TURBOCHARGER (w/ DPF) REMOVAL


  1. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)

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

    A01KF1Z

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

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

    A01KINS

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

  4. REMOVE REAR FLOOR MAT (for Double Cab)

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

    A01KGPT

    1. Remove the 8 screws and mat set plate.

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

  7. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH

  8. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH

  9. 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 }

  10. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  11. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    A01KIH2

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

  12. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    A01KH9J

    1. Remove the 2 bolts and No. 3 exhaust manifold heat insulator.

  13. REMOVE TURBINE OUTLET ELBOW STAY

    A01KEIN

    1. Remove the 4 bolts and turbine outlet elbow stay.

  14. REMOVE CATALYTIC WITH PIPE CONVERTER ASSEMBLY

    A01KG5U

    1. Remove the 3 nuts and catalytic with pipe converter assembly.

  15. REMOVE NO. 2 FUEL PIPE CLAMP


    1. Loosen the No. 3 fuel pipe union bolt.

    2. Remove the No. 2 fuel pipe clamp bolt, No. 2 fuel pipe clamp and No. 3 fuel pipe clamp bolt.

  16. REMOVE TURBINE OUTLET ELBOW

    A01KIAQ

    1. Disconnect the addition injector connector.

    2. Disconnect the No. 1 turbo water hose.

    3. A01KG26J02
      Text in Illustration
      *1 No. 3 Fuel Pipe
      *2 No. 4 Water By-pass Pipe
      *3 No. 13 Water By-pass Hose

      Remove the No. 4 water by-pass pipe union bolt and gasket.

    4. Remove the No. 3 fuel pipe union bolt and gasket.

    5. Disconnect the No. 4 water by-pass pipe from the No. 13 water by-pass pipe.

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

  17. DISCONNECT NO. 1 AIR HOSE

    A01KHAW

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

  18. REMOVE COMPRESSOR OUTLET ELBOW

    A01KEB4

    1. Loosen the hose clamp.

    2. Remove the bolt and compressor outlet elbow.

  19. REMOVE NO. 2 AIR CLEANER HOSE

    A01KHOK

    1. Disconnect the turbocharger motor connector.

    2. A01KH05

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

  20. SEPARATE ENGINE WIRE HARNESS

    A01KEZH

    1. Disconnect the turbocharger stroke sensor connector.

    2. A01KIQT

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

  21. REMOVE VENTILATION PIPE SUB-ASSEMBLY

    A01KGFJ

    1. Remove the bolt and ventilation pipe sub-assembly.

  22. REMOVE NO. 1 TURBO INSULATOR

    A01KFXV

    1. Remove the 2 bolts and No. 1 turbo insulator.

  23. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A01KHYL

    1. Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  24. REMOVE TURBOCHARGER STAY

    A01KFD3

    1. Remove the 2 bolts, nut and the turbocharger stay.

  25. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    A01KH75E01

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

      Note

      Do not loosen the nut labeled A. If the nut is mistakenly loosened, replace the turbocharger.

  26. REMOVE TURBOCHARGER

    A01KGJR

    1. Disconnect the 3 turbo water hoses.

    2. A01KF0L

      Remove the 3 nuts, turbocharger and gasket.

  27. REMOVE COMPRESSOR INLET ELBOW

    A01KHXY

    1. Remove the No. 4 turbo water hose.

    2. Remove the 2 nuts, compressor inlet elbow and gasket.

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

    A01KGMW

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