EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY

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  2. REMOVE NO. 1 TURBO INSULATOR


    1. A00Y547

      Remove the 2 bolts and No. 1 turbo insulator.

  3. REMOVE TURBO OIL OUTLET HOSE

    A00Y88Q

    1. Slide the 2 clips and remove the turbo oil outlet hose.

  4. REMOVE NO. 2 TURBO OIL OUTLET PIPE


    1. A00Y5M1

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

  5. REMOVE TURBOCHARGER WIRE


    1. A00Y6XC

      Disconnect the 2 connectors.

    2. Disengage the 3 wire harness clamps and remove the turbocharger wire.

  6. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A00Y7V9

      Disconnect the vacuum transmitting hose.

    2. Remove the bolt and No. 2 vacuum transmitting pipe sub-assembly.

  7. REMOVE NO. 3 WATER BY-PASS HOSE

    A00Y7HP

    1. Slide the 2 clips and remove the No. 3 water by-pass hose.

  8. REMOVE TURBO OIL OUTLET PIPE


    1. A00YBFY

      Remove the union bolt and gasket.

    2. A00Y8PZ

      Remove the 3 nuts, turbo oil outlet pipe and gasket.

  9. REMOVE TURBOCHARGER STAY


    1. A00Y9SDC01
      *1 Turbocharger Stay
      *2 Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

  10. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A00Y6MV

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

  11. REMOVE EXHAUST MANIFOLD


    1. A00Y58MC01
      *1 Collar

      Remove the 8 nuts, 8 collars and exhaust manifold.

    2. Remove the gasket from the cylinder head.

  12. REMOVE STUD BOLT

    Tech Tips

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


    1. For turbocharger sub-assembly:


      1. A00Y5CH

        Using an E8 "TORX" wrench, remove the stud bolt from the turbocharger sub-assembly.

      2. A00Y8B0

        Using an E8 "TORX" wrench, remove the 3 stud bolts from the turbocharger sub-assembly.

      3. A00Y9U2E01

        Remove the 2 stud bolts (A).

      4. Using an E5 "TORX" wrench, remove the 2 stud bolts (B).

    2. A00YBDB

      For exhaust manifold:

      Remove the stud bolt from the exhaust manifold.