Turbocharger and Exhaust Manifold Removal and Installation

Exploded View Removal Remove the engine cover. Remove the catalytic converter bracket (A), then remove the catalytic converter (B). |

Remove the breather hose (A) and vacuum hoses (B). Remove the vacuum line (C) from the cylinder head cover. |

Remove three bolts securing the cover. |

Remove the cover as illustration shown. |

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

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

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

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. |

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

Remove the exhaust manifold. |

Installation 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. |

Install the exhaust joint (A) with new gasket (B), then install the cover (C). Pour new engine oil into turbocharger oil line. |

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. |

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

Check the bolt (A) and oil bypass pipe (B) for clogged. If they are clogged clean or replace the bolt and/or pipe. Install the oil bypass pipe with new gaskets (C) and new washers (D). NOTE: Face the tab of the gaskets to the transmission side. Install the turbocharger bracket (E). |

Install the sealing bolt (A) with new washers (B). Install the water bypass hose (C). |

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

Install the breather hose (A) and vacuum hoses (B). Install the vacuum line (C) to the cylinder head cover. |

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