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

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly 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.

      A003HILE01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -
    2. Remove the radiator reservoir cap sub-assembly.

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

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock 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)


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )
  6. REMOVE FRONT DOOR SCUFF PLATE RH

  7. REMOVE FRONT SEAT ASSEMBLY RH


    1. A003DBM

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  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 (w/ Air Conditioning System)


    1. A003FUKE01

      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. A003GDE

      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. A003EG2

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

    2. Disconnect the front exhaust pipe assembly from the No. 4 exhaust pipe support.

    3. Remove the 2 gaskets.

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


    1. A003H3DE02

      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. A003C9R

      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 No. 1 transmission control cable bracket.

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


    1. A003F3C

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

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


    1. A003BEA

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

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


    1. A003FK0

      Remove the 2 nuts from the catalytic with pipe converter assembly.

    2. A003CBO

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

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


    1. A003AT1

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

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

  22. REMOVE TURBINE OUTLET ELBOW (w/ DPF)


    1. A003I4X

      Disconnect the fuel addition injector connector.

    2. Slide the clamp and disconnect the No. 1 turbo water hose from No. 1 injector holder.

    3. A003EC2E01
      Text in Illustration
      *1 No. 3 Fuel Pipe
      *2 No. 4 Water By-pass Pipe
      *3 No. 13 Water By-pass Hose

      Remove the union bolt and gasket and disconnect the No. 3 fuel pipe from the No. 1 injector holder.

    4. Remove the union bolt and gasket and disconnect the No. 4 water by-pass pipe from the No. 2 injector holder.

    5. Slide the clamp and remove the No. 4 water by-pass pipe from the No. 13 water by-pass hose.

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

  23. DISCONNECT NO. 1 AIR CLEANER HOSE


    1. A003B1T

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

  24. REMOVE AIR TUBE ASSEMBLY


    1. A003ESE

      Loosen the 2 hose clamps.

    2. Remove the 2 bolts, air tube assembly and No. 1 air cleaner hose.

  25. DISCONNECT TURBOCHARGER MOTOR CONNECTOR

    A003DA4
  26. REMOVE COMPRESSOR OUTLET ELBOW


    1. A003G3V

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

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


    1. A003FEFE01

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

  28. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A003FBY

      Detach the 3 clamps.

    2. Remove the bolt and wire harness clamp bracket.

  29. REMOVE VENTILATION PIPE


    1. w/ DPF:


      1. A003E8J

        Remove the bolt and ventilation pipe.

      2. Disconnect the 2 ventilation hoses.

    2. w/o DPF:


      1. A003HNF

        for Type A:

        Slide the 2 clamps and remove the No. 14 water by-pass hose from the ventilation pipe and No. 2 water by-pass pipe.

      2. for Type A:

        Slide the clamp and disconnect the No. 4 turbo water hose from the ventilation pipe.

      3. A003H0QE01
        Text in Illustration
        *A for Type A
        *B for Type B

        Remove the bolt and ventilation pipe.

      4. Disconnect the 2 ventilation hoses.

  30. REMOVE TURBO INSULATOR


    1. A003CTZ

      Remove the 2 bolts and turbo insulator.

  31. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003B96

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

  32. REMOVE TURBINE OUTLET ELBOW STAY


    1. A003EHQ

      w/ DPF:

      Remove the 2 bolts and turbine outlet elbow stay.

    2. A003CD7

      w/o DPF:

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

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


    1. A003C8S

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

  34. REMOVE TURBOCHARGER STAY


    1. A003FB2

      Remove the 2 bolts, nut and turbocharger stay.

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


    1. A003D09

      Remove the 2 bolts and No. 1 automatic transmission oil cooler tube clamp.

  36. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A003BUH

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

      Note

      A003AFA

      Do not loosen the nut as shown in the illustration. If the nut is mistakenly loosened, replace the turbocharger.

  37. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR

    A003G2I
  38. REMOVE TURBOCHARGER


    1. w/ DPF:


      1. A003GZ7

        Slide the 3 clamps and disconnect the 3 turbo water hoses from the No. 5 water by-pass pipe sub-assembly and No. 2 water by-pass pipe.

      2. A003B6H

        Remove the 3 nuts and disconnect the turbocharger.

      3. Temporarily place the turbocharger on the mounting bracket.

      4. A003DK4

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

      5. Remove the turbocharger and gasket.

    2. w/o DPF:


      1. A003CIM

        Remove the 3 nuts and disconnect the turbocharger.

      2. A003D8C

        for Type A:

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

      3. A003HTY

        for Type B:

        Slide the 2 clamps and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the No. 2 water by-pass pipe.

      4. A003F79E01
        Text in Illustration
        *A for Type A
        *B for Type B

        Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.

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

      6. Remove the turbocharger and gasket.

  39. REMOVE COMPRESSOR INLET ELBOW


    1. w/ DPF:


      1. A003BEV

        Slide the clamp and remove the No. 4 turbo water hose from the compressor inlet elbow.

      2. A003EMK

        Remove the 2 nuts, compressor inlet elbow and gasket.

    2. w/o DPF:


      1. A003DER

        for Type A:

        Slide the clamp and remove the No. 4 turbo water hose from the compressor inlet elbow.

      2. A003HLHE01
        Text in Illustration
        *A for Type A
        *B for Type B

        Remove the 2 nuts, compressor inlet elbow and gasket.

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


    1. w/ DPF:


      1. A003BSQ

        Slide the 3 clamps and remove the turbo water hose, No. 2 turbo water hose and No. 13 turbo water hose from the No. 1 turbo water pipe sub-assembly.

      2. A003DZG

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

    2. w/o DPF:


      1. A003BL3

        for Type A:

        Slide the 3 clamps and remove the No. 2 turbo water hose, No. 3 turbo water hose and plug from the No. 1 turbo water pipe sub-assembly.

      2. A003EIP

        for Type B:

        Slide the 2 clamps and remove the No. 1 turbo water hose and No. 2 turbo water hose from the No. 1 turbo water pipe sub-assembly.

      3. A003FUSE01
        Text in Illustration
        *A for Type A
        *B for Type B

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