TURBOCHARGER (w/ EGR Cooler) REMOVAL


  1. 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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)

  4. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)

  5. DRAIN ENGINE COOLANT

    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. A01DY58E01

      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.

      A01DY14E01

  6. REMOVE FRONT FENDER APRON SEAL UPPER


    1. for 4WD:

      Remove the 5 clips and front fender apron seal upper.

    2. for 2WD:

      Remove the 6 clips and front fender apron seal upper.

  7. REMOVE FRONT FENDER SEAL


    1. Remove the 5 clips and front fender seal.

  8. 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.

  9. REMOVE AIR CLEANER ASSEMBLY

    A01DWMDE02

    1. Disconnect the mass air flow meter connector and remove the clamp.

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

    3. Remove the 2 bolts and air cleaner assembly.

  10. REMOVE INTERCOOLER ASSEMBLY

    Click here

  11. REMOVE VENTILATION PIPE


    1. A01DXEZ

      for LHD:

      Disconnect the No. 12 water by-pass hose and No. 13 water by-pass hose.

    2. A01DXQXE01
      Text in Illustration
      *A for RHD
      *B for LHD

      Remove the bolt and ventilation pipe.

  12. REMOVE COMPRESSOR INLET ELBOW (for LHD)


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

    2. A01DX8N

      Disconnect the No. 1 turbo water hose.

    3. A01E0Z9E01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 13 Water By-pass Hose

      Disconnect the No. 2 water by-pass hose and No. 13 water by-pass hose.

    4. Remove the 2 nuts, compressor inlet elbow and gasket.

    5. A01DXHHE01
      Text in Illustration
      *1 No. 7 Water By-pass Hose
      *2 No. 12 Water By-pass Hose

      Remove the No. 7 water by-pass hose and No. 12 water by-pass hose.

  13. REMOVE COMPRESSOR INLET ELBOW (for RHD)


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

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

    3. A01E1F0

      Disconnect the 2 No. 1 turbo water hoses.

  14. REMOVE NO. 1 TURBO INSULATOR


    1. A01E0PK

      Remove the 2 bolts and No. 1 turbo insulator.

  15. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A01DYZA

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

  16. REMOVE TURBINE OUTLET ELBOW

    A01E08NE01

    1. Remove the 3 nuts, outlet elbow and gasket.

  17. REMOVE TURBOCHARGER STAY

    A01DYCJE02

    1. Remove the 2 bolts, nut and stay.

  18. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    A01DXE2E02

    1. Remove the 2 bolts, 2 nuts, union bolt, inlet pipe sub-assembly and 3 gaskets.

      Note

      Do not loosen the nut labeled A.

  19. REMOVE TURBOCHARGER SUB-ASSEMBLY

    A01E0IFE01

    1. Remove the 3 nuts, turbocharger sub-assembly and gasket.

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


    1. A01E2XL

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

    2. Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.