TURBOCHARGER REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock.

    2. Loosen the radiator drain cock plug.

      A003DK2E03
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Cap Sub-assembly
      *3 Radiator Reserve Tank Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    3. Remove the radiator cap sub-assembly.

    4. Loosen the cylinder block drain cock plug, and drain the engine coolant.

    5. Tighten the radiator drain cock plug.

    6. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    7. Disconnect the hose from the radiator drain cock.

  3. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Clean and install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  4. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  5. REMOVE PCV HOSE


    1. A003FYQ

      Slide the 2 clips, detach the clamp and remove the PCV hose.

  6. REMOVE PCV HOSE CLAMP


    1. Detach the wire harness clamp and disconnect the 2 clamps.

    2. A003E3D

      Remove the 2 bolts and PCV hose clamp from the timing chain case assembly.

  7. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A003AY6

      Slide the 2 clips and disconnect the No. 3 water by-pass hose and No. 2 water by-pass hose from the oil cooler assembly and water outlet sub-assembly.

    2. Remove the 2 bolts and No. 2 water by-pass pipe sub-assembly.

  8. DISCONNECT TURBO WATER HOSE

    A003C20

    1. Slide the clip and disconnect the No. 1 turbo water hose from the water pump assembly.

    2. Slide the clip and disconnect the No. 2 turbo water hose from the water outlet sub-assembly.

  9. REMOVE OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET


    1. A003AVD

      Remove the bolt and disconnect the oil cooler tube bracket.

  10. REMOVE TURBOCHARGER STAY

    A003DXT

    1. Remove the 3 bolts, nut and turbocharger stay.

  11. REMOVE TURBO OIL OUTLET PIPE

    A003IA9

    1. Slide the 2 clips and disconnect the turbo oil outlet hose from the turbo oil outlet pipe.

    2. Remove the 2 bolts, turbo oil outlet pipe and gasket.

  12. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    A003HMW

    1. Remove the union bolt and gasket.

    2. A003C1J
      A003EISE01

      Remove the 2 nuts and turbo oil inlet pipe sub-assembly.

      Note

      Do not loosen the nut labeled A.

    3. Remove the gasket.

  13. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A003ASM

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket from the turbocharger sub-assembly.

  14. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    1. A003BLU

      Remove the 4 nuts, bolt and No. 1 EGR pipe sub-assembly from the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 gaskets from the exhaust manifold and electric EGR control valve assembly.

    3. A003CTU

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.

  15. REMOVE EXHAUST MANIFOLD

    A003B8W

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

    2. Remove the gasket.

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

    A003ENS

    1. Slide the 2 hose clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the turbo water pipe sub-assembly.

    2. Remove the bolt.

    3. A003EAD

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

  17. REMOVE COMPRESSOR INLET ELBOW


    1. A003D5Y

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

    2. Remove the gasket.

  18. REMOVE COMPRESSOR OUTLET ELBOW


    1. A003GO7

      Remove the 2 nuts and compressor outlet elbow.

    2. Remove the gasket.

  19. REMOVE STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A003F18

      Using an E5 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.

    2. A003DEB

      Using an E8 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.

    3. A003HJ4

      Using an E10 "TORX" socket wrench, remove the 3 stud bolts shown in the illustration.