EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).

    Click here

  2. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  3. DRAIN ENGINE COOLANT

    Click here

  4. DRAIN ENGINE OIL

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  5. REMOVE INTERCOOLER AIR HOSE

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  6. REMOVE NO. 2 INTERCOOLER AIR HOSE

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  7. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY

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  8. REMOVE NO. 1 RADIATOR HOSE

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  9. REMOVE RADIATOR RESERVOIR ASSEMBLY

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  10. DISCONNECT NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)

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  11. REMOVE FAN SHROUD

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

    B001FZA

    1. Disconnect the mass air flow meter sub-assembly connector and detach the 2 harness clamps.

    2. Detach the 4 clips.

    3. Loosen the hose clamp and remove the air cleaner cap sub-assembly with air cleaner hose.

  13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner element sub-assembly from the air cleaner case.

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B001I00E01
      Text in Illustration
      *A for Cold Area Specification Vehicles

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

  15. DISCONNECT VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)

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  16. REMOVE WATER HOSE SUB-ASSEMBLY B (w/ Viscous Heater)

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  17. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B001H8H

      for Cold Area Specification Vehicles:

      Slide the 2 clips and remove the water hose from the compressor inlet elbow and No. 3 water by-pass pipe.

    2. B001D8ZE02
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

      Slide the 2 clips and disconnect the 2 water hoses from the oil cooler assembly and No. 2 water bypass pipe.

    3. Remove the bolt and No. 3 water by-pass pipe.

  18. REMOVE PCV PIPE (for Cold Area Specification Vehicles)

    B001HPF

    1. Slide the 2 clips and disconnect the No. 20 water by-pass hose from the compressor inlet elbow and No. 3 water by-pass pipe.

    2. Slide the clip and disconnect the No. 19 water bypass hose from the compressor inlet elbow.

    3. B001I0K

      Remove the bolt and disconnect the PCV pipe from the compression inlet elbow.

    4. B001G7V

      Slide the 2 clips and remove the PCV pipe.

  19. REMOVE PCV HOSE (except Cold Area Specification Vehicles)

    B001IEV

    1. Slide the 2 clips.

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

  20. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  21. DISCONNECT TURBO WATER HOSE

    B001G5A

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

  22. REMOVE OIL COOLER TUBE BRACKET AND WIREHARNESS CLAMP BRACKET


    1. B001EWO

      for Automatic Transmission:

      Remove the bolt and disconnect the oil cooler tube bracket.

    2. B001HKG

      Remove the bolt and disconnect the wire harness.

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

    B001DNB

    1. Remove the detach the clamp and disconnect the wire harness.

    2. B001G5P

      Remove the bolt and disconnect the No. 4 engine harness.

      Text in Illustration
      B001CHY No. 1 Viscous Heater Bracket Sub-assembly Bolt
      B001DEF No. 4 Engine Harness Bolt

    3. Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly.

  24. REMOVE TURBOCHARGER STAY

    B001G8Z

    1. for Type A:


      1. Remove the 3 bolts and nut.

      2. Using an E8 "TORX" socket wrench, remove the stud bolt and turbocharger stay.

    2. for Type B:

      Remove the 3 bolts, nut and the turbocharger stay.

  25. REMOVE TURBO OIL OUTLET PIPE

    B001DAU

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

    2. except Cold Area Specification Vehicles and w/ Cover

      Remove the cover from the turbo oil outlet pipe.

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

  26. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    B001I0U

    1. Remove the union bolt and gasket.

    2. B001DWZ

      Remove the 2 nuts and the turbo oil inlet pipe subassembly.

      Note

      Do not loosen the nut labeled A.

    3. Remove the gasket.

  27. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B001HQ2

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket from the exhaust manifold.

  28. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  29. REMOVE EXHAUST MANIFOLD

    B001GYN

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

    2. Remove the gasket.

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

    B001F52

    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. B001INI

      Remove the 2 nuts, turbo water pipe sub-assembly and gasket.

  31. REMOVE COMPRESSOR INLET ELBOW


    1. B001DI0E01
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

      Remove the 2 bolts and compressor inlet elbow stay.

    2. B001I5UE01
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

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

    3. B001I7FE02
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

      Using an E8 "TORX" socket wrench, remove the stud bolt shown in the illustration together with the compressor inlet elbow and gasket.

  32. REMOVE COMPRESSOR OUTLET ELBOW


    1. B001E3PE01
      Text in Illustration
      *A for Cold Area Specification Vehicles
      *B except Cold Area Specification Vehicles

      Remove the 2 nuts and compressor outlet elbow.

    2. Remove the gasket.

    3. B001CPX

      except Cold Area Specification Vehicles:

      Remove the bolt and hose clamp

  33. DISCONNECT STUD BOLT


    1. B001HQ7

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

      Note

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

    2. B001H0H

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

    3. B001E5N

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