TURBOCHARGER (w/ EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

    Note

    When disconnecting the cable, systems need to be initialized after the cable is reconnected Click here.

  2. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Loosen the radiator drain cock plug.

      Tech Tips

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

    2. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  3. REMOVE FRONT WHEEL RH

  4. REMOVE FRONT FENDER APRON SEAL UPPER


    1. Remove the 5 clips and front fender apron seal upper.

  5. REMOVE FRONT FENDER SEAL


    1. Remove the 5 clips and front fender seal.

  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the 2 bolts and 2 compression springs.

    2. Disconnect the front pipe from the outlet pipe and remove the gasket.

    3. Remove the front pipe from the pipe support.

  7. REMOVE AIR CLEANER ASSEMBLY


    1. A01DWMDE03

      Disconnect the MAF meter connector and detach the wire harness clamp.

    2. Loosen the hose clamp of the compressor inlet elbow.

    3. for Ventilation Hose Type:

      Disconnect the ventilation hose.

    4. Remove the 2 bolts and air cleaner.

  8. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01E1YJ

      Remove the 3 bolts, 2 nut and engine cover.

  9. REMOVE INTERCOOLER ASSEMBLY


    1. A01DY9J

      Detach the 2 clamps.

    2. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    3. Disconnect the IAT sensor connector and manifold absolute diesel pressure sensor connector.

    4. A01DXPG

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A01DV5L

      Loosen the 2 hose clamps of the No. 2 air hose.

    6. A01DZT1

      Remove the 4 bolts and intercooler.

  10. REMOVE COMPRESSOR INLET ELBOW


    1. A01DXDA

      for Ventilation Pipe Type:

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

    2. A01E2BV

      Detach the wire harness clamp.

    3. Remove the 2 nuts, inlet elbow and gasket.

  11. REMOVE NO. 1 TURBO INSULATOR


    1. A01DZS1

      Remove the 2 bolts and No. 1 turbo insulator.

  12. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Remove the bolt and No. 1 exhaust manifold heat insulator.

  13. REMOVE NO. 1 TURBO WATER HOSE


    1. A01E1F0

      Remove the 2 No. 1 turbo water hoses.

  14. REMOVE TURBINE OUTLET ELBOW


    1. A01E2CV

      Remove the 3 nuts, turbine outlet elbow and gasket.

  15. REMOVE TURBOCHARGER STAY


    1. A01E2RD

      Remove the 2 bolts, nut and turbocharger stay.

  16. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01DWEWE01

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe and 3 gaskets.

      Note

      Do not loosen the nut labeled A.

  17. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01DWFQ

      Remove the 3 nuts, turbocharger and gasket.

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


    1. A01DX1F

      Remove the 2 nuts, bolt, No. 1 turbo water pipe and gasket.