TURBOCHARGER REMOVAL


  1. REMOVE NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 4 bolts and No. 1 engine under cover.

  2. REMOVE NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 6 bolts and No. 2 engine under cover.

  3. DRAIN ENGINE COOLANT

    A01BDM5E01

    CAUTION:

    To avoid the danger of being burned, do not remove the reservoir 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. Loosen the radiator drain plug.

    2. Remove the reservoir cap.

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

    4. Tighten the radiator drain plug.

    5. Tighten the cylinder block drain plug (on the engine oil cooler cover).

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

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

  6. REMOVE FRONT DOOR SCUFF PLATE RH

  7. REMOVE FRONT SEAT ASSEMBLY RH

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet and remove the engine service hole sub cover.

  9. REMOVE FENDER APRON MUDGUARD SEAL RH

  10. REMOVE FAN AND GENERATOR V BELT


    1. A01BERGE01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  11. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

  12. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)

  13. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the connector.

    2. A01BFJ0

      Remove the 4 bolts and compressor and magnetic clutch.

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ DPF)

    Click here

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


    1. A01BBS3

      Remove the 2 bolts, 2 nuts and 2 compression springs.

    2. Disconnect the No. 4 exhaust pipe support and front exhaust pipe.

    3. Remove the 2 gaskets.

  16. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)


    1. A01BG2ME02

      Put matchmarks on the transmission control cable assembly and the select outer lever.

    2. Put matchmarks on the transmission control cable assembly and the shift outer lever.

    3. Remove the nut and disconnect the transmission control cable assembly from the select outer lever.

    4. Remove the nut and disconnect the transmission control cable assembly from the shift outer lever.

    5. A01BEXE

      Using a screwdriver, disengage the claws of the 2 clips.

    6. Remove the 2 transmission control cable assemblies and 2 clips from the No. 1 transmission control cable bracket.

  17. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transmission)


    1. Remove the 2 bolts and transmission control cable bracket.

  18. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. A01BCHI

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

  19. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. A01BGA0

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

  20. REMOVE CATALYTIC WITH PIPE CONVERTER ASSEMBLY (w/ DPF)


    1. A01BDMJ

      Remove the 2 nuts from the catalytic with pipe converter.

    2. A01BAA6

      Remove the 3 nuts, catalytic with pipe converter and gasket.

  21. REMOVE NO. 2 FUEL PIPE CLAMP (w/ DPF)


    1. A01BAR5

      Loosen the No. 3 fuel pipe union bolt.

    2. Remove the 2 bolts and No. 2 fuel pipe clamp.

  22. REMOVE TURBINE OUTLET ELBOW (w/ DPF)


    1. A01BHEA

      Disconnect the fuel addition injector connector and No. 1 turbo water hose.

    2. A01BCDGE01

      Remove the 2 union bolts and 2 gaskets from the turbine outlet elbow.

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

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

  23. DISCONNECT NO. 1 AIR CLEANER HOSE


    1. A01BHN9

      Pull the stopper upward and disconnect the No. 1 air cleaner hose from the compressor inlet elbow.

  24. REMOVE AIR TUBE ASSEMBLY


    1. Loosen the 2 hose clamps and remove the 2 bolts, air tube and No. 1 air cleaner hose.

      A01BGSIE01

  25. DISCONNECT TURBOCHARGER MOTOR CONNECTOR

    A01BBX8

  26. REMOVE COMPRESSOR ELBOW STAY


    1. A01BF8X

      Remove the 2 bolts and compressor elbow stay.

  27. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BFP8

      Loosen the 2 hose clamps and remove the bolt and compressor outlet elbow.

  28. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BFLCE01

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  29. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01BFVI

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness clamp bracket.

  30. REMOVE VENTILATION PIPE


    1. A01BGMD

      Remove the bolt and ventilation pipe.

    2. Disconnect the 2 ventilation hoses.

  31. REMOVE TURBO INSULATOR


    1. A01BHJZ

      Remove the 2 bolts and turbo insulator.

  32. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01BEHM

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

  33. REMOVE TURBINE OUTLET ELBOW STAY


    1. A01BD84

      w/ DPF:

      Remove the 2 bolts and turbine outlet elbow stay.

    2. A01BGMC

      w/o DPF:

      Remove the 2 bolts, 2 nuts and turbine outlet elbow stay.

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


    1. A01BAMN

      Remove the 3 nuts, exhaust manifold converter and gasket.

  35. REMOVE TURBOCHARGER STAY


    1. A01BCUS

      Remove the 2 bolts, nut and turbocharger stay.

  36. REMOVE NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)


    1. A01BFAK

      Remove the 2 bolts and clamp.

  37. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BDB5E01

      Remove the 2 bolts, 2 nuts and union bolt, and 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.

  38. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR

    A01BETM

  39. REMOVE TURBOCHARGER


    1. w/ DPF:


      1. A01BGTU

        Disconnect the 3 turbo water hoses.

      2. A01BD3I

        Remove the 3 nuts and disconnect the turbocharger.

      3. Temporarily place the turbocharger on the mounting bracket.

      4. Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

    2. w/o DPF:


      1. A01BD0E

        Remove the 3 nuts and disconnect the turbocharger.

      2. A01BEA3

        Disconnect the 2 turbo water hoses.

      3. A01BARH

        Disconnect the 2 water hoses.

      4. Remove the bolt, 2 nuts, No. 2 water by-pass pipe and gasket.

    3. Remove the turbocharger and gasket.

  40. REMOVE COMPRESSOR INLET ELBOW


    1. w/ DPF:


      1. A01BH17

        Remove the No. 4 turbo water hose.

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

    2. A01BHC9

      w/o DPF:

      Remove the 2 nuts, compressor inlet elbow and gasket.

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


    1. A01BHMPE01

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