EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE

1. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o Glow Plug Controller)

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2. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ Glow Plug Controller)

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3. DISCONNECT NO. 1 AIR HOSE

   1. 

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

4. DISCONNECT NO. 1 TURBO WATER HOSE (w/ Glow Plug Controller)

   1. 

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

5. DISCONNECT NO. 2 TURBO WATER HOSE (w/ Glow Plug Controller)

   1. 

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

6. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ Glow Plug Controller)

   1. 

      Remove the 4 bolts and No. 1 turbo water pipe sub-assembly from the turbocharger sub-assembly.

   2. Remove the water by-pass gasket from the turbocharger sub-assembly.

7. REMOVE TURBOCHARGER STAY

   1. 

      *A	w/o Glow Plug Controller
      *B	w/ Glow Plug Controller

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

8. REMOVE MANIFOLD STAY

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

      

      *A

      w/o Glow Plug Controller

      *B

      w/ Glow Plug Controller

9. SEPARATE INLET TURBO OIL PIPE SUB-ASSEMBLY

   1. 

      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.

10. REMOVE TURBOCHARGER SUB-ASSEMBLY

    1. 

       Disconnect the 2 turbocharger sub-assembly connectors.

    2. 

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

       Note:

       When removing the turbocharger sub-assembly, do not hold it by the electric actuator rod.

    3. 

       Remove the turbo to exhaust manifold gasket from the exhaust manifold.

    4. 

       Remove the inlet turbo oil gasket from the turbocharger sub-assembly.

    5. 

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

    6. 

       Remove the No. 1 outlet turbo oil gasket from the cylinder block sub-assembly.

11. REMOVE INLET COMPRESSOR ELBOW SUB-ASSEMBLY

    1. 

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

    2. 

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

12. REMOVE EXHAUST MANIFOLD (w/o Glow Plug Controller)

    1. 

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

    2. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

13. REMOVE EXHAUST MANIFOLD (w/ Glow Plug Controller)

    1. 

       	Bolt
       	Nut

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

    2. Remove the 2 bolts and No. 2 manifold support bracket from the cylinder head sub-assembly and cylinder block sub-assembly.

    3. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

14. REMOVE STUD BOLT

    Tip:

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

    1. 

       Using an E6 "TORX" wrench, remove the 3 stud bolts (A) from the turbocharger sub-assembly.

    2. Using an E10 "TORX" wrench, remove the stud bolt (B) from the turbocharger sub-assembly.

    3. 

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