EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)

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  2. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o DPF)

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  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (w/o DPF)

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  4. REMOVE FRONT NO. 1 VENTILATOR SEAL (w/o DPF)

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  5. REMOVE FRONT AIR SHUTTER SEAL RH (w/o DPF)

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  6. REMOVE INNER COWL TOP TO COWL BRACE (w/o DPF)

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  7. REMOVE OUTER COWL TOP PANEL (w/o DPF)

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  8. REMOVE NO. 1 ENGINE COVER (w/o DPF)

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  9. REMOVE NO. 2 ENGINE COVER BRACKET (w/o DPF)

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  10. REMOVE WIRE HARNESS CLAMP BRACKET (w/o DPF)

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  11. REMOVE NO. 1 TURBO INSULATOR (w/o DPF)

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  12. REMOVE MANIFOLD SUPPORT BRACKET (w/o DPF)


    1. A01VHD5

      Remove the 3 bolts and the manifold support bracket.

  13. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


    1. A01VGSR

      Remove the 3 nuts and the exhaust manifold converter sub-assembly.

    2. Remove the turbine outlet elbow gasket from the turbocharger sub-assembly.

  14. REMOVE NO. 1 AIR CLEANER HOSE


    1. A01VEF3

      Loosen the hose clamp and disconnect the No. 1 air cleaner hose from the air cleaner cap.

    2. Disengage the clamp and disconnect the 2 fuel hoses from the No. 1 air cleaner hose.

    3. Loosen the hose clamp and disconnect the ventilation hose from the cylinder head cover sub-assembly.

    4. Loosen the hose clamp and remove the No. 1 air cleaner hose from the compressor inlet elbow sub-assembly.

  15. REMOVE NO. 1 AIR HOSE


    1. A01VLDI

      Loosen the 2 hose clamps and remove the No. 1 air hose from the turbocharger sub-assembly.

  16. REMOVE TURBOCHARGER STAY


    1. A01VLF9

      Remove the 2 bolts, the nut and the turbocharger stay from the turbocharger sub-assembly.

  17. REMOVE MANIFOLD STAY


    1. A01VI0R

      Remove the 2 bolts and the manifold stay from the turbocharger sub-assembly.

  18. SEPARATE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01VI3QE02

      Remove the 2 nuts (A) and separate the turbo oil inlet pipe sub-assembly from the turbocharger sub-assembly.

    2. Loosen the 2 nuts (B) and separate the turbo oil inlet pipe sub-assembly from the cylinder block sub-assembly.

  19. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01VLA3

      Disconnect the 2 connectors of the turbocharger sub-assembly.

    2. A01VKMN

      Remove the 3 nuts and the turbocharger sub-assembly from the exhaust manifold.

    3. A01VLYB

      Remove the turbo to exhaust manifold gasket from the exhaust manifold.

    4. A01VG1K

      Remove the turbo oil inlet gasket from the turbocharger sub-assembly.

    5. A01VJRH

      Remove the 2 nuts and the turbo oil inlet pipe sub-assembly from the cylinder block.

    6. A01VI9O

      Remove the No. 1 turbo oil outlet gasket from the cylinder block.

  20. REMOVE COMPRESSOR INLET ELBOW SUB-ASSEMBLY


    1. A01VF74

      Remove the 3 nuts and the compressor inlet elbow sub-assembly from the turbocharger sub-assembly.

    2. Remove the compressor inlet gasket from the compressor inlet elbow sub-assembly.

  21. REMOVE EXHAUST MANIFOLD


    1. A01VJO9

      Remove the 8 nuts and the exhaust manifold from the cylinder head sub-assembly.

    2. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.