EXHAUST MANIFOLD W/ TURBOCHARGER (w/o DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


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

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DPA5

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01DNO9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01DMT5E01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 3 nuts and front exhaust pipe.

    2. Remove the gasket.

  6. REMOVE FRONT FENDER APRON SEAL RH


    1. Using a clip remover, remove the 4 clips and front fender apron seal RH.

  7. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Using a clip remover, remove the 5 clips and front No. 1 fender apron to frame seal RH.

  8. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  9. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)


    1. A01DS63

      Remove the 2 bolts and front heater bracket.

  10. REMOVE FAN AND GENERATOR V BELT


    1. Using the pulley set bolt of the tensioner, rotate the tensioner pulley clockwise to loosen the belt tension. Then remove the V belt.

  11. REMOVE NO. 1 AIR CLEANER HOSE


    1. A01DNR2

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

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    A01DTIXE02
    Text in Illustration
    *A except Cold Area Specification Vehicles
    *B for Cold Area Specification Vehicles

    1. except Cold Area Specification Vehicles:

      Detach the 2 clamps and disconnect the mass air flow meter connector.

    2. for Cold Area Specification Vehicles:

      Detach the 3 clamps and disconnect the mass air flow meter connector.

    3. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01DMCQ

      Remove the 3 bolts and air cleaner case sub-assembly.

  15. REMOVE NO. 1 AIR HOSE


    1. A01DTFB

      Loosen the 2 clamps.

    2. Remove the No. 1 air hose from the inlet pipe and intercooler.

  16. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01DTR4

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. A01DS15

      Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.

  17. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)


    1. Disconnect the viscous heater connector.

    2. A01DP9N

      Disconnect the water by-pass hose and water hose.

    3. A01DRFR

      Remove the 2 bolts and viscous heater with magnet clutch.

  18. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. A01DQ4P

      Remove the 4 bolts and No. 1 viscous heater bracket.

  19. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A01DR5G

      Disconnect the compressor connector.

    2. Remove the 4 bolts and disconnect the cooler compressor.

  20. REMOVE GENERATOR ASSEMBLY


    1. A01DT1P

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the generator wire.

    4. Remove the 2 bolts and generator.

  21. REMOVE GENERATOR BRACKET


    1. A01DLWN

      Remove the bolt and generator bracket.

  22. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A01DPQ1

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  23. REMOVE VENTILATION PIPE


    1. A01DQZ6

      Type A

      Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.

    2. A01DM23E01
      Text in Illustration
      *A Type A
      *B Type B

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.

  24. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01DT8L

      Remove the 2 bolts and engine oil level dipstick guide from the cylinder block sub-assembly.

    3. Remove the O-ring from the engine oil level dipstick guide.

  25. REMOVE COMPRESSOR INLET ELBOW


    1. A01DPZN

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket from the water inlet.

    3. Disconnect the 2 connectors and detach the wire harness clamp.

      A01DTACE01
      Text in Illustration
      *A Type A *B Type B

    4. Slide the clamp and disconnect the No. 2 turbo water hose from the No. 1 turbo water hose sub-assembly.

    5. Slide the clamp and disconnect the No. 3 turbo water hose from the No. 2 water by-pass pipe.

    6. Remove the 2 nuts, compressor inlet elbow and gasket from the turbocharger sub-assembly.

  26. REMOVE NO. 1 TURBO INSULATOR


    1. A01DROC

      Remove the 2 bolts and No. 1 turbo insulator from the turbocharger sub-assembly.

  27. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Remove the bolt and No. 1 exhaust manifold heat insulator from the exhaust manifold.

  28. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A01DNMI

      Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.

  29. REMOVE TURBINE OUTLET ELBOW


    1. A01DQ9I

      Remove the 3 nuts, turbine outlet elbow and gasket from the turbocharger sub-assembly.

  30. REMOVE TURBOCHARGER STAY


    1. A01DQXY

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

  31. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01DT27E01

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe sub-assembly and 3 gaskets from the turbocharger sub-assembly and cylinder block sub-assembly.

      Note

      Do not loosen the nut labeled A in the illustration.

  32. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. A01DP60

      Remove the 8 nuts, 8 plate washers and 8 collars from the exhaust manifold with turbocharger sub-assembly.

    2. Remove the exhaust manifold with turbocharger and gasket.

  33. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01DPOM

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

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


    1. A01DPAG

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