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 engine 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 ENGINE OIL LEVEL DIPSTICK GUIDE (for Bank 1)


    1. B00198V

      Remove the 2 bolts and engine oil level dipstick guide from the cylinder head sub-assembly and oil pan sub-assembly.

    2. Remove the O-ring from the engine oil level dipstick.

  5. REMOVE INTAKE AIR CONNECTOR PIPE (for Bank 1)


    1. B0018MV

      Disconnect the 4 connectors.

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

    3. B0018ZC

      Loosen the hose clamp, and remove the bolt and intake air connector pipe from the turbocharger sub-assembly and intake air connector bracket.

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


    1. B001A7JE04
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Slide the 2 clamps and remove the No. 2 ventilation hose from the ventilation tube sub-assembly and cylinder head cover sub-assembly.

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


    1. B0018SP

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

  8. REMOVE BREATHER PLUG RH (for Bank 1)


    1. B001AGN

      Disconnect the vacuum hose from the ventilation tube sub-assembly.

    2. Detach the clamp and remove the breather plug RH from the starter hose bracket sub-assembly.

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


    1. B001A35E04
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

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

  10. DISCONNECT TURBO OIL OUTLET HOSE (for Bank 1)


    1. B0018NT

      Slide the clamp and disconnect the turbo oil outlet hose from the oil pan sub-assembly.

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


    1. B001AYM

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

    2. Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe sub-assembly and gasket from the exhaust manifold and turbocharger sub-assembly.

  12. REMOVE TURBOCHARGER STAY (for Bank 1)


    1. B001AT6

      Remove the 2 bolts and turbocharger stay from the turbocharger sub-assembly and cylinder block sub-assembly.

  13. REMOVE VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)


    1. B0019IG

      Disconnect the No. 3 vacuum transmitting hose assembly from the turbocharger sub-assembly.

    2. Remove the union bolt, bolt, ventilation tube sub-assembly and gasket from the No. 1 turbo oil pipe and exhaust manifold.

  14. REMOVE TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD (for Bank 1)


    1. B001ANZ

      Remove the union bolt and gasket, and disconnect the turbo oil inlet pipe sub-assembly from the cylinder block sub-assembly.

    2. Remove the 10 nuts, 10 collars and turbocharger sub-assembly with exhaust manifold from the cylinder head sub-assembly.

      B0019N1E02
      Text in Illustration
      *A w/ DPF *B w/o DPF

    3. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

    4. w/ DPF:


      1. B001B3V

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

    5. Remove the 2 nuts and bolt, and separate the turbocharger sub-assembly and exhaust manifold.

      B001AJBE02
      Text in Illustration
      *A w/ DPF *B w/o DPF

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

  15. REMOVE COMPRESSOR INLET ELBOW (for Bank 1)


    1. B001B48

      Remove the 2 bolts, compressor inlet elbow and gasket from the turbocharger sub-assembly.

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


    1. B00198K

      Remove the 2 bolts, No. 1 turbo oil pipe and gasket from the turbocharger sub-assembly.

  17. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY (for Bank 1)


    1. B001AD6

      Remove the union bolt, bolt, turbo oil inlet pipe sub-assembly and gasket from the turbocharger sub-assembly.

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


    1. B0018HWE04
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Slide the 2 clamps and remove the No. 3 ventilation hose from the No. 2 ventilation tube sub-assembly and cylinder head cover sub-assembly LH.

  19. REMOVE BREATHER PLUG LH (for Bank 2)


    1. B0019RDE04
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the vacuum hose from the No. 2 ventilation tube sub-assembly.

    2. w/ DPF:


      1. Remove the breather plug LH.

    3. w/o DPF:


      1. Detach the clamp and remove the breather plug LH.

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


    1. B0019XX

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

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


    1. B001APPE04
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

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

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


    1. B0019GB

      Remove the 2 bolts, union bolt, No. 3 turbo water pipe sub-assembly and gasket from the No. 2 exhaust manifold and No. 2 turbocharger sub-assembly.

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


    1. B0018Z9

      Remove the front water by-pass joint and gasket from the No. 2 turbocharger sub-assembly.

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


    1. B0018FN

      Slide the clamp and disconnect the No. 3 water by-pass hose from the No. 2 water by-pass pipe sub-assembly.

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

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


    1. B0019CA

      Slide the 2 clamps and remove the No. 2 turbo oil outlet hose from the No. 2 turbo oil pipe and oil pan sub-assembly.

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


    1. B0018VV

      Remove the 2 bolts and No. 2 turbocharger stay from the No. 2 turbocharger sub-assembly and cylinder block sub-assembly.

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


    1. Disconnect the No. 2 vacuum transmitting hose assembly from the No. 2 turbocharger sub-assembly.

      B0019HOE04
      Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Remove the union bolt, bolt, No. 2 ventilation tube sub-assembly and gasket from the No. 2 turbo oil pipe and No. 2 exhaust manifold.

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


    1. B0018PO

      Disconnect the 2 connectors from the No. 2 turbocharger sub-assembly.

    2. B001A6O

      Remove the union bolt and gasket, and disconnect the turbo oil inlet pipe sub-assembly LH from the oil pan sub-assembly.

    3. Remove the 10 nuts, 10 collars and No. 2 turbocharger sub-assembly with No. 2 exhaust manifold from the cylinder head LH.

      B0018RXE04
      Text in Illustration
      *A w/ DPF *B w/o DPF

    4. Remove the No. 2 exhaust manifold to head gasket from the cylinder head LH.

    5. w/ DPF:


      1. B00192A

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

    6. B00191QE02
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 nuts, and separate the No. 2 turbocharger sub-assembly and No. 2 exhaust manifold.

    7. Remove the gasket from the No. 2 turbocharger sub-assembly.

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


    1. B0019J4

      Remove the 2 bolts, No. 2 compressor inlet elbow and gasket from the No. 2 turbocharger sub-assembly.

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


    1. B0018H8

      Remove the 2 bolts, No. 2 turbo oil pipe and gasket from the No. 2 turbocharger sub-assembly.

  31. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY LH (for Bank 2)


    1. B0018B4

      Remove the union bolt, bolt, turbo oil inlet pipe sub-assembly and gasket from the No. 2 turbocharger sub-assembly.

  32. REMOVE STUD BOLT

    Note

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