EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. PRECAUTION

    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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  4. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  5. REMOVE ENGINE UNDER COVER

    Click here

  6. DRAIN ENGINE COOLANT

    Click here

  7. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  8. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A004QH2

      Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp sub-assembly from the battery carrier, and then remove the battery clamp sub-assembly.

  9. REMOVE BATTERY INSULATOR

  10. REMOVE BATTERY

  11. REMOVE BATTERY TRAY

  12. REMOVE BATTERY CARRIER


    1. A004U3R

      Detach the 2 clamps and disconnect the engine wire.

    2. Remove the 4 bolts and battery carrier.

  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY


    1. A004QD9E03
      Text in Illustration
      *a Retainer

      Detach the clamp and disconnect the mass air flow meter sub-assembly connector.

    2. Detach the clamp and disconnect the vacuum hose from the air cleaner hose assembly.

    3. Detach the clamp and disconnect the No. 1 fuel hose from the air cleaner hose assembly.

    4. Detach the clamp and disconnect the No. 2 fuel hose from the air cleaner hose assembly.

    5. Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    6. Release the retainer and disconnect the air cleaner hose assembly from the turbocharger sub-assembly as shown in the illustration.

    7. Detach the 2 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  14. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A004TBL

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

  16. DISCONNECT COMPRESSOR OUTLET ELBOW


    1. A004RHNE02
      Text in Illustration
      *a Retainer

      Release the retainer and disconnect the compressor outlet elbow from the turbocharger sub-assembly as shown in the illustration.

  17. REMOVE TURBO OIL OUTLET PIPE


    1. A004RU1

      Remove the 3 bolts, turbo oil outlet pipe and gasket.

    2. Remove the O-ring from the turbo oil outlet pipe.

  18. DISCONNECT NO. 1 TURBO OIL PIPE


    1. A004RJW

      Remove the union bolt and 2 gaskets and disconnect the No. 1 turbo oil pipe.

  19. REMOVE NO. 1 EXHAUST MANIFOLD PIPE


    1. Disconnect the exhaust manifold pressure sensor connector.

    2. A004PDJ

      Remove the union bolt and 2 gaskets.

    3. Remove the bolt and No. 1 exhaust manifold pipe.

  20. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A004TLD

      Disconnect the connector from the turbocharger sub-assembly.

    2. Remove the 4 bolts, turbocharger sub-assembly and gasket.

  21. DISCONNECT ENGINE WIRE


    1. A004NRJ

      Detach the 2 clamps from the No. 1 air tube assembly.

    2. Remove the 2 bolts and disconnect the engine wire from the No. 1 air tube assembly.

  22. REMOVE NO. 4 WATER BY-PASS HOSE


    1. A004TEIE03
      Text in Illustration
      *a Retainer

      Release the retainer and disconnect the No. 4 water by-pass hose from the EGR cooler assembly as shown in the illustration.

    2. Slide the clamp and remove the No. 4 water by-pass hose from the No. 2 radiator pipe.

  23. DISCONNECT NO. 1 AIR TUBE ASSEMBLY


    1. A004Q39

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 2 radiator pipe.

    2. Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 radiator pipe.

    3. Detach the clamp and disconnect the water hose sub-assembly from the compressor outlet elbow.

    4. Slide the clamp and disconnect the water hose sub-assembly from the No. 1 radiator pipe.

    5. Slide the clamp and disconnect the outlet heater water hose from the No. 2 radiator pipe.

    6. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  24. DISCONNECT FUEL FEED PIPE SUB-ASSEMBLY

    Click here

  25. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  26. REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

    Click here

  27. REMOVE EXHAUST MANIFOLD


    1. A004PQK

      Remove the 8 nuts and exhaust manifold.

    2. Remove the 2 gaskets from the cylinder head sub-assembly.