EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL


  1. REMOVE EXHAUST PIPE (w/ Combustion Type Power Heater)


    1. Remove the exhaust pipe Click here.

  2. REMOVE FRONT WIPER MOTOR AND LINK


    1. Remove the front wiper motor and link Click here.

  3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A011AQSE01
      Text in Illustration
      *1 Wire harness clamp
      *2 Clamp

      Disconnect the connector and 2 wire harness clamps.

    2. Loosen the hose clamp and separate the air cleaner hose.

    3. Disengage the 2 clamps and 2 claws and remove the air cleaner cap.

  4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. A0118L6

      Remove the air cleaner filter element.

  5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A011AXX

      Remove the 3 bolts and the air cleaner case.

  6. REMOVE AIR CLEANER HOSE ASSEMBLY

    A011AWO

    1. Remove the air cleaner hose.

  7. REMOVE ENGINE COVER ASSEMBLY


    1. A011ACJ

      Disengage the 3 claws and remove the engine cover.

  8. REMOVE AIR FUEL RATIO SENSOR


    1. A0119BY

      Disconnect the union to connector tube hose.

    2. Disconnect the air fuel ratio sensor connector.

    3. Disengage the 3 wire harness clamps and separate the air fuel ratio sensor wire harness.

    4. A011BQ9E01

      Using SST, remove the air fuel ratio sensor.

      SST
      09224-00010

  9. REMOVE NO. 2 TURBO INSULATOR


    1. A011B21

      Remove the bolt, nut and No. 2 turbo insulator.

  10. REMOVE OIL LEVEL DIPSTICK GUIDE


    1. A0119YL

      Remove the bolt, disengage the harness clamp and separate the wire harness.

    2. Remove the 2 bolts and the oil level dipstick guide.

    3. Remove the O-ring from the oil level dipstick guide.

  11. REMOVE FRONT WHEEL RH

  12. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    A011ABK

    1. Remove the cotter pin and castle nut.

    2. A0117XGE01

      Install SST (spacer B) to the threaded section of the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

    3. Using SST, separate the tie rod end from the front axle assembly.

      A0119EDE01
      Text in Illustration
      *1 Place the wrench here
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the ball joint dust cover.

      • Do not damage the front disc brake dust cover.

  13. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. Remove the tail exhaust pipe assembly Click here.

  14. REMOVE NO. 2 MANIFOLD SUPPORT BRACKET


    1. A011BM4

      Remove the bolt, nut and No. 2 manifold support bracket.

  15. REMOVE MANIFOLD SUPPORT BRACKET


    1. A01192R

      Remove the 2 bolts, nut and manifold support bracket.

  16. REMOVE NO. 1 AIR HOSE


    1. A011BQY

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

  17. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)


    1. A011A9I

      Disconnect the connector and disengage the harness clamp.

    2. A011BJ8

      Remove the 3 nuts and exhaust manifold converter.

      Tech Tips


      • Fasten the exhaust manifold converter to the body with a piece of rope.

      • The exhaust manifold converter cannot be removed from the vehicle until the turbocharger is removed, due to lack of space

    3. Remove the gasket from the turbocharger.

  18. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


    1. A011BXE

      Remove the 3 nuts and exhaust manifold converter.


      • Fasten the exhaust manifold converter to the body with a piece of rope.

      • The exhaust manifold converter cannot be removed from the vehicle until the turbocharger is removed, due to lack of space

    2. Remove the gasket from the turbocharger.

  19. REMOVE NO. 1 TURBO INSULATOR


    1. A0117JH

      Remove the 2 bolts and the No. 1 turbo insulator.

  20. REMOVE TURBOCHARGER STAY


    1. A011AE8

      Remove the 2 bolts, the nut and the turbocharger stay.

  21. REMOVE NO. 2 TURBOCHARGER STAY


    1. A011BTI

      Remove the bolt, the nut and the No. 2 turbocharger stay.

  22. REMOVE MANIFOLD STAY


    1. A011BGB

      Remove the 2 bolts and the manifold stay.

  23. REMOVE TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD


    1. A0119VP

      Disconnect the 2 turbocharger connectors.

    2. A0119LH

      Remove the 11 nuts and turbocharger with exhaust manifold.

    3. Remove the 2 gaskets from the cylinder head and cylinder block.

  24. REMOVE INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. A011A40

      Remove the 2 nuts and inlet turbo oil pipe from the turbocharger.

    2. Remove the gasket from the turbocharger.

  25. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A0117VL

      Remove the 3 nuts and turbocharger.

    2. Remove the gasket from the exhaust manifold.