Removal Steps

Components For Removal And Installation Of The Turbocharger (1 Of 2):

Components For Removal And Installation Of The Turbocharger (2 Of 2):

TURBOCHARGER REMOVAL PROCEDURES
1. Disconnect negative (-) terminal cable from battery.

CAUTION: Work must not be started for at least 90 seconds after the ignition switch is turned to the LOCK position and the NEGATIVE (-) terminal cable is disconnected from the battery.

2. Drain engine coolant.
3. Remove engine under cover.




4. Disconnect cruise control actuator cable from throttle body.

5. Remove No.1 air hose.



- Loosen the 2 hose clamps, and remove the air hose.

6. Remove air cleaner duct.



- Remove the bolt and air cleaner duct.

7. Remove air cleaner and Mass Air Flow (MAF) Meter assembly.



(a) Remove the 3 bolts.
(b) Loosen the hose clamp, disconnect the air hose from the intake air connector.
(c) Disconnect the MAF meter wire from the clamp on the air cleaner case.
(d) Disconnect the MAF meter connector, and remove the air cleaner and MAF meter assembly.

8. Disconnect theft deterrent horn from body.



- Remove the bolt, and disconnect the horn from the body.

9. Remove front lower arm bracket stay.



- Remove the 2 bolts, nut, plate washer and arm bracket stay.

10. Remove upper front crossmember extension.
- Remove the 2 bolts, 2 nuts and crossmember extension.

11. Remove No.2 front exhaust pipe.



(a) Remove the 2 bolts and nuts holding the front exhaust pipe to the No.2 front exhaust pipe.
(b) Remove the 2 bolts and pipe support bracket.
(c) Disconnect the front exhaust pipe from the No.2 exhaust pipe and remove the gasket.




(d) Remove the 3 nuts, No.2 front exhaust pipe and gasket.

12. Remove heat insulator for No.2 front exhaust pipe.



- Remove the 2 bolts, 2 nuts and heat insulator.

13. Disconnect A/T oil cooler tubes from engine.



(a) Remove the bolt and tube clamp, and disconnect the oil cooler tubes from the bracket (front side) on the generator.
(b) Remove the bolt and tube clamp, and disconnect the oil cooler tubes from the bracket (rear side) on the cylinder block.
(c) Remove the bolt and tube bracket (rear side) from the cylinder block.

14. Disconnect engine wire protector from body.



- Remove the 2 bolts, and disconnect the wire protector from the body.

15. Disconnect the following hoses:
(1) heater hose from No.3 water bypass pipe
(2) EVAP hose from No.1 vacuum pipe




16. Disconnect iac valve pipe from No.2 air tube.
(a) Disconnect the engine wire from the clamp.
(b) Disconnect the following hoses:
(1) air hose (from No.1 vacuum pipe) from IAC valve pipe
(2) air hose from No.2 air tube
(c) Disconnect the IAC valve pipe from the clamp.

17. Disconnect No.1 vacuum pipe from air tubes.



(a) Disconnect the following connectors:
(1) VSV connector for intake air control valve
(2) VSV connector for exhaust bypass valve
(b) Disconnect the engine wire from the 3 clamps.




(c) Disconnect the following hoses:
(1) air hose from No.4 air tube
(2) air hose from No.1 air tube
(3) air hose (from VSV for waste gate valve) from vacuum pipe
(4) air hose (from VSV for exhaust gas control valve) from vacuum pipe
(5) vacuum hose (from air bypass valve) from No.1 air tube
(6) 2 air hoses (from VSV for exhaust bypass valve) from vacuum pipe
(7) air hose (from No.2 air tube) from vacuum pipe
(8) air hose from VSV for intake air control valve
(9) 2 air hoses (from pressure tank) from vacuum pipe
(d) Remove the 3 bolts and disconnect the vacuum pipe from the air tubes.

18. Remove VSV assembly.



(a) Disconnect the following:
(1) air hose from actuator for waste gate valve
(2) air hose from actuator for exhaust gas control valve
(3) air hose from hose clamp
(4) engine wire from wire clamp
(b) Remove the 2 bolts.
(c) Disconnect the 2 VSV connectors, and remove the VSV assembly.

19. REMOVE AIR TUBES AND INTAKE AIR CONNECTOR.
(a) Disconnect the following connector and hoses:



(1) crankshaft position sensor connector from clamp
(2) water bypass hose (from water pump) from No.1 turbo water pipe
(3) water bypass hose (from water outlet) from No.1 turbo water pipe
(4) water bypass hose (from water outlet) from No.2 turbo water pipe




(b) Remove the bolt, and disconnect the No.2 turbo water pipe from the No.4 air tube.




(c) Remove the 2 bolts, and disconnect the No.1 air tube from the No.1 turbocharger and remove the gasket.

(d) Remove the 2 bolts holding the No.4 air tube to the No.1 turbocharger and remove the gasket.
(e) Disconnect the following hoses, and remove the No.4 air tube and air bypass valve assembly.



(1) Air hose from No.4 air tube
(2) Air hose from intake air connector




(f) Remove the 2 nuts, intake air control valve and gasket.




(g) Disconnect the following hoses, and remove the intake air connector and No.1 air tube assembly.
(1) Air hose from No.2 air tube
(2) PCV hose from No.2 cylinder head cover




20. Remove air inlet duct.
- Remove the bolt, 2 nuts, cable bracket and air inlet duct.

21. Remove heat insulator for turbocharger.
- Remove the 4 bolts and heat insulator.

22. Remove exhaust bypass pipe.



- Remove the 4 nuts, bypass pipe and 2 gaskets.

23. Remove exhaust gas control valve stay.



- Remove the bolt, nut and valve stay.

24. Remove main heated oxygen sensor.
(a) Disconnect the oxygen sensor connector.



(b) Remove the 2 nuts, oxygen sensor and gasket.

25. Remove exhaust gas control valve.



- Remove the 3 nuts, control valve and 2 gaskets.

NOTICE: The control valve is ceramic and may be broken if dropped.




26. Remove No.1 turbocharger stay.
- Remove the bolt, nut and turbocharger stay.
27. Remove No.2 turbocharger stay.
- Remove the bolt, nut and turbocharger stay.




28. Remove the No.1 turbo oil pipe.
(a) Remove the union bolt holding the turbo oil pipe to the cylinder block. Remove the 2 gaskets.
(b) Remove the 2 nuts, and disconnect the turbo oil pipe from turbocharger. Remove the gasket.
(c) Disconnect the turbo oil hose from the turbo oil outlet on the No.1 oil pan, and remove the turbo oil pipe.

29. Remove No.2 turbo oil pipe.
(a) Remove the union bolt holding the turbo oil pipe to the cylinder block. Remove the 2 gaskets.
(b) Remove the 2 nuts, and disconnect the turbo oil pipe from turbocharger. Remove the gasket.
(c) Disconnect the turbo oil hose from the turbo oil outlet on the No.1 oil pan, and remove the turbo oil pipe.

30. Remove turbochargers and turbine outlet elbow assembly.



(a) Disconnect the following hoses:
(1) heater hose (from No.3 water bypass pipe) from No.2 water bypass pipe
(2) water bypass hose (from No.2 turbo water pipe) from No.2 water bypass pipe




(b) Remove the 8 nuts holding the turbochargers to the exhaust manifold.
(c) Remove the 2 turbochargers and turbine outlet elbow assembly.
(d) Remove the 2 gaskets.

31. Remove No.1 vacuum pipe from No.2 turbocharger.



- Disconnect the 2 air hoses from the actuator for the exhaust bypass valve, and remove the vacuum pipe.

32. Remove No.2 air tube and No.3 water bypass pipe assembly from NO.2 turbocharger.



- Remove the 2 bolts, the air tube, bypass pipe assembly and gasket.




33. Remove exhaust manifold plate from turbine outlet elbow.
- Remove the 2 bolts and manifold plate.

34. Remove No.2 turbo water pipe from No.2 turbocharger.
Remove the 2 nuts, water pipe and gasket.

35. Remove bearing housing side plate from No.1 turbocharger.
- Remove the 2 nuts, housing plate and gasket.




36. Remove No.1 turbo water pipe from No.1 turbocharger.
- Remove the 2 nuts, water pipe and gasket.

37. Remove bearing housing side plate from No.2 turbocharger.
- Remove the 2 nuts, housing plate and gasket.

38. Remove No.1 turbocharger from turbine outlet elbow.



- Remove the 6 nuts, turbocharger and gasket.

39. Remove No.2 turbocharger from turbine outlet elbow.
- Remove the 6 nuts, turbocharger and gasket.