EXHAUST MANIFOLD W/ TURBOCHARGER (for DPF) REMOVAL


  1. REMOVE EGR COOLER WITH PIPE ASSEMBLY

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  2. REMOVE NO. 1 TURBO INSULATOR


    1. A019GW0

      Remove the 2 bolts and No. 1 turbo insulator.

  3. REMOVE TURBO OIL OUTLET HOSE


    1. A019IDO

      Slide the 2 clamps and remove the turbo oil outlet hose from the turbo oil outlet pipe and No. 2 turbo outlet pipe.

  4. REMOVE NO. 2 TURBO OIL OUTLET PIPE


    1. A019FRD

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

  5. REMOVE TURBOCHARGER WIRE


    1. A019FTC

      Disconnect the 2 connectors.

    2. Detach the 3 wire harness clamps and remove the turbocharger wire.

  6. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A019G4H

      Disconnect the 2 vacuum transmitting hoses.

    2. Remove the bolt and No. 2 vacuum transmitting pipe sub-assembly.

  7. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A019FN0

      Slide the 2 clamps and remove No. 3 water by-pass hose from the No. 1 water by-pass pipe and turbo oil outlet pipe.

  8. REMOVE TURBO OIL OUTLET PIPE


    1. A019GRS

      Remove the union bolt and gasket.

    2. A019FVP

      Remove the 3 nuts, turbo oil outlet pipe and gasket.

  9. REMOVE TURBOCHARGER STAY


    1. A019G1EE01
      Text in Illustration
      *1 Turbocharger Stay
      *2 Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

  10. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A019H8U

      Remove the 3 nuts, turbocharger sub-assembly and gasket.

  11. REMOVE EXHAUST MANIFOLD


    1. A019HTYE01
      Text in Illustration
      *1 Collar

      Remove the 8 nuts, 8 collars and exhaust manifold.

    2. Remove the gasket from the cylinder head sub-assembly.

  12. REPLACE STUD BOLT

    Tech Tips

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


    1. A019FDWE02
      Text in Illustration
      *a 32 mm (1.26 in.)
      *b 20 mm (0.787 in.)
      *c 10 mm (0.394 in.)

      For turbocharger:


      1. Using an E8 "TORX" wrench, replace the 3 stud bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. A019GE1E03
        Text in Illustration
        *a 43 mm (1.69 in.)
        *b 16 mm (0.630 in.)
        *c 24.5 mm (0.965 in.)
        *d 12 mm (0.472 in.)
        *e 9.0 mm (0.354 in.)

        Replace the 2 stud bolts labeled A shown in the illustration.

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

      3. Using an E5 "TORX" wrench, replace the 2 stud bolts labeled B shown in the illustration.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A019INLE02
      Text in Illustration
      *a 47 mm (1.85 in.)
      *b 14 mm (0.551 in.)
      *c 15 mm (0.591 in.)

      For turbocharger:

      Using an E8 "TORX" wrench, replace the stud bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A019HYBE04
      Text in Illustration
      *a 43 mm (1.69 in.)
      *b 16 mm (0.630 in.)

      For exhaust manifold:

      Replace the stud bolt.

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