EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE

1. REMOVE EGR PIPE WITH COOLER SUB-ASSEMBLY

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2. REMOVE NO. 1 TURBO INSULATOR

   1. 

      Remove the 2 bolts and No. 1 turbo insulator.

3. REMOVE TURBO OIL OUTLET HOSE

   

   1. Slide the 2 clips and remove the turbo oil outlet hose.

4. REMOVE NO. 2 TURBO OIL OUTLET PIPE

   1. 

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

5. REMOVE TURBOCHARGER WIRE

   1. 

      Disconnect the 2 connectors.

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

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

   1. 

      Disconnect the vacuum transmitting hose.

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

7. REMOVE NO. 3 WATER BY-PASS HOSE

   

   1. Slide the 2 clips and remove the No. 3 water by-pass hose.

8. REMOVE TURBO OIL OUTLET PIPE

   1. 

      Remove the union bolt and gasket.

   2. 

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

9. REMOVE TURBOCHARGER STAY

   1. 

      *1	Turbocharger Stay
      *2	Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

10. REMOVE TURBOCHARGER SUB-ASSEMBLY

    1. 

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

11. REMOVE EXHAUST MANIFOLD

    1. 

       *1

       Collar

       Remove the 8 nuts, 8 collars and exhaust manifold.

    2. Remove the gasket from the cylinder head.

12. REMOVE STUD BOLT

    Tip:

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

    1. For turbocharger sub-assembly:

       1. 

          Using an E8 "TORX" wrench, remove the stud bolt from the turbocharger sub-assembly.

       2. 

          Using an E8 "TORX" wrench, remove the 3 stud bolts from the turbocharger sub-assembly.

       3. 

          Remove the 2 stud bolts (A).

       4. Using an E5 "TORX" wrench, remove the 2 stud bolts (B).

    2. 

       For exhaust manifold:

       Remove the stud bolt from the exhaust manifold.