EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL


  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. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  4. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  5. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IR30

      Remove the 6 bolts and 11 clips.

    2. Remove the No. 1 engine under cover.

  6. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Loosen the radiator drain cock plug and drain the engine coolant.

      A01IUCQE01
      Text in Illustration
      *1 Reservoir Cap *2 Air Release Valve
      *3 Radiator Drain Cock Plug - -

      Tech Tips

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

    2. Remove the reservoir cap.

  7. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A01IPK0

      Remove the 3 clips.

    2. Detach the 4 hooks and remove the radiator support opening cover.

  8. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A01ININ

      Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp sub-assembly from the battery carrier, and then remove the battery clamp sub-assembly.

  9. REMOVE BATTERY INSULATOR

  10. REMOVE BATTERY

  11. REMOVE BATTERY TRAY

  12. REMOVE BATTERY CARRIER


    1. A01IQXM

      Detach the 2 clamps and disconnect the engine wire.

    2. Remove the 4 bolts and battery carrier.

  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY


    1. A01IT1KE01
      Text in Illustration
      *1 Retainer

      Detach the clamp and disconnect the mass air flow meter sub-assembly connector.

    2. Detach the clamp and disconnect the vacuum hose from the air cleaner hose assembly.

    3. Detach the clamp and disconnect the No. 1 fuel hose from the air cleaner hose assembly.

    4. Detach the clamp and disconnect the No. 2 fuel hose from the air cleaner hose assembly.

    5. Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    6. Release the retainer and disconnect the air cleaner hose assembly from the turbocharger sub-assembly as shown in the illustration.

    7. Detach the 2 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  14. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01IN4S

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

  16. DISCONNECT COMPRESSOR OUTLET ELBOW


    1. A01IQQ6E01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the compressor outlet elbow from the turbocharger sub-assembly as shown in the illustration.

  17. REMOVE TURBO OIL OUTLET PIPE


    1. A01INN4

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

    2. Remove the O-ring from the turbo oil outlet pipe.

  18. DISCONNECT NO. 1 TURBO OIL PIPE


    1. A01IP0E

      Remove the union bolt and 2 gaskets and disconnect the No. 1 turbo oil pipe.

  19. REMOVE NO. 1 EXHAUST MANIFOLD PIPE


    1. Disconnect the exhaust manifold pressure sensor connector.

    2. A01IUNE

      Remove the union bolt and 2 gaskets.

    3. Remove the bolt and No. 1 exhaust manifold pipe.

  20. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01IPK6

      Disconnect the connector from the turbocharger sub-assembly.

    2. Remove the 4 bolts, turbocharger sub-assembly and gasket.

  21. DISCONNECT ENGINE WIRE


    1. A01IQ1V

      Detach the 2 clamps from the No. 1 air tube assembly.

    2. Remove the 2 bolts and disconnect the engine wire from the No. 1 air tube assembly.

  22. REMOVE NO. 4 WATER BY-PASS HOSE


    1. A01IQ3QE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the No. 4 water by-pass hose from the EGR cooler assembly as shown in the illustration.

    2. Slide the clamp and remove the No. 4 water by-pass hose from the No. 2 radiator pipe.

  23. DISCONNECT NO. 1 AIR TUBE ASSEMBLY


    1. A01IN8C

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 2 radiator pipe.

    2. Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 radiator pipe.

    3. Detach the clamp and disconnect the water hose sub-assembly from the compressor outlet elbow.

    4. Slide the clamp and disconnect the water hose sub-assembly from the No. 1 radiator pipe.

    5. Slide the clamp and disconnect the outlet heater water hose from the No. 2 radiator pipe.

    6. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  24. DISCONNECT FUEL FEED PIPE SUB-ASSEMBLY


    1. A01IS7O

      Detach the 2 clamps and disconnect the engine wire.

    2. A01ITOL

      Remove the 2 bolts and disconnect the fuel feed pipe sub-assembly.

    3. A01IOX3

      Disconnect the vacuum hose from the No. 2 fuel hose.

    4. Disconnect the fuel feed pipe sub-assembly from the fuel pipe clamp.

  25. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01ITIP

      Disconnect the air fuel ratio sensor connector.

    2. Raise the air fuel ratio sensor connector to remove the air fuel ratio sensor connector from the bracket.

    3. Detach the 2 clamps and disconnect the air fuel ratio sensor.

    4. Detach the 2 clamps and disconnect the engine wire.

  26. REMOVE EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY


    1. A01IUSY

      Disconnect the EGR valve assembly connector.

    2. Detach the clamp and disconnect the engine wire from the EGR valve assembly.

    3. Disconnect the hose clamp from the EGR cooler hose.

    4. A01IQK7

      Disconnect the vacuum hose from the EGR cooler assembly.

    5. A01ITBTE01

      Remove the 7 bolts and EGR cooler assembly with EGR valve assembly.

      Tech Tips


      • When removing the bolts labeled A, use a T45 "TORX" socket wrench.

      • When removing the bolts labeled B, use a 6 mm hexagon wrench.

      • The bolt labeled C in the illustration cannot be removed from the intake manifold.

    6. Remove the gasket.

    7. A01IPEN

      Remove the water pipe from the EGR cooler assembly.

  27. REMOVE EXHAUST MANIFOLD


    1. A01IRKA

      Remove the 8 nuts and exhaust manifold.

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