Repair Procedures

Removal

CAUTION:
Check that engine is cool enough to work.

1. Disconnect the negative (-) battery terminal (A).




2. Remove the drain plug (A) and drain the engine coolant.




3. Remove the front muffler (A).




4. Disconnect the breather hose (A), vacuum hose (B). And remove the air duct (C) and air cleaner assembly (D).

Tightening torque :
Bolt : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
Clamp : 2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.1 - 3.6lb-ft)




5. Disconnect the intercooler inlet hose (A).

Tightening torque :
Bolt : 14.7 - 19.6N.m (1.5 - 2.0kgf.m, 10.8 - 14.4lb-ft)
Clamp : 4.9 - 6.8N.m (0.5 - 0.7kgf.m, 3.6 - 5.0lb-ft)




6. Remove the drive belt (A).




7. Remove the turbo control hoses (A).




8. Remove the power steering pump.
9. Remove the steering pump bracket (A).

Tightening torque :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 13.4 - 17.4lb-ft)




10. Remove the exhaust manifold heat protector (A) and turbocharger heat protector (B).

Tightening torque :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)





CAUTION:
Check that engine is cool enough to work.

11. Remove the oxygen sensor connectors (A).




12. Remove the coolant hoses (A) and oil hoses (B) from turbocharger.








13. Remove the turbocharger stay bolt (A) and WCC stay bolt (B).

Tightening torque :
A: 49.0 - 53.9N.m (5.0 - 5.5kgf.m, 36.1 - 39.8lb-ft)
B: 8.6 - 27.4N.m (1.9 - 2.8kgf.m, 13.7 - 20.2lb-ft)




14. Remove the exhaust manifold & turbocharger assembly (A) and gasket.

Tightening torque :
49.0 - 53.9N.m (5.0 - 5.5kgf.m, 36.1 - 39.8lb-ft)




15. Installation is the reverse of removal.

NOTE:
- Always use the new turbocharger, exhaust manifold and WCC gaskets when replacing.
- Always use a new turbocharger nuts and, exhaust manifold nuts when it is removed.
- Check that turbo control hose is installed in the right position to avoid interference with another parts (Heat protector, air hose etc.).
- Take care whether the turbocharger coolant hose is interfered with heat protector and exhaust manifold.