Removal of CAC Assembly

[SteveSter]

Originally posted by: Matt64341

"There really isn't anything about it I would say is extremely hard to do, everything is very accessible, but there is a lot to remove and it can be time consuming. I also highly recommend you get a magnetic tray and maybe a couple of jars to hold bolts while you work because there are so many out it would be very hard not to lose any.

(10mm) disconnect and remove the battery

(10mm) remove plastic "miller cycle" cover and intercooler duct

(colored electrical tape)go towards the back of the engine above where the plastic cover was and mark all your wire connectors on each end and disconnect them

(10mm) remove the battery tray

(12/14mm, Large Pliers on >1996, Flat Screw Driver) remove the front and rear intercoolers (make sure to pull the two plastic harnesses off the back of the rear one - where the flat screw driver might help)

(colored electrical tape) Label the ends of the vac lines and their corresponding places on the ABV actuator.

(12mm) remove all the nuts/bolts attaching the CAC assembly to the engine
You do not want to remove it in pieces, It will come off as an entire unit, with the abv actuator attatched so not every nut and bolt will be removed

(10 or 12mm) unbolt and move rear solenoid bracket assembly out of the way

(colored electrical tape) label and disconnect vacuum lines on abv actuator

(pliers) remove larger diameter hose off abv that goes to a metal piping and the same on the other of the engine going from the vacuum pump to the metal pipe.

(2x10mm open end wrench or 2 pairs of pliers) Unhook and move the accelerator cable out of the way

Move any other obvious connectors or vacuum lines out of the path of removing the CAC assembly

(hardest part) lift the CAC piping and ABV actuator straight up and out as a single unit
This may take some time, make sure as you are going you notice and fix move anything that may be getting in the way. I lifted parts up and stuck a screw driver to hold it, and worked my way around until it all came free.

take plastic walmart bags, cut them in half and stick in the exposed holes to keep anything from getting in the engine (be very careful - there are metal gaskets between the CAC assembly and engine)

now every vacuum hose should be accessible"

This is what it should look like once the CAC assembly is off