EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

Note

w/ DPF:

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines,


  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 Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE ENGINE ASSEMBLY

    Click here

  4. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE (for Bank 1)


    1. A01578C

      Remove the 2 bolts and No. 1 engine oil level dipstick guide.

    2. Remove the O-ring from the No. 1 engine oil level dipstick.

  5. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE (for Bank 1)


    1. A015AXC

      Disconnect the 4 connectors.

    2. Using a clip remover, detach the 5 wire harness clamps.

    3. A015E2Z

      Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.

  6. REMOVE NO. 2 VENTILATION HOSE (for Bank 1)

    A0159XJE01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  7. REMOVE NO. 2 TURBO WATER HOSE (for Bank 1)

    A015C6G

  8. REMOVE BREATHER PLUG RH (for Bank 1)


    1. A015ATR

      Disconnect the hose.

    2. Detach the clamp and remove the breather plug RH.

  9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 1)


    1. A015DQXE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  10. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE (for Bank 1)

    A015952

  11. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 1)


    1. A01596N

      Disconnect the water hose.

    2. Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.

  12. REMOVE NO. 1 TURBOCHARGER STAY (for Bank 1)


    1. A015AVN

      Remove the 2 bolts and No. 1 turbocharger stay.

  13. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)


    1. A0156CB

      Disconnect the hose.

    2. Remove the union bolt, bolt, No. 1 ventilation tube and gasket.

  14. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH (for Bank 1)


    1. A015B3D

      Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.

    2. Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.

      A015A4VE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    3. Remove the gasket.

    4. A015D0F

      w/ DPF:

      Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.

    5. Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.

      A0155TWE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    6. Remove the gasket from the No. 1 turbocharger.

  15. REMOVE NO. 1 INLET COMPRESSOR ELBOW (for Bank 1)


    1. A0157Q5

      Remove the 2 bolts, No. 1 inlet compressor elbow and gasket.

  16. REMOVE NO. 1 TURBO OIL PIPE (for Bank 1)


    1. A015DCH

      Remove the 2 bolts, No. 1 turbo oil pipe and gasket.

  17. REMOVE NO. 1 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 1)


    1. A015DTT

      Remove the union bolt, bolt, No. 1 inlet turbo oil pipe and gasket.

  18. REMOVE NO. 3 VENTILATION HOSE (for Bank 2)

    A015CQ4E01
    Text in Illustration
    *A w/ DPF
    *B w/o DPF

  19. REMOVE BREATHER PLUG LH (for Bank 2)


    1. A01562TE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the hose.

    2. w/o DPF:

      Detach the clamp.

    3. Remove the breather plug LH.

  20. REMOVE NO. 2 TURBO WATER HOSE (for Bank 2)

    A0157W9

  21. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 2)


    1. A015ASCE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  22. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    1. A015D12

      Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.

  23. REMOVE FRONT WATER BY-PASS JOINT (for Bank 2)


    1. A0157D8

      Remove the front water by-pass joint and gasket.

  24. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    1. A015C38

      Disconnect the water hose.

    2. Remove the union bolt, bolt, No. 2 turbo water pipe and gasket.

  25. REMOVE NO. 2 OUTLET TURBO OIL HOSE (for Bank 2)

    A0156TV

  26. REMOVE NO. 2 TURBOCHARGER STAY (for Bank 2)


    1. A015A3Y

      Remove the 2 bolts and No. 2 turbocharger stay.

  27. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY (for Bank 2)


    1. Disconnect the hose.

      A0155F8E01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Remove the union bolt, bolt, No. 2 ventilation tube and gasket.

  28. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH (for Bank 2)


    1. A0158JX

      Disconnect the 2 connectors from the turbocharger.

    2. A015674

      Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.

    3. Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.

      A015D0BE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

    4. Remove the gasket.

    5. A015AVS

      w/ DPF:

      Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.

    6. A015BQJE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.

    7. Remove the gasket from the turbocharger.

  29. REMOVE NO. 2 INLET COMPRESSOR ELBOW (for Bank 2)


    1. A015E86

      Remove the 2 bolts, No. 2 inlet compressor elbow and gasket.

  30. REMOVE NO. 2 TURBO OIL PIPE (for Bank 2)


    1. A0155FC

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

  31. REMOVE NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 2)


    1. A015D3M

      Remove the union bolt, bolt, No. 2 inlet turbo oil pipe and gasket.

  32. REPLACE STUD BOLT

    Tech Tips

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


    1. For No. 1 Turbocharger:


      1. Using an E10 "TORX" wrench, replace the stud bolts labeled A and B shown in the illustration below.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      2. Replace the stud bolts labeled C shown in the illustration below.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
        A0159KBE02
    2. A01598SE01

      For No. 2 Turbocharger:

      Using an E10 "TORX" wrench, replace the stud bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A0157GUE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      For Exhaust Manifold LH:

      Using an E10 "TORX" wrench, replace the stud bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }