REMOVAL AND INSTALLATION


<Except high power engine>


Pre-removal Operation
  • 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 ).
  • Air Cleaner Assembly Removal (Refer to ).
  • Air Hose A1 Removal (Refer to ) <Vehicles with Intercooler>.
  • Exhaust Front Pipe Removal (Refer to ) <Vehicles without Catalytic Converter>.
  • Catalytic Converter Removal (Refer to GROUP 17 - Emission Control, Catalytic Converter ) <Vehicles with Catalytic Converter>.

 Post-installation Operation
  • Exhaust Front Pipe Installation (Refer to ) <Vehicles without Catalytic Converter>.
  • Catalytic Converter Installation (Refer to GROUP 17 - Emission Control, Catalytic Converter ) <Vehicles with Catalytic Converter>.
  • Air Hose A1 Installation (Refer to ) <Vehicles with Intercooler>.
  • Air Cleaner Assembly Installation (Refer to ).
  • 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 ).




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

<High power engine>


Pre-removal Operation
  • 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 ).
  • Air Cleaner Assembly Removal (Refer to ).
  • Air Hose A1 Removal (Refer to ).
  • Exhaust Front Pipe Removal (Refer to ) <Vehicles without Catalytic Converter>.
  • Catalytic Converter Removal (Refer to GROUP 17 - Emission Control, Catalytic Converter ) <Vehicles with Catalytic Converter>.

 Post-installation Operation
  • Exhaust Front Pipe Installation (Refer to ) <Vehicles without Catalytic Converter>.
  • Catalytic Converter Installation (Refer to GROUP 17 - Emission Control, Catalytic Converter ) <Vehicles with Catalytic Converter>.
  • Air Hose A1 Installation (Refer to ).
  • Air Cleaner Assembly Installation (Refer to ).
  • 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 ).




Removal steps


1.
 Turbocharger heat protector
<<A>>
2.
 Oil pipe


3.
 Gasket


4.
 Heat protector


5.
 Heat protector bracket


6.
 Water hose connection


7.
 Water hose connection

>>I<<
 8.
 Oil return hose assembly


9.
 Bolt and washer


10.
 Nut and washer


11.
 Turbocharger, turbocharger water pipe and oil return pipe assembly

>>H<<
 12.
 Turbocharger gasket

>>G<<
 13.
 Exhaust manifold heat protector A


14.
 Exhaust manifold heat protector B


15.
 Nut


16.
 Engine hanger


17.
 Nut and washer


18.
 Exhaust manifold


19.
 Exhaust manifold gasket




Removal steps


20.
 Oil return pipe

>>F<<
 21.
 Oil return pipe gasket


22.
 Water hose


23.
 Turbocharger water pipe

>>E<<
 24.
 Turbocharger water pipe gasket

>>C<<
 25.
 Turbocharger assembly

>>A<<
 26.
 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.

>>E<< TURBOCHARGER WATER PIPE GASKET INSTALLATION

Position the projection as shown in the illustration.

>>F<< OIL RETURN PIPE GASKET INSTALLATION

Position the projection as shown in the illustration.

>>G<< EXHAUST MANIFOLD HEAT PROTECTOR A INSTALLATION

1.Temporarily tighten the bolt A.
2.Temporarily tighten the bolt B.
3.Tighten the bolt A To the specified torque.
Tightening torque: 14 ± 1 N·m
4.Tighten the bolt B To the specified torque.
Tightening torque: 14 ± 1 N·m

>>H<< TURBOCHARGER GASKET INSTALLATION

Position the projection as shown in the illustration.

>>I<< OIL RETURN HOSE ASSEMBLY INSTALLATION

Install the oil return hose assembly and hose clip in the direction shown in the illustration.