REMOVAL AND INSTALLATION


Pre-removal Operation
  • Engine Cover Removal (Refer to GROUP 11G - Engine Assembly )
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining <4M4> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Cleaner Assembly Removal <4M4> (Refer to ).
  • EGR Pipe B Assembly, EGR Cooler Assembly Removal (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Front Catalytic Converter Removal <4M41> (Refer to ).
  • Turbocharger Water Inlet Pipe, Turbocharger Water Outlet Pipe Removal <4M41> (Refer to GROUP 14 - Water Hose and Water Pipe ).

 Post-installation Operation
  • Turbocharger Water Inlet Pipe, Turbocharger Water Outlet Pipe Installation <4M41> (Refer to GROUP 14 - Water Hose and Water Pipe ).
  • Front Catalytic Converter Installation <4M41> (Refer to ).
  • EGR Pipe B Assembly, EGR Cooler Assembly Installation (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Air Cleaner Assembly Installation <4M4> (Refer to ).
  • Engine Oil Refilling <4M4> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Under Skid Plate and Engine Room Under Cover (Front) Installation (Refer to GROUP 51 - Under Cover ).
  • Engine Cover Installation (Refer to GROUP 11G - Engine Assembly ).




Removal steps


1.
 Turbocharger heat protector


2.
 Vacuum hose


3.
 Snap ring


4.
 Waste gate actuator


5.
 Oil return hose


6.
 Oil return pipe

>>C<<
 7.
 Gasket


8.
 Oil pipe assembly


9.
 Gasket

>>B<<
 10.
 Turbocharger assembly


11.
 Gasket


12.
 Exhaust manifold heat protector

>>A<<
 13.
 Exhaust manifold


14.
 Exhaust manifold gasket

INSTALLATION SERVICE POINTS

>>A<< EXHAUST MANIFOLD INSTALLATION
Before using the tool to remove the exhaust manifold, move the heater hose clamp to a position where the tool would not interfere with it.

>>B<< TURBOCHARGER ASSEMBLY INSTALLATION
1.Check the internal surface, the eye bolt and the mating surface of the oil pipe and water pipe for clogging, and clean if necessary.
2.
caution Be careful not to allow foreign material to enter the turbocharger.
If deposits of carbon are accumulated on the turbocharger oil passage, remove them and clean using the compressed air.
3.Add clean engine oil through the oil feed pipe port on the turbocharger.

>>C<< GASKET INSTALLATION

The tab on the oil return pipe gasket should be position as shown.