EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT (w/ DPF)

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

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

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

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

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

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

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

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

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

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

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

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


    1. A01VHD5

      Remove the 3 bolts and manifold support bracket from the exhaust manifold converter sub-assembly and cylinder block sub-assembly.

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


    1. A01VGSR

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

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

  15. 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 to disconnect the No. 1 fuel hose sub-assembly from the No. 1 air cleaner hose.

    3. Slide the hose clip and disconnect the ventilation hose from the cylinder head cover sub-assembly.

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

  16. REMOVE NO. 1 AIR HOSE (w/o DPF)


    1. A01VLDI

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

  17. DISCONNECT NO. 1 TURBO WATER HOSE (w/ DPF)


    1. A01VH9W

      Slide the hose clip and disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.

  18. DISCONNECT NO. 2 TURBO WATER HOSE (w/ DPF)


    1. A01VEFP

      Slide the hose clip and disconnect the No. 2 turbo water hose from the No. 1 turbo water pipe sub-assembly.

  19. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ DPF)


    1. A01VLUG

      Remove the 4 bolts, No. 1 turbo water pipe sub-assembly and gasket from the turbocharger sub-assembly.

  20. REMOVE TURBOCHARGER STAY


    1. A01VG4S

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

  21. REMOVE MANIFOLD STAY


    1. A01VDYO

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

  22. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01VGXYE02

      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.

    3. A01VI4U

      Disconnect the 2 turbocharger sub-assembly connectors.

    4. A01VLCI

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

      Note

      When removing the turbocharger sub-assembly, do not hold it by the electric actuator rod.

    5. A01VK5W

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

    6. A01VLQR

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

    7. A01VI2Y

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

    8. A01VIFB

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

  23. REMOVE COMPRESSOR INLET ELBOW SUB-ASSEMBLY


    1. A01VFJW

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

    2. A01VF9L

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

  24. REMOVE EXHAUST MANIFOLD (w/o DPF)


    1. A01VJO9

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

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

  25. REMOVE EXHAUST MANIFOLD (w/ DPF)


    1. A01VF4Q

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

    2. Remove the 2 bolts and No. 2 manifold support bracket from the cylinder head sub-assembly and cylinder block sub-assembly.

    3. A01VKSM

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

  26. REMOVE STUD BOLT

    Tech Tips

    Only perform this procedure when replacement of the stud bolt is necessary.


    1. A01VDSN

      Using "TORX" socket wrench E10, remove the stud bolt from the exhaust manifold.

    2. A01VDLK

      Using "TORX" socket wrench E10, remove the stud bolt from the turbocharger sub-assembly.

    3. A01VM8P

      Using "TORX" socket wrench E6, remove the 3 stud bolts from the turbocharger sub-assembly.

    4. A01VF8L

      Using a double nut, remove the 3 stud bolts from the turbocharger sub-assembly.

    5. A01VDR0

      Using "TORX" socket wrench E5, remove the 2 stud bolts from the turbocharger sub-assembly.

    6. A01VKOV

      Using "TORX" socket wrench E10, remove the 2 stud bolts from the turbocharger sub-assembly.