EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the turbocharger sub-assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link

  • Replacement of diesel throttle body assembly

  • Replacement of electric EGR control valve assembly

  • Replacement of turbocharger sub-assembly

  • Replacement of turbocharger sub-assembly or turbocharger variable nozzle motor

 Perform initialization -

Click here

CAUTION:


  • B0068EY

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

  • To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

PROCEDURE


  1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ EGR Cooler)


  2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/o EGR Cooler)

    Click here

  3. REMOVE NO. 1 TURBO INSULATOR (w/o EGR Cooler)

    Click here

  4. REMOVE NO. 2 EXHAUST PIPE SUPPORT STAY (w/o EGR Cooler)

    Click here

  5. REMOVE EXHAUST PIPE SUPPORT STAY (w/o EGR Cooler)

    Click here

  6. REMOVE TURBINE OUTLET ELBOW (w/o EGR Cooler)

    Click here

  7. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  8. DRAIN ENGINE COOLANT

    Click here

  9. DRAIN ENGINE OIL

    Click here

  10. REMOVE NO. 1 AIR HOSE

    Click here

  11. REMOVE NO. 4 AIR HOSE

    Click here

  12. REMOVE NO. 2 AIR TUBE

    Click here

  13. REMOVE NO. 1 RADIATOR HOSE

    Click here

  14. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  15. REMOVE NO. 1 OIL RESERVOIR BRACKET

    Click here

  16. REMOVE RADIATOR RESERVOIR

    Click here

  17. REMOVE FAN SHROUD

    Click here

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


    1. B00288U

      Disconnect the mass air flow meter sub-assembly connector and detach the 2 harness clamps.

    2. B0028AB

      Detach the 4 clips.

    3. Loosen the hose clamp and remove the air cleaner cap sub-assembly with air cleaner hose.

  19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. B0028VR

      Remove the air cleaner element sub-assembly from the air cleaner case.

  20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B0068ZK

      Disconnect the 3 wire harness clamps.

    2. B00278X

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

  21. REMOVE WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  22. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)

    Click here

  23. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B0024HN

      for Cold Specification Vehicles:

      Slide the 2 clips and remove the water hose from the compressor inlet elbow and No. 3 water by-pass pipe.

    2. B00292AC01
      *A for Cold Specification Vehicles
      *B except Cold Specification Vehicles

      Slide the 2 clips and disconnect the 2 water hoses from the oil cooler assembly and No. 2 water by-pass pipe.

    3. Remove the bolt and No. 3 water by-pass pipe.

  24. REMOVE PCV PIPE (for Cold Area Specification Vehicles)


    1. B0026OI

      Slide the 2 clips and disconnect the No. 20 water by-pass hose from the compressor inlet elbow and No. 3 water by-pass pipe.

    2. Slide the clip and disconnect the No. 19 water by-pass hose from the compressor inlet elbow.

    3. B0026SO

      Remove the bolt and disconnect the PCV pipe from the compression outlet elbow.

    4. B0025WP

      Slide the 2 clips and remove the PCV pipe.

  25. REMOVE PCV HOSE (except Cold Area Specification Vehicles)


    1. B0027KA

      Slide the 2 clips.

    2. Slide the 2 clips, detach the clamp and remove the PCV hose.

  26. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  27. DISCONNECT TURBO WATER HOSE


    1. B0025WGC01
      *A for Cold Specification Vehicles
      *B except Cold Specification Vehicles

      Slide the 2 clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the water outlet sub-assembly and water pump assembly.

  28. DISCONNECT BRACKET OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET (for Automatic Transmission)


    1. B002766

      Remove the bolt and disconnect the oil cooler tube bracket.

    2. B0027XF

      w/ DPF:

      Detach the 2 clamps and disconnect the wire harness.

    3. B0027GW

      w/o DPF:

      Remove the bolt and disconnect the wire harness.

  29. DISCONNECT WIRE HARNESS CLAMP BRACKET (for Manual Transmission)


    1. B00272B

      w/ DPF:

      Remove the bolt, detach the clamp and disconnect the wire harness.

    2. B0027GW

      w/o DPF:

      Remove the bolt and disconnect the wire harness.

  30. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. B0027V7

      Remove the bolt, detach the clamp and disconnect the wire harness.

    2. B0025JP

      Remove the 4 bolts and the No. 1 viscous heater bracket sub-assembly.

  31. REMOVE TURBOCHARGER STAY


    1. B0028VC

      Remove the 3 bolts, nut and the turbocharger stay.

  32. REMOVE TURBO OIL OUTLET PIPE


    1. B0028V2

      Slide the 2 clips and disconnect the turbo oil outlet hose from the turbo oil outlet pipe.

    2. Remove the 2 bolts and turbo oil outlet pipe and gasket.

  33. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. B0024SY

      Remove the union bolt and gasket.

    2. B0025C4

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

      Note

      Do not loosen the nut labeled A.

      B0027DLE01

    3. Remove the gasket.

  34. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. B00258PC01
      *A w/ DPF
      *B w/o DPF

      Remove the 3 nuts and turbocharger sub-assembly.

    2. Remove the gasket from the exhaust manifold.

  35. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System)

    Click here

  36. REMOVE EGR HOLE COVER PLATE (w/o EGR System)


    1. B0024R2

      Remove the 2 nuts, EGR hole cover plate and gasket.

    2. B0068JS

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts shown in the illustration.

  37. REMOVE EXHAUST MANIFOLD


    1. B0027OXC01
      *A w/ DPF
      *B w/o DPF

      Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

    2. Remove the gasket.

  38. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. B002929C01
      *A w/ DPF
      *B w/o DPF

      Slide the 2 hose clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the turbo water pipe sub-assembly.

    2. Remove the bolt.

    3. B0027HR

      Remove the 2 nuts, turbo water pipe sub-assembly and gasket.

  39. REMOVE COMPRESSOR INLET ELBOW


    1. B00268VC01
      *A for Cold Specification Vehicles
      *B except Cold Specification Vehicles

      Remove the 2 bolts and compressor inlet elbow stay.

    2. B00265LC01
      *A for Cold Specification Vehicles
      *B except Cold Specification Vehicles

      Remove the 2 nuts and compressor inlet elbow from turbocharger sub-assembly.

    3. B00250UC02
      *A for Cold Specification Vehicles
      *B except Cold Specification Vehicles

      Using an E8 "TORX" socket wrench, remove the stud bolt shown in the illustration together with the compressor inlet elbow and gasket.

  40. REMOVE COMPRESSOR OUTLET ELBOW


    1. B002706C01
      *A for Cold Specification Vehicles
      *B except Cold Specification Vehicles

      Remove the 2 nuts and compressor outlet elbow.

    2. Remove the gasket.

    3. B0024F2

      except Cold Specification Vehicle:

      Remove the bolt and hose clamp.

  41. REMOVE STUD BOLT

    Note

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


    1. B00283C

      Using an E5 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.

    2. B00246M

      Using an E8 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.

    3. B00253L

      Using an E10 "TORX" socket wrench, remove the 3 stud bolts shown in the illustration.