TURBOCHARGER REMOVAL


  1. REMOVE NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 4 bolts and No. 1 engine under cover.

  2. REMOVE NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Remove the 6 bolts and No. 2 engine under cover.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly 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.

      B007OT1E01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block drain cock plug (on the engine oil cooler cover), and drain the engine coolant.

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  6. REMOVE FRONT DOOR SCUFF PLATE RH

  7. REMOVE FRONT SEAT ASSEMBLY RH


    1. B007T2L

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet and remove the engine service hole sub cover.

  9. REMOVE FENDER APRON MUDGUARD SEAL RH

  10. REMOVE FAN AND GENERATOR V BELT (w/ Air Conditioning System)


    1. B007OR0E01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  11. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

  12. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)

  13. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the connector.

    2. B007QP1

      Remove the 4 bolts and compressor and magnetic clutch.

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ DPF)

    Click here

  15. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o DPF)


    1. B007VXQ

      Remove the 2 bolts, 2 nuts and 2 compression springs.

    2. Disconnect the front exhaust pipe assembly from the No. 4 exhaust pipe support.

    3. Remove the 2 gaskets.

  16. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)


    1. B007VCTE02

      Put matchmarks on the transmission control cable assembly and the select outer lever.

    2. Put matchmarks on the transmission control cable assembly and the shift outer lever.

    3. Remove the nut and disconnect the transmission control cable assembly from the select outer lever.

    4. Remove the nut and disconnect the transmission control cable assembly from the shift outer lever.

    5. B007UDO

      Using a screwdriver, disengage the claws of the 2 clips.

    6. Remove the 2 transmission control cable assemblies and 2 clips from the No. 1 transmission control cable bracket.

  17. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transmission)


    1. Remove the 2 bolts and No. 1 transmission control cable bracket.

  18. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. B007SXB

      Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

  19. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. B007VK0

      Remove the 2 bolts and No. 3 exhaust manifold heat insulator.

  20. REMOVE CATALYTIC WITH PIPE CONVERTER ASSEMBLY (w/ DPF)


    1. B007U91

      Remove the 2 nuts from the catalytic with pipe converter assembly.

    2. B007U98

      Remove the 3 nuts, catalytic with pipe converter assembly and gasket.

  21. REMOVE NO. 2 FUEL PIPE CLAMP (w/ DPF)


    1. B007OZL

      Loosen the union bolt of the No. 3 fuel pipe.

    2. Remove the 2 bolts and No. 2 fuel pipe clamp.

  22. REMOVE TURBINE OUTLET ELBOW (w/ DPF)


    1. B007QJC

      Disconnect the fuel addition injector connector.

    2. Slide the clamp and disconnect the No. 1 turbo water hose from No. 1 injector holder.

    3. B007UYQE01
      Text in Illustration
      *1 No. 3 Fuel Pipe
      *2 No. 4 Water By-pass Pipe
      *3 No. 13 Water By-pass Hose

      Remove the union bolt and gasket and disconnect the No. 3 fuel pipe from the No. 1 injector holder.

    4. Remove the union bolt and gasket and disconnect the No. 4 water by-pass pipe from the No. 2 injector holder.

    5. Slide the clamp and remove the No. 4 water by-pass pipe from the No. 13 water by-pass hose.

    6. Remove the 3 nuts, turbine outlet elbow and gasket.

  23. DISCONNECT NO. 1 AIR CLEANER HOSE


    1. B007OVI

      Pull the stopper upward and disconnect the No. 1 air cleaner hose from the compressor inlet elbow.

  24. REMOVE AIR TUBE ASSEMBLY


    1. B007VEO

      Loosen the 2 hose clamps.

    2. Remove the 2 bolts, air tube assembly and No. 1 air cleaner hose.

  25. DISCONNECT TURBOCHARGER MOTOR CONNECTOR

    B007W2Y

  26. REMOVE COMPRESSOR OUTLET ELBOW


    1. B007P7D

      Loosen the 2 hose clamps and remove the bolt and compressor outlet elbow.

  27. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. B007S7ZE01

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  28. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B007U5B

      Detach the 3 clamps.

    2. Remove the bolt and wire harness clamp bracket.

  29. REMOVE VENTILATION PIPE


    1. w/ DPF:


      1. B007RAA

        Remove the bolt and ventilation pipe.

      2. Disconnect the 2 ventilation hoses.

    2. w/o DPF:


      1. B007S63

        for Type A:

        Slide the 2 clamps and remove the No. 14 water by-pass hose from the ventilation pipe and No. 2 water by-pass pipe.

      2. for Type A:

        Slide the clamp and disconnect the No. 4 turbo water hose from the ventilation pipe.

      3. B007VG9E01
        Text in Illustration
        *A for Type A
        *B for Type B

        Remove the bolt and ventilation pipe.

      4. Disconnect the 2 ventilation hoses.

  30. REMOVE TURBO INSULATOR


    1. B007TX8

      Remove the 2 bolts and turbo insulator.

  31. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B007VSU

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  32. REMOVE TURBINE OUTLET ELBOW STAY


    1. B007RVK

      w/ DPF:

      Remove the 2 bolts and turbine outlet elbow stay.

    2. B007RRO

      w/o DPF:

      Remove the 2 bolts, 2 nuts and turbine outlet elbow stay.

  33. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


    1. B007OWY

      Remove the 3 nuts, exhaust manifold converter sub-assembly and gasket.

  34. REMOVE TURBOCHARGER STAY


    1. B007RUC

      Remove the 2 bolts, nut and turbocharger stay.

  35. REMOVE NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)


    1. B007QH8

      Remove the 2 bolts and No. 1 automatic transmission oil cooler tube clamp.

  36. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. B007TB2

      Remove the 2 bolts, 2 nuts and union bolt, and then remove the turbo oil inlet pipe sub-assembly and 3 gaskets.

      Note

      B007TBJ

      Do not loosen the nut as shown in the illustration. If the nut is mistakenly loosened, replace the turbocharger.

  37. DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR

    B007SFQ

  38. REMOVE TURBOCHARGER


    1. w/ DPF:


      1. B007Q72

        Slide the 3 clamps and disconnect the 3 turbo water hoses from the No. 5 water by-pass pipe sub-assembly and No. 2 water by-pass pipe.

      2. B007RAS

        Remove the 3 nuts and disconnect the turbocharger.

      3. Temporarily place the turbocharger on the mounting bracket.

      4. B007QBL

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

      5. Remove the turbocharger and gasket.

    2. w/o DPF:


      1. B007PQ7

        Remove the 3 nuts and disconnect the turbocharger.

      2. B007VDX

        for Type A:

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

      3. B007TAK

        for Type B:

        Slide the 2 clamps and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the No. 2 water by-pass pipe.

      4. B007T8QE01
        Text in Illustration
        *A for Type A
        *B for Type B

        Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.

      5. Remove the bolt, 2 nuts, No. 2 water by-pass pipe and gasket.

      6. Remove the turbocharger and gasket.

  39. REMOVE COMPRESSOR INLET ELBOW


    1. w/ DPF:


      1. B007S4O

        Slide the clamp and remove the No. 4 turbo water hose from the compressor inlet elbow.

      2. B007RL2

        Remove the 2 nuts, compressor inlet elbow and gasket.

    2. w/o DPF:


      1. B007SG0

        for Type A:

        Slide the clamp and remove the No. 4 turbo water hose from the compressor inlet elbow.

      2. B007WEOE01
        Text in Illustration
        *A for Type A
        *B for Type B

        Remove the 2 nuts, compressor inlet elbow and gasket.

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


    1. w/ DPF:


      1. B007W2R

        Slide the 3 clamps and remove the turbo water hose, No. 2 turbo water hose and No. 13 turbo water hose from the No. 1 turbo water pipe sub-assembly.

      2. B007ODL

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

    2. w/o DPF:


      1. B007VBL

        for Type A:

        Slide the 3 clamps and remove the No. 2 turbo water hose, No. 3 turbo water hose and plug from the No. 1 turbo water pipe sub-assembly.

      2. B007UET

        for Type B:

        Slide the 2 clamps and remove the No. 1 turbo water hose and No. 2 turbo water hose from the No. 1 turbo water pipe sub-assembly.

      3. B007UUUE01
        Text in Illustration
        *A for Type A
        *B for Type B

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