EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

CAUTION / NOTICE / HINT

Note

w/ DPF:

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines,

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. REMOVE ENGINE ASSEMBLY

    Click here

  4. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE (for Bank 1)


    1. B001WG7

      Remove the 2 bolts and No. 1 engine oil level dipstick guide.

    2. Remove the O-ring from the No. 1 engine oil level dipstick.

  5. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE (for Bank 1)


    1. B001X2O

      Disconnect the 4 connectors.

    2. Using a clip remover, detach the 5 wire harness clamps.

    3. B001WR1

      Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.

  6. REMOVE NO. 2 VENTILATION HOSE (for Bank 1)

    B001ZMNE03
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  7. REMOVE NO. 2 TURBO WATER HOSE (for Bank 1)

    B001YEW

  8. REMOVE BREATHER PLUG RH (for Bank 1)


    1. B001ZKD

      Disconnect the hose.

    2. Detach the clamp and remove the breather plug RH.

  9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 1)


    1. B001WAEE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

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

  10. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE (for Bank 1)

    B001ZJG

  11. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 1)


    1. B001XZ7

      Disconnect the water hose.

    2. Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.

  12. REMOVE NO. 1 TURBOCHARGER STAY (for Bank 1)


    1. B001WPM

      Remove the 2 bolts and No. 1 turbocharger stay.

  13. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)


    1. B001YRU

      Disconnect the hose.

    2. Remove the union bolt, bolt, No. 1 ventilation tube and gasket.

  14. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH (for Bank 1)


    1. B001VYA

      Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.

    2. Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.

      B001Z51E01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    3. Remove the gasket.

    4. B001Z85

      w/ DPF:

      Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.

    5. Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.

      B001VPJE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    6. Remove the gasket from the No. 1 turbocharger.

  15. REMOVE NO. 1 INLET COMPRESSOR ELBOW (for Bank 1)


    1. B001YTA

      Remove the 2 bolts, No. 1 inlet compressor elbow and gasket.

  16. REMOVE NO. 1 TURBO OIL PIPE (for Bank 1)


    1. B001WZ5

      Remove the 2 bolts, No. 1 turbo oil pipe and gasket.

  17. REMOVE NO. 1 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 1)


    1. B001XYL

      Remove the union bolt, bolt, No. 1 inlet turbo oil pipe and gasket.

  18. REMOVE NO. 3 VENTILATION HOSE (for Bank 2)

    B001ZWCE03
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  19. REMOVE BREATHER PLUG LH (for Bank 2)


    1. B001YPDE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the hose.

    2. w/o DPF:

      Detach the clamp.

    3. Remove the breather plug LH.

  20. REMOVE NO. 2 TURBO WATER HOSE (for Bank 2)

    B001VML

  21. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 2)


    1. B001XAUE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

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

  22. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    1. B001XPC

      Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.

  23. REMOVE FRONT WATER BY-PASS JOINT (for Bank 2)


    1. B001YMW

      Remove the front water by-pass joint and gasket.

  24. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    1. B001X99

      Disconnect the water hose.

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

  25. REMOVE NO. 2 OUTLET TURBO OIL HOSE (for Bank 2)

    B001Z8L

  26. REMOVE NO. 2 TURBOCHARGER STAY (for Bank 2)


    1. B001XDQ

      Remove the 2 bolts and No. 2 turbocharger stay.

  27. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY (for Bank 2)


    1. Disconnect the hose.

      B001XDIE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Remove the union bolt, bolt, No. 2 ventilation tube and gasket.

  28. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH (for Bank 2)


    1. B001Z4R

      Disconnect the 2 connectors from the turbocharger.

    2. B001XSB

      Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.

    3. Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.

      B001Y2XE03
      Text in Illustration
      *A w/ DPF *B w/o DPF

    4. Remove the gasket.

    5. B001VUH

      w/ DPF:

      Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.

    6. B001YWWE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.

    7. Remove the gasket from the turbocharger.

  29. REMOVE NO. 2 INLET COMPRESSOR ELBOW (for Bank 2)


    1. B001ZVB

      Remove the 2 bolts, No. 2 inlet compressor elbow and gasket.

  30. REMOVE NO. 2 TURBO OIL PIPE (for Bank 2)


    1. B001ZH0

      Remove the 2 bolts, No. 2 turbo oil pipe and gasket.

  31. REMOVE NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 2)


    1. B001XFI

      Remove the union bolt, bolt, No. 2 inlet turbo oil pipe and gasket.

  32. REPLACE STUD BOLT

    Tech Tips

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


    1. For No. 1 Turbocharger:


      1. Using an E10 "TORX" wrench, replace the stud bolts labeled A and B shown in the illustration below.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      2. Replace the stud bolts labeled C shown in the illustration below.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
        B001X3RE02
    2. B001X1WE02
      *1 20 mm (0.787 in.)
      *2 39.5 mm (1.56 in.)
      *3 14 mm (0.551 in.)

      For No. 2 Turbocharger:

      Using an E10 "TORX" wrench, replace the stud bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. B001VX9E02
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      For Exhaust Manifold LH:

      Using an E10 "TORX" wrench, replace the stud bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }