REMOVAL AND INSTALLATION


Pre-removal Operation
  • Engine Cover Removal (Refer to GROUP 11C - Engine Assembly ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Cleaner Assembly Removal (Refer to ).
  • EGR Pipe B Assembly and EGR Cooler Assembly Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Except Emission Regulation Euro 5>.
  • EGR Pipe B Assembly and EGR Cooler Assembly Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Emission Regulation Euro 5>.
  • Front Exhaust Pipe Removal (Refer to ) <Vehicles without DPF>.
  • Front Exhaust Pipe Removal (Refer to ) <Vehicles with DPF-M/T>.
  • Front Exhaust Pipe Removal (Refer to ) <Vehicles with DPF-A/T>.
  • E-VRV Assembly and E-VRV Bracket Assembly Removal (Refer to GROUP 13B - Fuel Injector and Common Rail ).
  • Turbocharger Water Pipe B Removal (Refer to GROUP 14 - Water Hose and Water Pipe ) <Except Emission Regulation Euro 5>.
  • Turbocharger Water Pipe B Removal (Refer to GROUP 14 - Water Hose and Water Pipe ) <Emission Regulation Euro 5>.

 Post-installation Operation
  • Turbocharger Water Pipe B Installation (Refer to GROUP 14 - Water Hose and Water Pipe ) <Except Emission Regulation Euro 5>.
  • Turbocharger Water Pipe B Installation (Refer to GROUP 14 - Water Hose and Water Pipe ) <Emission Regulation Euro 5>.
  • E-VRV Assembly and E-VRV Bracket Assembly Installation (Refer to GROUP 13B - Fuel Injector and Common Rail ).
  • Front Exhaust Pipe Installation (Refer to ) <Vehicles without DPF>.
  • Front Exhaust Pipe Installation (Refer to ) <Vehicles with DPF-M/T>.
  • Front Exhaust Pipe Installation (Refer to ) <Vehicles with DPF-A/T>.
  • EGR Pipe B Assembly and EGR Cooler Assembly Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Except Emission Regulation Euro 5>.
  • EGR Pipe B Assembly and EGR Cooler Assembly Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Emission Regulation Euro 5>.
  • Air Cleaner Assembly Installation (Refer to ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Under Skid Plate and Engine Room Under Cover (Front) Installation (Refer to GROUP 51 - Under Cover ).
  • Engine Cover Installation (Refer to GROUP 11C - Engine Assembly ).




Removal steps


1.
 Harness bracket <vehicles with DPF-M/T>


2.
 Turbocharger heat protector


3.
 Oil return hose


4.
 Oil pipe assembly

>>C<<
 5.
 Gasket


6.
 Gasket


7.
 Exhaust manifold heat protector

>>B<<
 8.
 Turbocharger assembly


9.
 Gasket

>>A<<
 10.
 Exhaust manifold


11.
 Exhaust manifold gasket

INSTALLATION SERVICE POINTS

>>A<< EXHAUST MANIFOLD INSTALLATION
Before using the tool to remove the exhaust manifold, move the heater hose clamp to a position where the tool would not interfere with it.

>>B<< TURBOCHARGER ASSEMBLY INSTALLATION
1.Check the internal surface, the mating surface of the oil pipe and water pipe for clogging, and clean if necessary.
2.
caution Be careful not to allow foreign material to enter the turbocharger.
If deposits of carbon are accumulated on the turbocharger oil passage, remove them and clean using the compressed air.
3.Add clean engine oil through the oil feed pipe port on the turbocharger.

>>C<< GASKET INSTALLATION

The tab on the oil pipe gasket should be position as shown.