EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE

  1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  2. DISCONNECT NO. 1 AIR HOSE

    1. A210054

      Loosen the hose clamp and disconnect the No. 1 air hose from the turbocharger sub-assembly.

  3. REMOVE TURBOCHARGER STAY

    1. A193582

      Remove the 2 bolts, nut and turbocharger stay from the turbocharger sub-assembly.

  4. REMOVE MANIFOLD STAY

    1. A193583

      Remove the 2 bolts and manifold stay from the turbocharger sub-assembly.

  5. SEPARATE INLET TURBO OIL PIPE SUB-ASSEMBLY

    1. A294237E02

      Remove the 2 nuts (A) and separate the inlet turbo oil pipe sub-assembly from the turbocharger sub-assembly.

    2. Loosen the 2 nuts (B) and separate the inlet turbo oil pipe sub-assembly from the cylinder block sub-assembly.

  6. REMOVE TURBOCHARGER SUB-ASSEMBLY

    1. A210055

      Disconnect the 2 connectors from the turbocharger sub-assembly.

    2. A193585

      Remove the 3 nuts and turbocharger sub-assembly from the exhaust manifold.

    3. Remove the gasket from the exhaust manifold.

    4. A193587

      Remove the gasket from the turbocharger sub-assembly.

    5. A193589

      Remove the 2 nuts and inlet turbo oil pipe sub-assembly from the cylinder block.

    6. A198860

      Remove the gasket from the cylinder block.

  7. REMOVE INLET COMPRESSOR ELBOW SUB-ASSEMBLY

    1. A203330

      Remove the 3 nuts and inlet compressor elbow sub-assembly.

    2. Remove the gasket from the inlet compressor elbow sub-assembly.

  8. REMOVE EXHAUST MANIFOLD

    1. A295034

      Remove the 8 nuts and exhaust manifold from the cylinder head sub-assembly.

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

  9. REMOVE STUD BOLT

    Tip:

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

    1. A295056E01

      For turbocharger sub-assembly:

      1. Using an E6 "TORX" wrench, remove the 3 stud bolts (A).

      2. Using an E10 "TORX" wrench, remove the stud bolt (B).

    2. A295057

      For exhaust manifold:

      1. Using an E10 "TORX" wrench, remove the stud bolt from the exhaust manifold.