EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  2. DISCONNECT NO. 1 AIR HOSE


    1. B0044LP

      Loosen the hose clamp and disconnect the No. 1 air hose from the turbocharger sub-assembly.

  3. DISCONNECT NO. 1 TURBO WATER HOSE


    1. B0041OP

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

  4. DISCONNECT NO. 2 TURBO WATER HOSE


    1. B004485

      Slide the clip and disconnect the No. 2 turbo water hose from the No. 1 turbo water pipe sub-assembly.

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


    1. B0043KU

      Remove the 4 bolts and No. 1 turbo water pipe sub-assembly from the turbocharger sub-assembly.

    2. Remove the water by-pass gasket from the turbocharger sub-assembly.

  6. REMOVE TURBOCHARGER STAY


    1. B00442L

      Remove the 2 bolts, nut and turbocharger stay from the turbocharger sub-assembly and cylinder head sub-assembly.

  7. REMOVE MANIFOLD STAY


    1. B0044A8

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

  8. SEPARATE INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. B0043U6E02

      Remove the 2 nuts (A) and separate the inlet turbo oil pipe sub-assembly from the turbocharger sub-assembly.

    2. Loosen the 2 nuts (B) and separate the inlet turbo oil pipe sub-assembly from the cylinder block sub-assembly.

  9. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B0042YA

      Disconnect the 2 turbocharger sub-assembly connectors.

    2. B00452A

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

      Note

      When removing the turbocharger sub-assembly, do not hold it by the electric actuator rod.

    3. B0042BD

      Remove the turbo to exhaust manifold gasket from the exhaust manifold.

    4. B0044D7

      Remove the inlet turbo oil gasket from the turbocharger sub-assembly.

    5. B004300

      Remove the 2 nuts and inlet turbo oil pipe sub-assembly from the cylinder block sub-assembly.

    6. B0041UE

      Remove the No. 1 outlet turbo oil gasket from the cylinder block sub-assembly.

  10. REMOVE INLET COMPRESSOR ELBOW SUB-ASSEMBLY


    1. B0044YE

      Remove the 3 nuts and inlet compressor elbow sub-assembly from the turbocharger sub-assembly.

    2. B0044TW

      Remove the inlet compressor gasket from the inlet compressor elbow sub-assembly.

  11. REMOVE EXHAUST MANIFOLD


    1. B00446XC02
      B0042CO Bolt
      B0043VS Nut

      Remove the 8 nuts and exhaust manifold from the cylinder head sub-assembly.

    2. Remove the 2 bolts and No. 2 manifold support bracket from the cylinder head sub-assembly and cylinder block sub-assembly.

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

  12. REMOVE STUD BOLT

    Tech Tips

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


    1. B0042J0E01

      Using an E6 "TORX" wrench, remove the 3 stud bolts (A) from the turbocharger sub-assembly.

    2. Using an E10 "TORX" wrench, remove the stud bolt (B) from the turbocharger sub-assembly.

    3. B0042C6

      Using an E10 "TORX" wrench, remove the stud bolt from the exhaust manifold.