EXHAUST MANIFOLD W/ TURBOCHARGER > REMOVAL

for Preparation Click here

1. Remove the exhaust pipe (Click here).
   

1. Remove the front wiper motor and link (Click here).
   

1. Disconnect the connector and 2 wire harness clamps.
   

   Text in Illustration 

   *1	Wire harness clamp
   *2	Clamp

2. Loosen the hose clamp and separate the air cleaner hose.
   

3. Disengage the 2 clamps and 2 claws and remove the air cleaner cap.
   

1. Remove the air cleaner filter element.
   

1. Remove the 3 bolts and the air cleaner case.
   

1. Remove the air cleaner hose.
   

1. Disengage the 3 claws and remove the engine cover.
   

1. Disconnect the union to connector tube hose.
   

2. Disconnect the air fuel ratio sensor connector.
   

3. Disengage the 3 wire harness clamps and separate the air fuel ratio sensor wire harness.
   

4. Using SST, remove the air fuel ratio sensor.
   

   SST

   09224-00010  
   

1. Remove the bolt, nut and No. 2 turbo insulator.
   

1. Remove the bolt, disengage the harness clamp and separate the wire harness.
   

2. Remove the 2 bolts and the oil level dipstick guide.
   

3. Remove the O-ring from the oil level dipstick guide.
   

1. Remove the cotter pin and castle nut.
   

2. Install SST (spacer B) to the threaded section of the tie rod end.
   

   SST

   09960-20010   (09961-02060)
   

   NOTICE:

   Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

3. Using SST, separate the tie rod end from the front axle assembly.
   
   

   
   
   
   

   Text in Illustration 

   *1	Place the wrench here

   SST

   09960-20010   (09961-02010)
   

   NOTICE:

   1. Make sure to tie the string of SST to the vehicle to prevent SST from dropping.
      
   2. Install SST so that A and B are parallel.
      
   3. Be sure to place the wrench on the part indicated in the illustration.
      
   4. Do not damage the ball joint dust cover.
      
   5. Do not damage the front disc brake dust cover.
      

1. Remove the tail exhaust pipe assembly (Click here).
   

1. Remove the bolt, nut and No. 2 manifold support bracket.
   

1. Remove the 2 bolts, nut and manifold support bracket.
   

1. Loosen the 2 hose clamps and remove the No. 1 air hose.
   

1. Disconnect the connector and disengage the harness clamp.
   

2. Remove the 3 nuts and exhaust manifold converter.
   

   HINT:

   1. Fasten the exhaust manifold converter to the body with a piece of rope.
      
   2. The exhaust manifold converter cannot be removed from the vehicle until the turbocharger is removed, due to lack of space
      

3. Remove the gasket from the turbocharger.
   

1. Remove the 3 nuts and exhaust manifold converter.
   

   1. Fasten the exhaust manifold converter to the body with a piece of rope.
      
   2. The exhaust manifold converter cannot be removed from the vehicle until the turbocharger is removed, due to lack of space
      

2. Remove the gasket from the turbocharger.
   

1. Remove the 2 bolts and the No. 1 turbo insulator.
   

1. Remove the 2 bolts, the nut and the turbocharger stay.
   

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

1. Remove the 2 bolts and the manifold stay.
   

1. Disconnect the 2 turbocharger connectors.
   

2. Remove the 11 nuts and turbocharger with exhaust manifold.
   

3. Remove the 2 gaskets from the cylinder head and cylinder block.
   

1. Remove the 2 nuts and inlet turbo oil pipe from the turbocharger.
   

2. Remove the gasket from the turbocharger.
   

1. Remove the 3 nuts and turbocharger.
   

2. Remove the gasket from the exhaust manifold.