EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the turbocharger sub-assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Replacement Part or Procedure Effects/Inoperative when not Performed Link

  • Replacement of diesel throttle body assembly

  • Replacement of turbocharger sub-assembly

 Perform initialization -

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CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B003Q0P

PROCEDURE


  1. PRECAUTION

    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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE INTERCOOLER ASSEMBLY

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  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. REMOVE NO. 2 ENGINE UNDER COVER

  6. DRAIN ENGINE COOLANT

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  7. REMOVE FRONT FENDER APRON SEAL UPPER


    1. Remove the 5 clips and front fender apron seal upper.

  8. REMOVE FRONT FENDER SEAL


    1. Remove the 5 clips and front fender seal.

  9. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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


    1. B003QRJ

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

    2. B003PMK

      Detach the 4 clips.

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

  11. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. B003S0S

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

  12. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B003N3S

      Disconnect the 3 wire harness clamps.

    2. B003L5A

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

  13. REMOVE PCV PIPE


    1. B003QKF

      Remove the bolt and disconnect the 2 PCV hoses and PCV pipe from the cylinder head sub-assembly and compressor inlet elbow.

  14. REMOVE COMPRESSOR INLET ELBOW


    1. B003M12

      Disconnect the 2 connectors from the turbocharger sub-assembly.

    2. Detach the wire harness clamp from the compressor inlet elbow.

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

  15. REMOVE NO. 1 TURBO INSULATOR


    1. B003N9F

      Remove the 2 bolts and No. 1 turbo insulator from the turbocharger sub-assembly.

  16. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B003MZV

      Remove the bolt and No. 1 exhaust manifold heat insulator from the exhaust manifold.

  17. REMOVE NO. 1 TURBO WATER HOSE


    1. B003RPB

      Remove the 2 No. 1 turbo water hoses from the No. 3 water by-pass pipe and cylinder block sub-assembly.

  18. REMOVE TURBINE OUTLET ELBOW


    1. B003L70

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

  19. REMOVE TURBOCHARGER STAY


    1. B003ORD

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

  20. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. B003M8CN01

      Remove the 2 bolts, 2 nuts and 2 gaskets from the turbocharger sub-assembly and cylinder block sub-assembly.

      Note

      Do not loosen the nut labeled A.

    2. Remove the union bolt and turbo oil inlet pipe sub-assembly from the turbocharger sub-assembly and cylinder block sub-assembly.

  21. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B003KOJ

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket.

  22. REMOVE EXHAUST MANIFOLD


    1. B003NA2

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

    2. Remove the gasket.

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


    1. B003R3G

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