EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  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

    Click here

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

    Click here

  4. DRAIN ENGINE COOLANT

    Click here

  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  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

    Click here

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

    Click here

  10. REMOVE FAN AND GENERATOR V BELT

    Click here

  11. REMOVE NO. 1 AIR CLEANER HOSE


    1. B001ICF

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

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    B001D6UE03
    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. B001EB7

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

  15. REMOVE NO. 1 AIR HOSE

    Click here

  16. REMOVE COMPRESSOR OUTLET ELBOW


    1. B001D5Z

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. B001FYV

      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)

    Click here

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

    Click here

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

    Click here

  20. REMOVE GENERATOR ASSEMBLY

    Click here

  21. REMOVE GENERATOR BRACKET

    Click here

  22. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

    Click here

  23. REMOVE VENTILATION PIPE


    1. B001GJY

      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. B001FVVE02
      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. B001EXX

      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. B001DKR

      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.

      B001ERKE01
      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. B001DOZ

      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. B001DC4

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

  29. REMOVE TURBINE OUTLET ELBOW


    1. B001DTQ

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

  30. REMOVE TURBOCHARGER STAY


    1. B001GPZ

      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. B001GIIE02

      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. B001FX0

      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. B001GNM

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

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


    1. B001G1G

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