TURBOCHARGER (w/o EGR Cooler) REMOVAL

PRECAUTION

Note

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)
REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)
DRAIN ENGINE COOLANT (w/ Intercooler)
Note

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. Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
2. Loosen the cylinder block drain cock plug and the radiator drain cock plug.
  
  Tech Tips
  
  Collect the coolant in a container and dispose of it according to the regulations in your area.
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.
REMOVE FRONT FENDER APRON SEAL UPPER
1. Remove the 5 clips and front fender apron seal upper.
REMOVE FRONT FENDER SEAL
1. Remove the 5 clips and front fender seal.
REMOVE VENTILATION HOSE HEAT INSULATOR (w/o Intercooler)
1. Remove the 2 bolts and ventilation hose heat insulator.
REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

Click here
REMOVE AIR CLEANER ASSEMBLY
1. w/ Mass Air Flow Meter:
  1. Disconnect the mass air flow meter connector and detach the wire harness clamp.
    
    Text in Illustration
    
    *A w/ Intercooler *B w/o Intercooler
  2. Loosen the hose clamp, and then remove the No. 1 air cleaner hose from the turbocharger sub-assembly.
  3. w/o Intercooler:
    
    Slide the clamp and disconnect the ventilation hose from the cylinder head cover sub-assembly.
  4. Remove the 2 bolts and air cleaner assembly.
2. w/o Mass Air Flow Meter:
  1. Detach the clamp and disconnect the intake air temperature sensor connector.
  2. Loosen the hose clamp, and then remove the air cleaner hose from the turbocharger sub-assembly.
  3. Slide the clamp and disconnect the ventilation hose from the cylinder head cover sub-assembly.
  4. Remove the 2 bolts and air cleaner assembly.
REMOVE VENTILATION PIPE (w/ Intercooler)
1. for Type A:
  
  Slide the 2 clamps and disconnect the No. 12 water by-pass hose and No. 13 water by-pass hose from the ventilation pipe.
2. Text in Illustration
  
  *A for Type B
  
  *B for Type A
  
  Remove the bolt and ventilation pipe.

Text in Illustration
*A	w/ Intercooler	*B	w/o Intercooler

Text in Illustration
*A	for Type B
*B	for Type A

REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o Intercooler)

w/ No. 1 Engine Cover

Text in Illustration
*1	No. 1 Engine Cover Sub-assembly
*2	Claw
*3	Pin

Detach the 4 claws from the pins of the engine cover bracket and remove the No. 1 engine cover sub-assembly.

Remove the 2 bolts and engine cover bracket.

Disconnect the manifold absolute pressure sensor connector.
Disconnect the vacuum hose from the gas filter.
Loosen the 2 clamps.
Remove the bolt and disconnect the No. 2 air cleaner pipe sub-assembly together with the 2 air hoses.

REMOVE COMPRESSOR INLET ELBOW (w/ Intercooler)

Disconnect the 2 connectors and detach the wire harness clamp.

for Type A:

Slide the clamp and disconnect the No. 1 turbo water hose from the cylinder block sub-assembly.

Text in Illustration
*1	No. 2 Water By-pass Hose
*2	No. 13 Water By-pass Hose

Slide the 2 clamps and disconnect the No. 2 water by-pass hose and No. 13 water by-pass hose from the No. 2 water by-pass pipe sub-assembly and compressor inlet elbow.

Remove the 2 nuts, compressor inlet elbow and gasket.

Text in Illustration
*1	No. 7 Water By-pass Hose
*2	No. 12 Water By-pass Hose

for Type A:

Slide the 2 clamps and remove the No. 7 water by-pass hose and No. 12 water by-pass hose from the compressor inlet elbow.

for Type B:

Slide the 4 clamps and disconnect the 2 No. 1 turbo water hoses from the No. 1 turbo water pipe sub-assembly and cylinder block sub-assembly.

REMOVE NO. 1 TURBO INSULATOR (w/ Intercooler)
1. Remove the 2 bolts and No. 1 turbo insulator.
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ Intercooler)
1. Remove the bolt and No. 1 exhaust manifold heat insulator.
REMOVE TURBINE OUTLET ELBOW
1. w/o Intercooler:
  
  Remove the 2 bolts, 4 nuts, turbine outlet elbow (with turbocharger stay) and gasket.
2. w/ Intercooler:
  
  Remove the 3 nuts, turbine outlet elbow and gasket.
REMOVE TURBOCHARGER STAY (w/ Intercooler)
1. Remove the 2 bolts, nut and turbocharger stay.
REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY (w/ Intercooler)
1. Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe sub-assembly and 3 gaskets.
  
  Note
  
  Do not loosen the nut labeled A.
REMOVE TURBOCHARGER SUB-ASSEMBLY
1. w/o Intercooler:
  1. Remove the 2 bolts and manifold stay.
  2. Remove the 2 bolts, union bolt and 2 gaskets.
  3. Remove the 3 nuts, turbocharger sub-assembly (with turbo oil pipe sub-assembly) and gasket.
  4. Remove the 2 nuts, turbo oil pipe sub-assembly and gasket from the turbocharger sub-assembly.
2. w/ Intercooler:
  
  Remove the 3 nuts, turbocharger sub-assembly and gasket.
REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ Intercooler)
1. Remove the 2 nuts, bolt, No. 1 turbo water pipe sub-assembly and gasket.
2. Slide the clamp and disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.