Turbocharger removal (RZ4E-TC)

1. Component views

Turbocharger

Part name

  1. Nut
  2. Bolt
  3. Water feed and return pipe
  4. Turbocharger
  5. Nut
  6. Turbocharger heat protector
  7. Bolt
  8. Nut
  9. Bolt
  10. Turbocharger oil pipe
  11. Bolt
  12. Bolt
  13. Bolt
  14. Turbocharger bracket
  15. Bolt
  16. Bolt
  17. Nut
  18. Bolt
  19. Catalytic converter
  20. Catalytic converter bracket
  21. Bolt

Tightening torque

1: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 52 N・m { 5.3 kgf・m / 38 lb・ft }

9: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12: 22.5 N・m { 2.3 kgf・m / 17 lb・ft }

13: 25 N・m { 2.5 kgf・m / 18 lb・ft }

15: 52 N・m { 5.3 kgf・m / 38 lb・ft }

16: 52 N・m { 5.3 kgf・m / 38 lb・ft }

17: 52 N・m { 5.3 kgf・m / 38 lb・ft }

18: 52 N・m { 5.3 kgf・m / 38 lb・ft }

21: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

3. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

4. Coolant drain

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

  1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

5. Engine cover removal

1) Remove the engine cover from the engine.

Legend

  1. Engine cover

6. Air duct removal

1) Remove the intake air duct from the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the PCV hose from the cylinder head cover and air duct.

Legend

  1. PCV hose
  2. Clamp

3) Remove the air duct from the air cleaner and turbocharger.

Legend

  1. Air duct

7. Intake hose removal

1) Remove the intake hose from the intercooler and turbocharger.

Legend

  1. Turbocharger
  2. Intercooler
  3. Intake hose
  4. Clamp

8. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Remove the air cleaner from the vehicle.

Legend

  1. Air cleaner
  2. MAF and IAT sensor
  3. Barometric pressure sensor

9. Vacuum hose removal

1) Remove the vacuum hose from the turbocharger and vacuum pipe.

10. Catalytic converter removal

1. Euro4 specifications

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter removal".

11. Exhaust pipe removal

1. Except for Euro4 specifications

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) exhaust pipe removal".

12. Turbocharger water hose disconnect

1) Disconnect the turbocharger water feed hose from the water feed pipe and return pipe.

2) Disconnect the turbocharger water return hose from the water feed pipe and return pipe.

Legend

  1. Turbocharger water feed hose
  2. Turbocharger water return hose

13. Turbocharger oil pipe removal

1) Remove the turbocharger oil pipe and gasket from the turbocharger and cylinder block.

Caution

  • To prevent the intrusion of foreign material, seal the connections.
  • Do not reuse the gasket.

Legend

  1. Turbocharger oil pipe
  2. Gasket

14. Turbocharger bracket removal

1) Remove the turbocharger bracket from the turbocharger and cylinder block.

15. Turbocharger heat protector removal

1) Remove the turbocharger heat protector from the turbocharger.

16. Turbocharger removal

1) Remove the turbocharger and gasket from the exhaust manifold.

Caution

  • To prevent the intrusion of foreign material, seal the connections.
  • Do not reuse the gasket.

2) Remove the water feed and return pipe, as well as the gasket from the turbocharger.

Caution

  • Do not reuse the gasket.

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