REMOVAL AND INSTALLATION <4D5>


Pre-removal Operation
  • Under Skid Plate and Engine Room Under Cover Front Removal.
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Change ).
  • Air Cleaner Assembly Removal (Refer to ).
  • Air Hose A1 Removal (Refer to ).
  • Catalytic Converter Removal (Refer to GROUP 17 - Emission Control, Catalytic Converter ) <Except Euro2>.
  • Exhaust Front Pipe Removal (Refer to ) <Euro2>.

 Post-installation Operation
  • Catalytic Converter Installation (Refer to GROUP 17 - Emission Control, Catalytic Converter ) <Except Euro2>.
  • Exhaust Front Pipe Installation (Refer to ) <Euro2>.
  • Air Hose A1 Installation (Refer to ).
  • Air Cleaner Assembly Installation (Refer to ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Change ).
  • Under Skid Plate and Engine Room Under Cover Front Installation.




Removal steps
<<A>>
1.
 Oil pipe


2.
 Gasket


3.
 Water hose connection


4.
 Water pipe B


5.
 Gasket


6.
 Water hose connection


7.
 Water pipe C


8.
 Gasket


9.
 Oil return pipe

>>D<<
 10.
 Oil return pipe gasket


11.
 Nut and washer

>>C<<
 12.
 Turbocharger assembly

>>B<<
 13.
 Turbocharger gasket

>>A<<
 14.
 Stud


15.
 Exhaust manifold heat protector


16.
 Nut


17.
 Engine hanger


18.
 Nut and washer


19.
 Exhaust manifold


20.
 Exhaust manifold gasket

>>A<<
 21.
 Stud

REMOVAL SERVICE POINT

<<A>> OIL PIPE REMOVAL
caution Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the oil pipe is removed.

INSTALLATION SERVICE POINTS

>>A<< STUD INSTALLATION
The stud should protrude 25 to 27 mm from the end of the exhaust manifold or turbocharger.

>>B<< TURBOCHARGER GASKET INSTALLATION

Position the projection as shown in the illustration.

>>C<< 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.

>>D<< OIL RETURN PIPE GASKET INSTALLATION

Position the projection as shown in the illustration.