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 injector 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 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.

B0026TA

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. B00288U

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

    2. B0028AB

      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. B0028VR

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

  12. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B0068ZK

      Disconnect the 3 wire harness clamps.

    2. B00278X

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

  13. REMOVE PCV PIPE


    1. A01W8CT

      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. A01WA9C

      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. A01WBDZ

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

  16. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01WADN

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

  17. REMOVE NO. 1 TURBO WATER HOSE


    1. A01W9TH

      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. A01W80V

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

  19. REMOVE TURBOCHARGER STAY


    1. A01W9SK

      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. A01WA0JN01

      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. A01W9G4

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket.

  22. REMOVE EXHAUST MANIFOLD


    1. A01W9XU

      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. A01W908

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