EXHAUST MANIFOLD W/ TURBOCHARGER (w/ DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the engine 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.

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

  2. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  3. REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  4. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 4 bolts and No. 1 engine under cover.

  5. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A00JWDE

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A00JTSGE01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  6. REMOVE FRONT FENDER APRON SEAL RH


    1. Using a clip remover, remove the 5 clips and front fender apron seal RH.

  7. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL RH


    1. Using a clip remover, remove the 4 clips and front No. 1 fender apron to frame seal RH.

  8. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  9. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)


    1. A0098I9

      Remove the 2 bolts and front heater bracket.

  10. REMOVE FAN AND GENERATOR V BELT


    1. Using the pulley set bolt of the tensioner, rotate the tensioner pulley clockwise to loosen the belt tension. Then remove the V belt.

  11. REMOVE NO. 1 AIR CLEANER HOSE


    1. A00K0ML

      Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    A00JU9YE01
    Text in Illustration
    *A except Cold Area Specification Vehicles
    *B for Cold Area Specification Vehicles

    1. except Cold Area Specification Vehicles:

      Detach the 2 clamps and disconnect the mass air flow meter connector.

    2. for Cold Area Specification Vehicles:

      Detach the 3 clamps and disconnect the mass air flow meter connector.

    3. Detach the 4 clamps and remove the air cleaner cap.

  13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A00JXU4

      Remove the 3 bolts and air cleaner case.

  15. DISCONNECT HEATER HOSE AND PIPE (w/ Rear Air Conditioning System)


    1. A00JWUN

      Disconnect the 3 heater hoses and remove the bolt.

  16. REMOVE HEATER HOSE (w/o Rear Air Conditioning System)

    A00JTSK

  17. REMOVE NO. 1 AIR HOSE


    1. A00OADW

      Loosen the 2 clamps.

    2. Remove the No. 1 air hose from the inlet pipe and intercooler.

  18. REMOVE COMPRESSOR OUTLET ELBOW


    1. A00JYG3

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. A00JWGZ

      Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.

  19. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)


    1. Disconnect the viscous heater connector.

    2. A00O4ER

      Disconnect the water by-pass hose and water hose.

    3. A00O4BR

      Remove the 2 bolts and viscous heater with magnet clutch.

  20. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. A00O4PQ

      Remove the 4 bolts and No. 1 viscous heater bracket.

  21. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A00OAI3

      Disconnect the compressor connector.

    2. Remove the 4 bolts and disconnect the cooler compressor.

  22. REMOVE GENERATOR ASSEMBLY


    1. A00JWKJ

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the generator wire.

    4. Remove the 2 bolts and generator.

  23. REMOVE GENERATOR BRACKET


    1. A00JVLM

      Remove the bolt and generator bracket.

  24. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00JXLV

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  25. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A00K1IA

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

  26. REMOVE TURBINE OUTLET ELBOW STAY


    1. A00JYXE

      Remove the 2 bolts and turbine outlet elbow stay.

  27. REMOVE NO. 2 TURBINE OUTLET ELBOW


    1. A00JTRW

      Remove the 3 nuts, No. 2 turbine outlet elbow and gasket.

  28. DISCONNECT NO. 1 FUEL PIPE


    1. A00JWLX

      Remove the 2 bolts, union bolt and gasket.

      Text in Illustration
      A00JYOS Union Bolt

    2. Disconnect the No. 1 fuel pipe from the turbine outlet elbow.

  29. REMOVE FUEL PIPE CLAMP


    1. A00JVSM

      Remove the bolt and fuel pipe clamp.

  30. REMOVE NO. 11 WATER BY-PASS HOSE


    1. A00JWCX

      Disconnect the exhaust fuel addition injector connector.

    2. Remove the No. 11 water by-pass hose.

  31. REMOVE TURBINE OUTLET ELBOW


    1. A00JY22E01
      Text in Illustration
      *1 No. 4 Water By-pass Pipe
      *2 No. 12 Water By-pass Hose
      *3 Turbine Outlet Elbow
      *4 Gasket
      *5 Union Bolt

      Remove the union bolt and gasket from the turbine outlet elbow.

    2. Disconnect the No. 4 water by-pass pipe from the No. 12 water by-pass hose.

    3. Remove the 3 nuts, turbine outlet elbow and gasket.

  32. DISCONNECT VENTILATION PIPE


    1. A00JWRJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  33. REMOVE NO. 1 TURBO INSULATOR


    1. A00K0PW

      Remove the 2 bolts and No. 1 turbo insulator.

  34. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Remove the 2 bolts and No. 1 exhaust manifold heat insulator.

  35. DISCONNECT ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A00K1CV

      Remove the bolt.

    2. Disconnect the engine oil level dipstick guide.

  36. DISCONNECT NO. 1 TURBO WATER HOSE


    1. A00K1L5E01
      Text in Illustration
      *1 No. 1 Turbo Water Hose
      *2 No. 3 Turbo Water Hose

      Disconnect the No. 1 turbo water hose from the No. 2 water by-pass pipe.

  37. DISCONNECT NO. 3 TURBO WATER HOSE


    1. Disconnect the No. 3 turbo water hose from the No. 2 water by-pass pipe.

  38. REMOVE TURBOCHARGER STAY


    1. A00JXIX

      Remove the 2 bolts, nut and turbocharger stay.

  39. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A00JTYE

      Remove the bolt and wire harness clamp bracket.

  40. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A00K21PE01

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe and 3 gaskets.

      Note

      Do not loosen the nut labeled A in the illustration.

  41. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. A00K02U

      Remove the 8 nuts and 8 plate washers from the exhaust manifold with turbocharger.

    2. Remove the exhaust manifold with turbocharger and gasket.

  42. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A00JUXW

      Remove the 3 nuts, turbocharger and gasket.

  43. REMOVE COMPRESSOR INLET ELBOW


    1. A00K09H

      Remove the 2 nuts, compressor inlet elbow and gasket.

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


    1. A00JYP3

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