Turbocharger and Exhaust Manifold Removal and Installation

Expoloded View


 











 

Removal


1.Drain the engine coolant.

2.Remove the splash shield.

3.Loosen the bands (A) securing the turbocharger outlet hose and intercooler intake hose, and remove the intercooler intake hose (B), then remove the intercooler intake pipe mounting bolts (C).

 

4.Remove the intercooler intake pipe bracket (D), then remove the intercooler intake pipe (E).

5.Remove the turbocharger outlet hose.

 

6.Remove exhaust pipe A.

 

7.Remove the warm up four way catalytic converter bracket (A), then remove the four way catalytic converter (B).

 

8.Remove the air cleaner housing.

9.Remove the engine cover.

 

10.Remove the air flow tube.

 

11.Remove the breather hose (A) and vacuum hoses (B), then remove the air flow pipe bracket (C).

 

12.Remove the vacuum line (D) from the cylinder head cover.

13.Remove the exhaust manifold cover.

 

14.Remove the sealing bolt (A) and water bypass hose (B).

 

15.Remove the turbocharger bracket (A), then remove the oil bypass pipe (B).

 

16.Remove the turbocharger assembly, then seal the air inlet, air outlet, oil line hole, and water line hole with tape.

NOTE:
  • To avoid damaging the turbocharger.
  • Do not turn the actuator rod adjust nut.
  • Do not tach the impeller.

 

17.Remove the water bypass pipe (A), breather pipe (B), and air flow pipe (C).

 

18.Remove the cover (A), then remove the exhaust joint (B).

 

19.Remove the exhaust manifold.

 

Installation


1.Install the exhaust manifold (A) with a new gasket (B) and new self-locking nuts (C), and tighten the nuts in a crisscross pattern in two or three steps, beginning with the inner nut.

 

2.Install the exhaust joint (A) with new gasket (B), then install the cover (C).

 

3.Install the air flow pipe (A), water bypass pipe (B), and breather pipe (C) with new gaskets (D).

 

4.Pour new engine oil into turbocharger oil line.

5.Install the turbocharger assembly (A) with a new gasket (B).

NOTE:
  • To avoid damaging the turbocharger.
  • Do not turn the actuator rod adjust nut.
  • Do not tach the impeller.

 

6.Check the bolt (A) and oil bypass pipe (B) for clogged. If they are clogged clean or replace the bolt and/or pipe.

 

7.Install the oil bypass pipe with new gaskets (C) and new washers (D).

8.Install the turbocharger bracket (E).

9.Install the sealing bolt (A) with new washers (B).

 

10.Install the water bypass hose (C).

11.Install the exhaust manifold cover.

 

12.Install the vacuum line (A) to the cylinder head cover.

 

13.Install the air flow pipe bracket (B), then install breather hose (C) and vacuum hoses (D).

14.Install the air flow tube.

 

15.Install the engine cover.

 

16.Install the air cleaner housing.

17.Install the four way catalytic converter (A). Use new gasket (B), then install four way catalytic converter bracket (C).

 

18.Install exhaust pipe A. Use new gaskets (B) and new self locking nuts (C).

 

19.Install the turbocharger outlet hose, and align the mark (A) on the hose with the pointer (B) on the turbocharger, then secure the hose with the band.

 

20.Install the intercooler intake pipe (A) to the turbocharger outlet hose (B), then install the intercooler intake pipe bracket (C).

 

21.Loosely tighten the intercooler intake pipe mounting bolts (D). Make sure the mark (E) of the intercooler intake pipe contacts with the turbocharger outlet hose end.

22.Tighten the intercooler intake pipe mounting bolts, and secure the turbocharger outlet hose with the band (F), then install the intercooler intake hose (G), and secure the hose with band (H).

23.Install the splash shield.

24.Refill the expansion tank with engine coolant, and bleed air from the cooling system with the heater valve open.