Turbocharger and Exhaust Manifold Removal and Installation

Exploded View Removal

1. Remove the engine cover.

1. Remove the catalytic converter bracket (A), then remove the catalytic converter (B).

1. Remove the breather hose (A) and vacuum hoses (B).

1. Remove the vacuum line (C) from the cylinder head cover.

1. Remove three bolts securing the cover.

1. Remove the cover as illustration shown.

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

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

1. Remove the turbocharger inlet hose (A) and turbocharger outlet hose (B).

1. Remove the turbocharger, 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 touch the impeller.

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

1. 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.

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

1. Pour new engine oil into turbocharger oil line.

1. Install the turbocharger (A) with a new gasket (B).
   NOTE: To avoid damaging the turbocharger;
   - Do not turn the actuator rod adjust nut.
   - Do not touch the impeller.

1. Install the turbocharger inlet hose (A) and turbocharger outlet hose (B).

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

1. Install the oil bypass pipe with new gaskets (C) and new washers (D).
   NOTE: Face the tab of the gaskets to the transmission side.

1. Install the turbocharger bracket (E).

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

1. Install the water bypass hose (C).

1. Install the cover on the exhaust manifold, then tighten the three bolts securing the cover.

1. Install the breather hose (A) and vacuum hoses (B).

1. Install the vacuum line (C) to the cylinder head cover.

1. Install the catalytic converter (A) with new gaskets (B), then install the catalytic converter bracket (C).

1. Install the engine cover.