TURBOCHARGER (w/o DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


  1. DRAIN ENGINE COOLANT

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  2. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH (for Double Cab)


    1. A01KGS6

      Remove the 5 bolts and remove the fender side apron sub-assembly RH.

  3. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH (for Double Cab)


    1. Remove the 3 bolts and detach the wire harness clamp.

    2. Remove the engine side cover sub-assembly RH from the vehicle.

  4. REMOVE REAR DOOR SCUFF PLATE LH (for Double Cab)

    A01KF1Z

    1. Remove the 3 screws and rear door scuff plate.

  5. REMOVE REAR DOOR SCUFF PLATE RH (for Double Cab)

    A01KINS

    1. Remove the 3 screws and rear door scuff plate.

  6. REMOVE REAR FLOOR MAT (for Double Cab)

  7. REMOVE NO. 4 MAT SET PLATE (for Double Cab)

    A01KGPT

    1. Remove the 6 screws and mat set plate.

  8. REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)

    A01KIQM

    1. Remove the 12 bolts and service hole cover.

  9. SEPARATE FRONT EXHAUST PIPE ASSEMBLY


    1. A01KGYPE02
      Text in Illustration
      *A w/ Heater
      *B w/o Heater

      Remove the 2 bolts and 2 compression springs.

    2. Remove the 2 hangers and front exhaust pipe.

    3. Remove the gasket.

  10. DISCONNECT NO. 1 AIR HOSE


    1. A01KHAW

      Loosen the hose clamp and disconnect the No. 1 air hose.

  11. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01KEB4

      Remove the hose clamp and bolt shown in the illustration and remove the compressor outlet elbow with No. 2 air hose.

  12. DISCONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01KHOK

      Disconnect the turbocharger motor connector from the turbocharger sub-assembly.

  13. REMOVE NO. 2 AIR CLEANER HOSE

    A01KHEKE02
    Text in Illustration
    *A w/ EGR Cooler Bypass Valve
    *B w/o EGR Cooler Bypass Valve

    1. w/ EGR Cooler Bypass Valve:

      Loosen the clip and disconnect the No. 2 ventilation hose.

    2. Loosen the 2 hose clamps and remove the No. 2 air cleaner hose.

  14. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR


    1. A01KEZH

      Disconnect the turbocharger stroke sensor connector from the turbocharger sub-assembly.

  15. SEPARATE ENGINE WIRE HARNESS (for LHD)


    1. A01KG9Q

      Remove the 2 bolts and separate the engine wire harness with bracket.

  16. SEPARATE ENGINE WIRE HARNESS (for RHD)


    1. A01KIQT

      Remove the 2 bolts and separate the engine wire harness with bracket.

  17. REMOVE VENTILATION PIPE (w/ EGR Cooler Bypass Valve)

    A01KFAJ

    1. Remove the bolt and ventilation pipe.

  18. REMOVE VENTILATION PIPE (w/o EGR Cooler Bypass Valve)


    1. A01KGB4

      Remove the bolt and ventilation pipe.

    2. Remove the O-ring.

  19. REMOVE NO. 1 TURBO INSULATOR


    1. A01KGR2

      Remove the 2 bolts and No. 1 turbo insulator.

  20. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01KG7W

      Remove the 2 bolts and No. 1 exhaust manifold heat insulator.

  21. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A01KH3Z

      Loosen the 2 clamps and disconnect the No. 1 turbo water hose.

  22. REMOVE COMPRESSOR INLET ELBOW


    1. A01KEUC

      Remove the 2 bolts, compressor inlet elbow and gasket.

  23. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ EGR Cooler Bypass Valve)

    A01KFSI

    1. Remove the 3 nuts, 2 bolts, exhaust manifold converter sub-assembly and gasket.

  24. REMOVE TURBINE OUTLET ELBOW (w/o EGR Cooler Bypass Valve)

    A01KEND

    1. Remove the 3 nuts, turbine outlet elbow and gasket.

  25. REMOVE TURBOCHARGER STAY


    1. A01KFD3

      Remove the 2 bolts, nut and turbocharger stay.

  26. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KH3BE03
      Text in Illustration
      *A w/ EGR Cooler Bypass Valve
      *B w/o EGR Cooler Bypass Valve

      Remove the 2 bolts, 2 nuts and union bolt, then remove the turbo oil inlet pipe sub-assembly and gasket.

      Note

      Do not loosen the nut labeled A.

  27. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01KH22

      Remove the 3 nuts, turbocharger sub-assembly and gasket.

  28. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01KHXG

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