, a RH rear muffler and resonator
assembly (5), and on vehicles equipped with dual exhaust, LH resonator and tailpipe assembly (4).
 EXHAUST SYSTEM - V8 DUAL SYSTEM

1 - LH REAR RESONATOR AND TAIL PIPE

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2 - ISOLATOR
3 - BALL FLARE FLANGE 5.7L / BALL FLARE BAND CLAMP 6.1L
4 - RH REAR MUFFLER AND RESONATOR
5 - BAND CLAMPS
6 - CATALYTIC CONVERTER ASSEMBLY
7 - BALL FLANGE

Both catalytic converters attach directly to the exhaust manifold using studs and nuts. The exhaust down pipes exit
the converters and connect into the rear muffler and resonator (1 and 4). On the 2.7L/3.5L equipped vehicles, there
is a flex coupler directly behind the LH catalytic converter. The upstream oxygen sensors are located in each
exhaust manifold. On 5.7L equipped vehicles there is a flex coupler behind both LH and RH catalytic converters.
The downstream oxygen sensors are located behind the flex couplers. The 6.1L does not use flex couplers. The
downstream oxygen sensors are located behind the catalytic converters.
For the single exhaust systems, the RH muffler, resonator and tailpipe (4) are one single unit.

DIAGNOSIS AND TESTING

EXHAUST SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

EXCESSIVE EXHAUST NOISE 1. Exhaust manifold cracked or 1. Replace manifold.

(UNDER HOOD) broken.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR tube to manifold gasket 3. Tighten fasteners or replace
leakage. gasket.
4. EGR Valve to EGR tube gasket 4. Tighten fasteners or replace
leakage. gasket.
5. Exhaust to manifold leak. 5. Tighten or replace nuts
6. Pipe and shell noise from front 6. Characteristic of single wall pipe.
exhaust pipe.

EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
 CONDITION POSSIBLE CAUSES CORRECTION

2. Burned or rusted out muffler 2. Replace muffler and resonator

assembly or exhaust pipe. assembly and/or LH rear resonator
and tailpipe assembly as necessary.
3. Burned or rusted out 3. Replace replace RH muffler and
resonator(s). resonator assembly and/or RH
resonator and tailpipe as necessary.
4. Restriction in exhaust system. 4. Remove restriction if possible, or
replace components as necessary.
5. Converter material in muffler or 5. Replace replace RH muffler and
resonators. resonator assembly and/or RH
resonator and tailpipe as necessary.
Check fuel injection and ignition
systems for proper operation.

INSPECTION
Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corro-
sion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for
cracks and corrosion damage.

NOTE: Slip joint band clamps are spot/tack welded to exhaust system. If a band clamp must be replaced,
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the spot/tack weld must be ground off.

ADJUSTMENTS
A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust system com-
ponents. These noises are sometimes hard to distinguish from other chassis noises. Inspect exhaust system for
broken or loose clamps, heat shields, isolators, and brackets. Replace or tighten as necessary. It is important that
exhaust system clearances and alignment be maintained.
Perform the following procedures to align the exhaust system:
1. Loosen clamps and support brackets.
2. Align the exhaust system starting at the front, working rearward.
3. Tighten all clamps and brackets once alignment and clearances are achieved.
 SPECIFICATIONS
TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Nut - Catalytic Converter
12 - 106
to Ball Flange Snug fit
Nut - Catalytic Converter
34 25 -
to Ball Flange
Band Clamp 50 36 -
Nut - Catalytic Converter
55 40 -
to Support Bracket
Fasteners - Exhaust
25 - 215
Support Bracket
Retainers - Heat Shield 10 - 98
Nuts - Tunnel 25 - 215
Reinforcement
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 SPECIAL TOOLS

Back Pressure Test Adapter - CH8519

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DRB III & PEP Module - OT-CH6010A

Pressure Transducer CH7063

 CATALYTIC CONVERTER
DESCRIPTION
The close coupled, three-way catalytic converter inlets
are connected to the exhaust manifolds by the use of
ball flange (1). The 2.7L and 3.5L RWD vehicles incor-
porate a flex joint downstream of the LH catalytic con-
verter to improve NVH. The 5.7L equipped RWD
vehicles incorprate a flex joint downstream of the LH
and RH catalytic converters. The 6.1L equipped RWD
vehicles do use a flex joint downstream of the LH and
RH catalytic converters.The left (4) and right (2) side
converter outlet pipe connects to the exhaust system.
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REMOVAL
RIGHT HAND CATALYTIC CONVERTER
WARNING: The normal operating temperature of
the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

1. Disconnect negative battery cable.

2. Raise vehicle on hoist.
3. Disconnect downstream oxygen sensor (2) connec-
tors.
4. Remove muffler and resonator (Refer to 11 -
EXHAUST SYSTEM/MUFFLER - REMOVAL).
 5. 2.7L/3.5L Only - Remove nuts and cross-brace (2).
6. Remove catalytic converter to ball flange nuts (1).
7. Remove catalytic converter (3).

LEFT HAND CATALYTIC CONVERTER

1. Raise vehicle on hoist.
2. Hoist vehicle.
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WARNING: The normal operating temperature of

the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

3. Disconnect downstream oxygen sensor electrical

connectors.
4. Remove muffler and resonator assembly (Refer to
11 - EXHAUST SYSTEM/MUFFLER - REMOVAL).
5. Remove ball flange nuts.
6. Remove catalytic converter ball fange nut.
7. Remove catalytic converter.
 REMOVAL - DIESEL
WARNING: The normal operating temperature of
the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. Special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

1. Disconnect negative battery cable.

2. Raise vehicle on hoist.
3. Disconnect differential pressure ports (2).
4. Disconnect exhaust temperature sensors (3).
5. Disconnect downstream oxygen sensor connectors
(4).

6. Remove exhaust from the diesel particulate filter

(5).
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7. Remove mounting bolts (4) and (7).

8. Remove the nuts from the down pipe (2).
9. Remove the catalyst assembly.
 INSTALLATION - DIESEL
WARNING: The normal operating temperature of
the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. Special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

1. Install the catalyst assembly.

2. Install the nuts to the down pipe (2).
3. Install mounting bolts (4) and (7).
4. Install exhaust onto the diesel particulate filter (5).

5. Connect downstream oxygen sensor connectors

(4).
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6. Connect exhaust temperature sensors (3).

7. Connect differential pressure ports (2).
8. Connect negative battery cable.

INSPECTION
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THERE-
FORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPE-
CIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE
TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATION TIME.

Check catalytic converter for a flow restriction. (Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS AND TESTING)
Exhaust System Restriction Check for procedure.
Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and
insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect
element for cracked or melted substrate.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter
failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test
procedures.
 INSTALLATION
RIGHT HAND CATALYTIC CONVERTER
1. Install catalytic converter (3) onto exhaust manifold
ball flange. Only finger tighten nuts at this time.
2. Install muffler and resonator assembly (Refer to 11
- EXHAUST SYSTEM/MUFFLER - REMOVAL).
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3. Install bolts and cross brace (3). Tighten bolts to 55

N·m (40 ft. lbs.).
4. TIghten manifold ball flange nut to 12 N·m (106 in.
lbs.).
5. Check clearance between exhaust module and fuel
tank. Clearance is 14mm (.55 in.) for V8 engine
and 16mm (.62 in.) for V6 engine.
6. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
7. Adjust clearance as necessary.
8. Tighten ball flange nuts to 34 N·m (25 ft. lbs.).
9. Connect oxygen sensor (2) connectors.
10. Lower vehicle.
11. Connect negative battery cable.
12. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
 LEFT HAND CATALYTIC CONVERTER
1. Install catalytic converter (3) onto exhaust manifold
ball flange. Only finger tighten nuts at this time.
2. Install muffler and resonator assembly (Refer to 11
- EXHAUST SYSTEM/MUFFLER - INSTALLA-
TION).
3. Install bolts and cross brace. Tighten bolts to 55
N·m (40 ft. lbs.).
4. Tighten manifold ball flange nut to 12 N·m (106 in.
lbs.).
5. Check clearance between exhaust module and fuel
tank. Clearance is 14mm (.55 in.) for V8 engine
and 16mm (.62 in.) for V6 engine.
6. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
7. Adjust clearance as necessary.
8. Tighten ball flange nuts to 34 N·m (25 ft. lbs.).
9. Lower vehicle.
10. Connect negative battery cable.
11. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
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 HEAT SHIELDS
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR
ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL
CARE SHOULD BE TAKEN WHEN WORKING
NEAR THE CATALYTIC CONVERTER. THE TEM-
PERATURE OF THE CONVERTER RISES TO A
HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATION TIME.

1. Raise vehicle.
2. Remove nuts (2).
3. Remove heat shields (1).
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INSTALLATION
1. Position heat shields (1).
2. Install nuts (2). Tighten nuts to 10 N·m (98 in. lbs.).
 MUFFLER
DESCRIPTION
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EXHAUST PIPE ASSEMBLY V6

1 - BALL FLANGE
2 - CATALYTIC CONVERTER ASSEMBLY
3 - CROSS BRACE
4 - BAND CLAMPS
5 - RH REAR MUFFLER AND RESONATOR
6 - ISOLATORS

The 2.7L/3.5L exhaust pipe assembly consists of:

Muffler and resonator assembly module (5)
Isolators (6)
The muffler and resonator assembly is serviced as an assembly.
 1 - BALL FLANGE
2 - FRONT EXHAUST PIPE MUFFLER AND RESONATOR ASSEMBLY
3 - BAND CLAMPS
4 - ISOLATOR
5 - RH REAR RESONATOR AND TAILPIPE ASSEMBLY
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The 5.7L RH muffler and tailpipe assembly consists of:

Front exhaust pipe and muffler (2) and resonator (5)
Ball flange (1)
Isolators (4)
Band clamps (3)
The muffler and resonator assembly is serviced as an assembly.

1 - BALL FLARE BAND CLAMP

2 - FRONT EXHAUST PIPE MUFFLER AND RESONATOR ASSEMBLY
3 - BAND CLAMPS
4 - ISOLATOR
5 - RH REAR RESONATOR AND TAILPIPE ASSEMBLY

The 6.1L RH muffler and tailpipe assembly consists of:

Front exhaust pipe and muffler (2) and resonator (5)
 Band clamp(1)
Isolators (4)
Band clamps (3)
The muffler and resonator assembly is serviced as an assembly.

REMOVAL
1. Raise vehicle.
2. Remove catalytic converter to muffler and resona-
tor clamps (2).
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3. Remove nuts (1) and tunnel reinforcement (2).

 4. 5.7L/6.1L Engine - Remove LH resonator and tailpipe assembly (Refer to 11 - EXHAUST SYSTEM/RESONATOR
- REMOVAL).
5. Remove isolators (4).
6. Remove muffler and tailpipe assembly (5) by twisting/turning while pulling assembly out of catalytic converters.
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INSTALLATION
1. Position front exhaust pipe module clamps (2) on
exhaust pipe assembly.
2. Install exhaust pipe assembly into catalytic convert-
ers (3 and 4).

NOTE: Isolators will have an approximately 10°

forward angle when installed.

3. Install isolators.
 4. 5.7L/6.1L Engine - Install LH rear resonator and tailpipe assembly (Refer to 11 - EXHAUST SYSTEM/RESONA-
TOR - INSTALLATION).

NOTE: Check for proper alignment and clearance to underbody and engine compartment components
before tightening clamps.
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5. Tighten band clamps to 61 N·m (45 ft. lbs.).

6. Install tunnel reinforcement (2) and nuts (1).
Tighten nuts to 25 N·m (215 in. lbs.)
7. Check clearance between muffler and resonator
assembly and fuel tank. Clearance is 14mm (.55
in.) for V8 engine and 16mm (.62 in.) for V6
engine.
8. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
9. The tailpipe should be centered in the rear fascia
opening.
10. Adjust clearance as necessary.
11. Lower vehicle.
12. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
 RESONATOR - 5.7L
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR
ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL
CARE SHOULD BE TAKEN WHEN WORKING
NEAR THE CATALYTIC CONVERTER. THE TEM-
PERATURE OF THE CONVERTER RISES TO A
HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATION TIME.

1. Raise vehicle.
2. Remove two nuts (2).
3. Remove isolators (1).
4. Remove LH resonator and tailpipe assembly (5).
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INSTALLATION
1. Position LH resonator and tailpipe assembly (5) in
vehicle.
2. Install isolators (1).
3. install ball flange nuts (2). Tighten nuts finger tight.
4. Check clearance between muffler and tailpipe
assembly and fuel tank. Clearance is 14mm (.55
in.) for V8 engine and 16mm (.62 in.) for V6
engine.
5. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
6. The tailpipe should be centered in the rear fascia
opening.
7. Tighten ball flange nuts (2) to 47 N·m (35 ft. lbs.).
8. Lower vehicle.
9. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
 RESONATOR - 6.1L
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR
ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL
CARE SHOULD BE TAKEN WHEN WORKING
NEAR THE CATALYTIC CONVERTER. THE TEM-
PERATURE OF THE CONVERTER RISES TO A
HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATION TIME.

1. Raise vehicle.
2. Remove the bolt (2).
3. Remove isolators (1).
4. Remove LH resonator and tailpipe assembly (5).
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INSTALLATION
1. Position LH resonator and tailpipe assembly (5) in
vehicle.
2. Install isolators (1).
3. install ball clamp bolt (2). Tighten bolt finger tight.
4. Check clearance between muffler and tailpipe
assembly and fuel tank. Clearance is 14mm (.55
in.) for V8 engine.
5. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
6. The tailpipe should be centered in the rear fascia
opening.
7. Tighten ball clamp bolt (2) to 47 N·m (35 ft. lbs.).
8. Lower vehicle.
9. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
 PARTICULATE FILTER
DESCRIPTION
A diesel particulate filter (1) DPF is installed for
exhaust gas after-treatment. The DPF is located
downstream of the main oxidation catalyst (5). The
DPF filters, stores and burns particulate matter (soot)
that is generated during the combustion process. The
soot is oxidized to carbon dioxide CO2 at exhaust
temperatures over 600° C (1,112° F).
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OPERATION
The oxidation catalysts raise the exhaust gas temper-
atures to regenerate the DPF (1), which is passive
regeneration. If the passive regeneration cannot keep
up with the build up of soot in the DPF, the ECM will
actively regenerate the DPF to burn off the soot. Res-
idue remains inside the DPF in the form of non burn-
able ash. Ash comes from the oils and other materials
that are trapped in the oils and are present in the
soot. Ash is not eliminated by the regeneration cycle.
Excessive ash accumulation requires the replacement
of the DPF. The DPF uses a silicon carbide wall-flow
monolith with a platinum coating to trap particulates.
The monolith contains a large number of square par-
allel channels, which run in the axial direction and are
separated by thin porous walls. The channels are
alternatively open at one end, but plugged at the
other. The exhaust gases flow through the walls and
escape through the pores in the wall material. Partic-
ulates, however, are too large to escape and are
trapped in the monolith walls. The ECM starts the
regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition
of the DPF based upon the exhaust gas pressure upstream (2) and downstream (2) of the DPF. A pressure differ-
ential sensor (2) provides the pressure input to the ECM. During the regeneration process, the ECM raises the
temperature in the DPF to burn off the soot accumulated. Under normal operation, the engine does not produce
enough heat to oxidize the soot inside the DPF. This process requires temperatures above 550 °C (1,022 °F). After
regeneration, the ECM reads the actual pressure difference at the DPF and compares it with a reference value.
From this comparison, the ECM determines the ash quantity inside the DPF.
 REMOVAL
WARNING: The normal operating temperature of
the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

1. Disconnect negative battery cable.

2. Disconnect differential pressure ports (2).
3. Remove exhaust from the diesel particulate filter
(1).
4. Remove the catalyst to diesel particulate filter fas-
teners.
5. Remove the diesel particulate filter assembly.

INSTALLATION
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WARNING: The normal operating temperature of

the exhaust system is very high. therefore, never
work around or attempt to service any part of the
exhaust system until it is cooled. special care
should be taken when working near the catalytic
converter. The temperature of the converter rises
to a high level after a short period of engine oper-
ation time.

1. Install the diesel particulate filter assembly (1).

2. Install the catalyst to diesel particulate filter fasten-
ers.
3. Reconnect the exhaust to the diesel particulate fil-
ter (1).
4. Connect differential pressure ports (2).
5. Connect negative battery cable.
 TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part and must not be tampered with. The actuator bracket is
an integral part of the turbocharger. Tampering with the actuator or other components can reduce durability
by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure.
Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger
boost WILL NOT increase engine power.

The turbocharger used on this vehicle is of the variable turbine type. These turbochargers use the entire exhaust
energy to boost efficiency of the turbocharger and the engine.
The advantages of a turbocharger with variable turbine geometry are:
Higher charge pressure already in the lower and in upper engine speed ranges.
Higher torque as a result of improved cylinder charge.
Reduction in exhaust emissions as a result of an improvement in the air supply of the engine.
Increased power output as a result of the higher charge pressure combined with a reduced exhaust back pres-
sure and thus improved charge cycle.

OPERATION
The exhaust gases of the engine are directed through
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the exhaust manifold into the turbine housing (6) onto

the turbine wheel (7). The flow energy of the exhaust
gases cause the turbine wheel (7) to rotate. Conse-
quently, the compressor wheel, which is connected
through the turbine shaft with the turbine wheel (7), is
driven at the same speed. The fresh air (A) inducted
by the compressor wheel is compressed and passed
to the engine.
The charge pressure is controlled by varying the posi-
tion of the guide vanes (2). The guide stud (3) of the
control linkage of the boost pressure actuator turns
the adjusting ring (5) in the turbine housing (6). As a
result, all the guide vanes (3) whose guide studs (4)
likewise mesh into the adjusting ring (5), are also
turned.
At low speeds, the flow cross-section is reduced by
closing the guide vanes (2). Consequently the speed
at which the exhaust gas impacts on the turbine wheel
(7) is increased, as a result of which the speed of the turbocharger and thus the charge pressure rises.
At high engine speeds the guide vanes (2) are increasingly opened and the flow cross-section is thus enlarged, as
a result of which the speed of the turbocharger reduces and the charge pressure drops.
The turbocharger guide veins are controlled by the electronic actuator. The ECM monitors the boost and charge air
changes to the turbocharger system during operation. The ECM sends a PWM signal to the actuator. The actuator
will then respond to the signal adjusting the guide veins.
 TURBOCHARGER
DIAGNOSIS AND TESTING - TURBOCHARGER
NOTE: Some horizontal and lateral movement of the turbine wheel is normal operation and should not be
confused with premature turbocharger bearing failure.

The turbocharger is not adjustable and has no replacable internal components. If a failure is determined, replace the
turbocharger.

CONDITION POSSIBLE CAUSES CORRECTION

CONDITION A Possible Cause 1 Correction 1

Possible Cause 2 Correction 2

CONDITION B Possible Cause 1 Correction 1
Possible Cause 2 Correction 2

REMOVAL - TURBOCHARGER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
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NEVER WORK AROUND OR ATTEMPT TO SER-

VICE ANY PART OF THE EXHAUST SYSTEM UNTIL
IT IS COOL. CARE SHOULD BE TAKEN WHEN
WORKING NEAR THE TURBOCHARGER. THE
TEMPERATURE OF THE TURBOCHARGER RISES
TO A HIGH LEVEL AFTER A SHORT PERIOD OF
ENGINE OPERATION TIME.

NOTE: THERE IS NO PROCEDURE FOR REPAIR-

ING THE TURBOCHARGER. IF DAMAGE IS FOUND
DURING INSPECTION, THE TURBOCHARGER
MUST BE REPLACED.

1. Disconnect negative battery cable.

2. Remove the engine trim cover.
3. Remove air intake tube (air cleaner to turbo) (1).
4. Remove engine cover front bracket (2).
5. Remove air tube (turbo to cooler) (3).
6. Remove the turbo heat shield (4).
 7. Remove the exhaust clamp (elbow to converter)
(1).

8. Remove the turbo front bracket retaining bolts (1).

9. Drain cooling system (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE).
10. Disconnect the downstream catalytic converter at
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the extension pipe.

11. Disconnect the extension pipe to muffler.
12. Disconnect O2 sensor wire connector.
13. Reposition extension pipe and catalytic converter.
14. Lower vehicle and disconnect catalytic converter
to downstream catalytic converter clamp.
15. Remove upstream catalytic converter.
16. Disconnect transmission fill tube and trim cover
bracket and set aside.

17. Disconnect exhaust elbow at turbo (2).

18. Disconnect EGR tube at manifold to left cylinder
head (3).
19. Remove left and right exhaust manifold retaining
bolts and gaskets (4).
 20. Remove front turbo retaining bolts (1).
21. Remove turbo mount retaining bolts.
22. Remove turbo.
23. Disconnect turbo boost pressure servo connector
(2).

INSPECTION
Visually inspect the turbocharger and exhaust manifold
gasket surfaces. Replace stripped or eroded mounting
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studs.
1. Visually inspect the turbocharger for cracks. The
following cracks are NOT acceptable:
Cracks in the turbine and compressor housing
that go completely through.
Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
Cracks in the mounting flange that intersect bolt
through-holes.
Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
2. Visually inspect the impeller and compressor wheel
fins for nicks, cracks, or chips. Note: Some impel-
lers may have a factory placed paint mark which, after normal operation, appears to be a crack. Remove this
mark with a suitable solvent to verify that it is not a crack.
3. Visually inspect the turbocharger compressor housing for an impeller rubbing condition. Replace the turbocharger
if the condition exists.
 4. Measure the turbocharger end play:
a. Install a dial indicator (1) as shown. Zero the
indicator at one end of travel.
b. Move the impeller shaft fore and aft and record
the measurement. Allowable end play is 0.026
mm (0.0001 in.) MIN. and 0.127 mm (0.005 in.)
MAX. If the recorded measurement falls out-
side these parameters, replace the turbo-
charger assembly.

5. Measure the turbocharger bearing radial clearance:

a. Insert a narrow blade or wire style feeler gauge
(1) between the compressor wheel and the
housing.
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b. Gently push the compressor wheel toward the

housing and record the clearance.
c. With the feeler gauge in the same location,
gently push the compressor wheel away from
the housing and again record the clearance.
d. Subtract the smaller clearance from the larger
clearance. This is the radial bearing clearance.
e. Allowable radial bearing clearance is 0.076 mm
(0.003 in.) MIN. and 0.102 mm (0.040 in.)
MAX. If the recorded measurement falls out-
side these specifications, replace the turbo-
charger assembly.
 INSTALLATION
1. Reconnect turbo boost pressure servo connector
(2).
2. Position and install the turbocharger on the exhaust
manifold, tighten the retainers to 30N.m (22 lbs.ft.).

CAUTION: Make sure the gasket is installed prop-

erly or the turbo oil feed hole will be blocket.

3. Install front turbo retaining bolts and gasket and

install turbo (1).

4. Install left and right exhaust manifold retaining bolts

and gaskets (4).
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5. Reconnect EGR tube at manifold to left cylinder

head (3).
6. Reconnect EGR tube at manifold to left cylinder
head (3).
7. Reconnect transmission fill tube and trim cover
bracket and set aside.
8. Install upstream catalytic converter.
9. Raise vehicle and reconnect catalytic converter to
downstream catalytic converter clamp.
10. Install extension pipe and catalytic converter.
11. Reconnect O2 sensor wire connector.
12. Reconnect the extension pipe to muffler.
13. Reconnect the downstream catalytic converter at
the extension pipe.
14. Refill cooling system (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE).
15. Lower vehicle, install the turbo front bracket retaining bolts (2).
 16. Install the exhaust clamp (elbow to converter) (1).

17. Install the turbo heat shield (4).

18. Install air tube (turbo to cooler) (3).
19. Install engine cover front bracket (2).
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20. Install air intake tube (air cleaner to turbo) (1).

21. Install the engine trim cover.
22. Reconnect negative battery cable.
 CHARGE AIR COOLER AND PLUMBING
DESCRIPTION
The charge air system consists of a inlet air compressor which is part of the turbocharger housing, charge air cooler
locate in front of the radiator, and charge air cooler plumbing. The is also a electronic control valve placed after the
charge air cooler, inline, that assists with air flow during the EGR operating mode.
The charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake
air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature
increases engine efficiency and power. Refer to (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
OPERATION).

OPERATION
Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Once inside the housing
the air is compressed by the rotation of the turbine wheel. The turbine wheel is driven by exhaust gasses, Refer to
(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - OPERATION) to understand the turbine speed
operation.
This air compression process causes heat. Pressurized air (charge air) from the turbocharger then flows forward
through the charge air cooler, located in front of the radiator, to be cooled by the air flow from vehicle motion rush-
ing past the cooler fins. From the charge air cooler the air flows back into the intake manifold, past an air control
valve that assists in EGR mode. There are also resonators located in the charge air stream that assist with air flow
and noise suppression.
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DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS

NOTE: Slight engine oil pooling in the charge air inlet hose IS NOT premature turbocharger failure. Slight
pooling is the normal result of the breather system. Test the air breather tube for normal operation by refer-
ring to the appropriate diagnostic manual.

Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or
it’s plumbing. The following procedure outlines how to check for leaks in the charge air cooler system.
1. Loosen clamp and remove turbocharger to air inlet duct rubber sleeve from turbocharger.
2. Insert Special Tool 9556 Adapter into the rubber sleeve. Tighten existing clamp to 8 N·m (72 in. lbs.).
3. Separate the breather hose at the breather heater and block off.
4. Remove the oil level indicator and block off tube.

CAUTION: Do not apply more then 0.6 bar (10 psi) air pressure to the charge air cooler system, sever dam-
age to the charge air cooler system may occur.

5. Connect regulated air supply to air fitting on Special Tool 9556 Adapter. Set air pressure to approximately 0.6 bar
(10 psi).
6. Using soapy water check the air inlet ducts, rubber sleeves, charge air cooler and intake manifold for leaks.

REMOVAL - CHARGE AIR COOLER

WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT.

NOTE: Note the location of the rubber air charge cooler to A/C condenser and air charger cooler to radiator
air seals. The seals are use to prevent overheating and improve charge air and A/C efficiency.

1. Disconnect the battery negative cables.

2. Remove cooling module (Refer to 7 - COOLING/ENGINE/RADIATOR - REMOVAL).
3. Remove the front grill.
4. Mark the position of the radiator upper cross member and remove cross member.
5. Unbolt the transmission auxiliary cooler and power steering cooler from the charge air cooler and set aside.
 6. Remove the boost tubes from the charge air cooler.
7. Remove power steering reservoir retaining bolt, and set reservoir aside.
8. Remove the charge air cooler bolts.

NOTE: Care must be taken not to damage the charge air cooler fins and the fins of other ancillary cooler
components.

9. Pivot the charge air cooler rearward and up to remove.

INSPECTION
Visually inspect the charge air cooler and plumbing for cracks, holes, loose clamps, or damage. Inspect the tubes,
fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit.

INSTALLATION - CHARGE AIR COOLER

1. Position the power steering reservoir along with charge air cooler. Install the bolts and tighten to 2 N·m (17 in.
lbs.).
2. Install cooling module (Refer to 7 - COOLING/ENGINE/RADIATOR - INSTALLATION) (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
3. Install the transmission auxiliary cooler (if equipped) (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER
- INSTALLATION).
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4. Install the power steering cooler.

5. Install the boost tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 N·m (95 in.
lbs.)
6. Align and install upper cross member.
7. Install the front grill (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTALLATION).
8. Connect the battery negative cable.
9. Start engine and check for leaks.
 MOTOR-BOOST PRESSURE SERVO
DESCRIPTION
The turbocharger boost pressure servomotor is bolted to the side of the turbocharger housing and is responsible for
controlling turbocharger boost pressure. It controls the boost pressure by varying the position of the guide vanes.
The servomotor operates in response to a PWM signal from the ECM.

OPERATION
The turbocharger boost pressure servomotor receives
a PWM signal from the ECM.
At low speed, the turbocharger boost pressure servo-
motor reduces the flow cross section of the guide
vanes(2). The speed at which the exhaust gas impacts
on the turbine wheel is increased, as a result of which
the speed of the turbocharger and thus the charge
pressure rises.
At high engine speed, the turbocharger servomotor
increases the flow cross section of the guide vanes(2).
The speed at which the exhaust gas impacts on the
turbine wheel is reduced, as a result of which the
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speed of the turbocharger reduces and the charge

pressure drops.

REMOVAL
SERVOMOTOR
1. Disconnect the negative battery cable.
2. Remove the air cleaner housing.
3. Remove the turbo heat shield.
4. Remove circlip from actuator rod at turbocharger
end (2).
5. Remove mounting bolts and remove servomotor
and actuator rod(3).
6. Remove circlip and actuator rod from servomo-
tor(1).
 INSTALLATION
SERVOMOTOR
1. Install actuator rod onto servomotor (4).
2. Install circlip (1).
3. Position servomotor and actuator rod onto turbo-
charger (5).
4. Install mounting bolts (3). Tighten bolts to 8 N·m
(70 lbs.in).
5. Install circlip on the actuator rod at the turbo-
charger end (2).
6. Connect electrical connector (6).
7. Install the turbo heat shield.
8. Connect negative battery cable.
9. Install air cleaner housing.
10. Connect negative battery cable.
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