TURBOCHARGER REMOVAL


  1. REMOVE ENGINE COVER


    1. A0138OOE01

      Disengage the 3 claws and remove the engine cover.

  2. REMOVE ENGINE UNDER COVER


    1. A013649

      Remove the 9 bolts.

    2. Remove the 5 screws and engine under cover.

  3. REMOVE FRONT BUMPER COVER

    A0138CFE01

    1. Apply protective tape to the outer circumference of the front bumper cover, as shown in the illustration.

    2. Using a clip remover, remove the clip.

    3. Remove the 3 bolts, 5 screws and 2 clips.

    4. A01360O

      Disengage the 13 claws and remove the front bumper cover.

    5. A0136YZ

      Remove the 2 clips.

  4. DRAIN ENGINE COOLANT

    Note

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


    1. A01375N

      Remove the drain plug and clip, then drain the engine coolant.

    2. Disconnect the radiator by uncoupling the radiator hose No.2.

    3. A01379O

      Remove the hose clamp, disconnect the water by-pass hose.

    4. Remove the reservoir tank cap sub-assembly.

      A01389E

  5. REMOVE SUPPORT RH SUB-ASSEMBLY

  6. REMOVE SUPPORT LH SUB-ASSEMBLY

  7. DISCONNECT COOLING FAN MOTOR CONNECTOR


    1. A0137JZ

      Disconnect the cooling fan motor connector.

  8. DISCONNECT RESISTOR CONNECTORS (w/ Air Conditioning System)


    1. A0137ZT

      Disconnect the 2 resistor connectors.

  9. DISCONNECT WATER BY-PASS HOSE


    1. A01379O

      Remove the hose clip, and disconnect the water by-pass hose from the radiator assembly.

  10. DISCONNECT RADIATOR HOSE


    1. A0137E8

      Disconnect the radiator hose and clamp from the radiator assembly.

  11. DISCONNECT RADIATOR HOSE NO.2


    1. A0135SS

      Disconnect the radiator hose No.2 and clamp from the radiator assembly.

  12. DISCONNECT CONDENSER ASSEMBLY (w/ Air Conditioning System)


    1. A0136TM

      Remove the 2 bolts, and disconnect the condenser assembly from the radiator assembly.

  13. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A0138MG

      Remove the 6 bolts and front cross member sub-assembly.

  14. REMOVE RADIATOR ASSEMBLY

    Tech Tips

    Click here

  15. REMOVE EXHAUST FRONT PIPE ASSEMBLY


    1. Remove the bolt and clamp.

    2. Remove the exhaust front pipe stay nut and exhaust pipe support No.4.

    3. Remove the nut, clamp and the exhaust front pipe assembly.

      A0137Z8E02

  16. REMOVE TURBO INSULATOR NO.1

    Tech Tips

    Click here

  17. REMOVE MANIFOLD HEAT SHIELD

    Tech Tips

    Click here

  18. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Remove the nut and exhaust manifold converter clamp.

    2. A0136EB

      Remove the 2 nuts, exhaust manifold converter sub-assembly, catalytic converter support bracket and converter separator insulator No.1.

      Tech Tips

      The catalytic converter operates to purify exhaust gas.

  19. REMOVE AIR HOSE


    1. A0137HDE03

      Loosen the clamp bolt.

    2. Using a screwdriver and pliers, remove the clip.

    3. Remove the air hose.

  20. REMOVE INTAKE AIR RESONATOR


    1. A01390W

      Disconnect and remove the water reservoir tube from the intake air resonator.

    2. A0138YRE02

      Disconnect the turbocharger air temperature sensor connector and loosen the clamp.

    3. Remove the bolt.

    4. Using a "torx" socket wrench, remove the screw.

    5. A0135Z7E02

      Turn the intake air resonator, and remove the intake air resonator as shown in the illustration.

    6. Remove the O-ring from the intake air resonator.

  21. DISCONNECT TURBOCHARGER LUBRICATION PIPE


    1. A0137FX

      Using a hexagon socket wrench, remove the union bolt and 2 gaskets.

    2. Disconnect the turbocharger lubrication pipe.

  22. DISCONNECT LUBRICATION RETURN HOSE


    1. A0137VS

      Loosen the clamp.

    2. Disconnect the lubrication return hose.

  23. REMOVE TURBOCHARGER ASSEMBLY


    1. A0136OR

      Remove the 4 nuts.

    2. Remove the turbocharger assembly from the exhaust manifold.