TURBOCHARGER (w/o EGR Cooler) REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  4. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  5. DRAIN ENGINE COOLANT (w/ Intercooler)

    Note

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    2. Loosen the cylinder block drain cock plug and the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

      A01DY14E01

  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the 2 bolts and 2 compression springs.

    2. Disconnect the front pipe from the outlet pipe and remove the gasket.

    3. Remove the front pipe from the pipe support.

  7. REMOVE FRONT FENDER APRON SEAL UPPER


    1. Remove the 5 clips and apron seal.

  8. REMOVE FRONT FENDER SEAL


    1. Remove the 5 clips and fender seal.

  9. REMOVE VENTILATION HOSE HEAT INSULATOR (w/o Intercooler)


    1. Remove the 2 bolts and insulator.

  10. REMOVE INTERCOOLER ASSEMBLY

    Click here

  11. REMOVE AIR CLEANER ASSEMBLY


    1. w/ Mass Air Flow Meter:


      1. Disconnect the mass air flow meter connector and detach the wire harness clamp.

        A01E03XE01
        Text in Illustration
        *A w/ Intercooler *B w/o Intercooler

      2. Loosen the hose clamp, and then remove the air cleaner hose from the turbocharger.

      3. w/o Intercooler:

        Disconnect the ventilation hose and remove the 2 bolts and air cleaner.

    2. w/o Mass Air Flow Meter:


      1. A01DV6E

        Remove the clamp and disconnect the intake air temperature sensor connector.

      2. Loosen the clamp of the turbocharger.

      3. Slide the clamp and disconnect the ventilation hose.

      4. Remove the 2 bolts and air cleaner.

  12. REMOVE VENTILATION PIPE (w/ Intercooler)


    1. A01E0R6

      Remove the bolt and ventilation pipe.

  13. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o Intercooler)

    A01E0K7

    1. Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the vacuum hose from the gas filter.

    3. Loosen the 2 clamps.

    4. Remove the bolt and disconnect the pipe together with the 2 air hoses.

  14. REMOVE COMPRESSOR INLET ELBOW (w/ Intercooler)


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

    2. A01DWIU

      Remove the 2 nuts, compressor inlet elbow and gasket.

  15. REMOVE NO. 1 TURBO INSULATOR (w/ Intercooler)


    1. A01E0PK

      Remove the 2 bolts and No. 1 turbo insulator.

  16. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ Intercooler)


    1. A01DYZA

      Remove the bolt and No. 1 exhaust manifold heat insulator.

  17. REMOVE NO. 1 TURBO WATER HOSE (w/ Intercooler)


    1. A01E1F0

      Disconnect the 2 No. 1 turbo water hoses.

  18. REMOVE TURBINE OUTLET ELBOW


    1. A01DVB7E02

      w/o Intercooler:

      Remove the 2 bolts, 4 nuts, outlet elbow (with turbocharger stay) and gasket from the turbocharger.

    2. A01E2CV

      w/ Intercooler:

      Remove the 3 nuts, turbine outlet elbow and gasket.

  19. REMOVE TURBOCHARGER STAY (w/ Intercooler)


    1. A01E2RD

      Remove the 2 bolts, nut and turbocharger stay.

  20. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01DXE2E02

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe and 3 gaskets.

      Note

      Do not loosen the nut labeled A.

  21. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01DWTJE02

      w/o Intercooler:

      Remove the 2 bolts and manifold stay.

    2. Remove the 2 bolts, union and 2 gaskets.

    3. A01DZM3E02

      Remove the 3 nuts, turbocharger (with turbo oil pipe) and gasket.

    4. A01DVX4

      Remove the 2 nuts, turbo oil pipe and gasket from the turbocharger.

    5. A01E0IFE01

      w/ Intercooler:

      Remove the 3 nuts, turbocharger and gasket.

  22. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01E2XL

      Remove the 2 nuts, bolt, No. 1 turbo water pipe and gasket.

    2. Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe.