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 engine assembly removal/installation are shown below.

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

  • Replacement of diesel throttle body assembly

  • Replacement of electric EGR control valve assembly

  • Replacement of turbocharger sub-assembly

  • Replacement of turbocharger sub-assembly or turbocharger variable nozzle motor

 Perform initialization -

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CAUTION:


  • B003QVR

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

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

PROCEDURE


  1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  2. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  3. DRAIN ENGINE COOLANT

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  4. DRAIN ENGINE OIL

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  5. REMOVE NO. 1 AIR HOSE

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  6. REMOVE NO. 4 AIR HOSE

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  7. REMOVE NO. 2 AIR TUBE

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  8. REMOVE NO. 1 RADIATOR HOSE

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  9. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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  10. REMOVE NO. 1 OIL RESERVOIR BRACKET

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  11. REMOVE RADIATOR RESERVOIR

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  12. REMOVE FAN SHROUD

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  13. 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.

  14. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. B003S0S

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

  15. 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.

  16. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B003RAV

      Slide the 2 clips and disconnect the 2 water hoses from the oil cooler assembly and No. 2 water by-pass pipe.

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

  17. REMOVE PCV HOSE


    1. B003OOU

      Slide the 2 clips.

    2. Detach the clamp and remove the PCV hose.

  18. REMOVE NO. 1 WATER BY-PASS PIPE

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  19. DISCONNECT TURBO WATER HOSE


    1. B003O85

      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.

  20. REMOVE TURBOCHARGER STAY


    1. B003KUX

      for Automatic Transmission:

      Remove the bolt and disconnect the oil cooler tube bracket.

    2. B003K3Q

      Remove the bolt and disconnect the wire harness.

    3. B003NAL

      Remove the 3 bolts, nut and the turbocharger stay.

  21. REMOVE TURBO OIL OUTLET PIPE


    1. B003Q8N

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

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

  22. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. B003NU3

      Remove the union bolt and gasket.

    2. B003P5T

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

      Note

      Do not loosen the nut labeled A.

      B003OO0E01

    3. Remove the gasket.

  23. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B003M1H

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket from the exhaust manifold.

  24. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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  25. REMOVE EXHAUST MANIFOLD


    1. B003OXV

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

    2. Remove the gasket.

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


    1. B003R1H

      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. B003ODJ

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

  27. REMOVE COMPRESSOR INLET ELBOW


    1. B003QZ1

      Remove the 2 bolts and compressor inlet elbow stay.

    2. B003LKR

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

    3. B003RQU

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

  28. REMOVE COMPRESSOR OUTLET ELBOW


    1. B003PWA

      Remove the 2 nuts and compressor outlet elbow.

    2. Remove the gasket.

    3. B003NU0

      Remove the bolt and hose clamp.

  29. REMOVE STUD BOLT

    Note

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


    1. B003KHE

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

    2. B003K9K

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

    3. B003R03

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