TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

Fuel injector (2pin type)

Washer
 
Quantity: 4
 
Location of use: Water pipe No.1
Gasket
 
Quantity: 1
 
Location of use: Water pipe No.1
Washer
 
Quantity: 4
 
Location of use: Oil pipe No.4
Gasket
 
Quantity: 2
 
Location of use: Water pipe No.3
Nut
 
Quantity: 4
 
Location of use: Turbocharger
Gasket
 
Quantity: 1
 
Location of use: Turbocharger
Washer
 
Quantity: 2
 
Location of use: Water pipe No.2
Gasket
 
Quantity: 1
 
Location of use: Water pipe No.2
Gasket
 
Quantity: 2
 
Location of use: Oil pipe No.2
Gasket
 
Quantity: 1
 
Location of use: Oil pipe No.3
Washer
 
Quantity: 4
 
Location of use: Oil pipe No.1
Vacuum hose
 
Quantity: 1
 
Location of use: MAP sensor No.1

Fuel injector (6pin type)

Stud
 
Quantity: 3
 
Location of use: Turbocharger
Gasket
 
Quantity: 1
 
Location of use: Oil pipe No.3
Gasket
 
Quantity: 1
 
Location of use: Oil pipe No.4
Gasket
 
Quantity: 1
 
Location of use: Turbocharger air inlet pipe
Nut
 
Quantity: 3
 
Location of use: Turbocharger
Gasket
 
Quantity: 1
 
Location of use: Turbocharger
Gasket
 
Quantity: 1
 
Location of use: Oil pipe No.5
Gasket
 
Quantity: 2
 
Location of use: Oil pipe No.1
Gasket
 
Quantity: 2
 
Location of use: Oil pipe No.2
Vacuum hose No.1
 
Quantity: 1
 
Location of use: MAP sensor No.1
—
—

Warning
•  A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.
Caution
•  Perform exhaust gas temperature sensor removal/installation only when inspection or replacement is required, such as when DTCs for the sensor are displayed, because it may cause exhaust gas leakage. If the exhaust gas temperature sensor is removed once, always verify that there is no exhaust gas leakage after reinstallation.
Note
•  If the turbocharger is replaced or removed/installed, perform the “Operation After Replacing or Removal/Installation Turbocharger” procedure.

Operation After Replacing or Removal/Installation Turbocharger

1.  If the turbocharger is replaced or removed/installed, perform the following procedure.

Fuel injector (2pin type)

STEP

ACTION

PAGE/CONDITION
1
Perform turbocharger initialization procedure.
(See TURBOCHARGER INITIALIZATION [SKYACTIV-D 2.2].)
2
Switch the ignition off.
—
3
Wait for 20 s.
—
4
Switch the ignition ON (engine off).
—
5
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
6
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)

Fuel injector (6pin type)

STEP

ACTION

PAGE/CONDITION
1
Switch the ignition ON (engine off).
—
2
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
3
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)


Turbocharger Removal/Installation (Fuel injector (2pin type))

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

4.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose
•  Air inlet pipe
•  Breather hose
•  Turbocharger air inlet hose
•  Blow-by heater

7.  Set the turbocharger air outlet pipe component aside as a single unit as shown in the figure. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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8.  Remove the wiring harness clip shown in the figure.

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9.  Disconnect the regulating valve position sensor connector.

10.  Detach the wiring harness clips shown in the figure.

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11.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

12.  Remove the catalytic converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Remove the transfer. (4WD)(See TRANSFER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-D 2.2)].)

14.  Remove in the order shown in the figure.

15.  Install in the reverse order of removal.

16.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

17.  Perform the following procedure.

When newly replacing turbocharger
•  Replace the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-D 2.2].)
When installing a removed turbocharger
•  Inspect the engine oil level. (See ENGINE OIL LEVEL INSPECTION [SKYACTIV-D 2.2].)

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1
Water hose
2
Vacuum hose
(See Vacuum hose installation note.)
3
Turbocharger bracket
4
Water pipe No.1
5
Turbocharger insulator No.1
6
Water pipe No.2 installation bolt
7
Water pipe No.3 installation bolt
8
Turbocharger insulator No.2
9
Oil pipe No.1
10
Oil pipe No.2 installation bolt
11
Turbocharger
(See Turbocharger installation note.)
(See Operation After Replacing or Removal/Installation Turbocharger.)
12
Oil pipe No.2
(See Oil pipe No.2 removal note.)
(See Oil pipe No.2 installation note.)
13
Oil pipe No.3
14
Oil pipe No.4
(See Oil pipe No.4 installation note.)
15
Turbocharger insulator No.3
16
Water pipe No.2
(See Water pipe No.2 installation note.)
17
Water pipe No.3
18
Turbocharger insulator No.4


Oil pipe No.2 removal note

1.  Remove oil pipes No.2 and 3 as a single unit.

2.  Remove oil pump No.2.


Water pipe No.2 installation note

Note
•  Water pipe No.2 can be installed in the correct position by temporarily putting the flange nut as shown in the figure.

1.  Insert a flange nut (M10 (Approx. 9 mm {0.4 in})) between the position shown in the figure and tighten water pipe No.2 (turbocharger side).

ac5wzw00008621

Water pipe No.2 (turbocharger side) tightening torque
40—52 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}

2.  Measure the distance shown in the figure and verify that water pipe No.2 is installed correctly.

ac5wzw00008622


Oil pipe No.4 installation note

Caution
•  Oil pipe No.4 may be damaged if it is secured out of the securement range. Secure oil pipe No.4 within the securement range.

1.  Secure oil pipe No.4 using a wrench so that it does not rotate.

ac5wzw00008623

2.  Tighten the oil pipe No.4.

Oil pipe No.4 tightening torque
40—52 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}


Oil pipe No.2 installation note

1.  Install the oil pipe No.2 as shown in the figure.

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Turbocharger installation note

1.  Install the turbocharger using the following procedure.

(1)  Temporarily tighten nuts in the order shown in the figure.
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Tightening torque
23—27 N·m {2.4—2.7 kgf·m, 17—19 ft·lbf}
(2)  Tighten the nuts in the order shown in the figure.
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Tightening torque
44—57 N·m {4.5—5.8 kgf·m, 33—42 ft·lbf}


Vacuum hose installation note

1.  Install the vacuum hose as shown in the figure.

ac5wzw00006722


Turbocharger Removal/Installation (Fuel injector (6pin type))

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

4.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

5.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air hose
•  Air inlet pipe

7.  Remove the nuts and set the turbocharger air outlet pipe component aside. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

ac5wzw00012021

8.  Disconnect the blow-by heater connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Disconnect the breather hose from the blow-by heater side. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Remove the bolts shown in the figure and set aside the wiring harness bracket and wiring harness as a single unit.

ac5wzw00012022

11.  Disconnect the MAP sensor No.1 connector. (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

12.  Disconnect the wiring harness clips shown in the figure.

ac5wzw00012023

13.  Disconnect the variable turbine geometry turbocharger actuator mid-connector.

ac8wzw00002658

14.  Disconnect the regulating valve actuator connector using the following procedure.

(1)  Pull the tab in the direction of the arrow shown in the figure.
ac5wzw00012025
(2)  Disconnect the regulating valve actuator connector.

15.  Remove the bolts shown in the figure and set aside the wiring harness bracket and wiring harness as a single unit.

ac5wzw00012026

16.  Disconnect the vacuum hose as shown in the figure.

ac5wzw00012027

17.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

18.  Remove the catalytic converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

19.  Remove the transfer. (4WD)(See TRANSFER REMOVAL/INSTALLATION [GW6AX-EL (SKYACTIV-D 2.2)].)

20.  Disconnect the water hose as shown in the figure.

ac5wzw00012028

21.  Remove the bolts shown in the figure and set aside the water pipe.

ac5wzw00012029

22.  Remove in the order shown in the figure.

23.  Install in the reverse order of removal.

24.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

25.  Perform the following procedure.

When newly replacing turbocharger
•  Replace the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-D 2.2].)
When installing a removed turbocharger
•  Inspect the engine oil level. (See ENGINE OIL LEVEL INSPECTION [SKYACTIV-D 2.2].)

Step 1

ac5wzw00012030

1
Turbocharger bracket
2
Turbocharger insulator No.1
3
Turbocharger component
(See Turbocharger component installation note.)

Step 2

ac5wzw00014359

1
Turbocharger air inlet pipe
2
Turbocharger insulator No.2
3
Turbocharger insulator No.3
4
Oil pipe No.1
(See Oil pipe No.1 installation note.)
5
Oil pipe No.2
(See Oil pipe No.2 installation note.)
6
Oil pipe No.3
7
Oil hose No.1
(See Oil hose No.1 installation note.)
8
Oil pipe No.4
(See Oil pipe No.4 installation note.)
9
Oil hose No.2
(See Oil hose No.2 installation note.)
10
Oil pipe No.5
11
Vacuum hose No.1
(See Vacuum hose No.1 installation note.)
12
Vacuum hose No.2
(See Vacuum hose No.2 installation note.)
13
MAP sensor No.1
14
Variable turbine geometry turbocharger actuator connector
15
Turbocharger


Vacuum hose No.2 installation note

1.  Install the vacuum hose No.2 as shown in the figure.

ac5wzw00012032


Vacuum hose No.1 installation note

1.  Install the vacuum hose No.1 as shown in the figure.

ac5wzw00012033


Oil hose No.2 installation note

1.  Install the oil hose No.2 as shown in the figure.

ac5wzw00012034


Oil pipe No.4 installation note

1.  Temporarily tighten bolts (1), and (2) shown in the figure.

ac5wzw00012035

2.  Tighten bolt (1).

Tightening torque
8—11 N·m {82—112 kgf·m, 71—97 ft·lbf}

3.  Tighten bolt (2).

Tightening torque
8—11 N·m {82—112 kgf·m, 71—97 ft·lbf}


Oil hose No.1 installation note

1.  Install the Oil hose No.1 as shown in the figure.

Oil pipe No.4 side

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Oil pipe No.3 side

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Oil pipe No.2 installation note

1.  Install the gasket as shown in the figure.

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2.  Temporarily tighten bolts (1), (2), and (3) shown in the figure.

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3.  Tighten bolts (1) and (2).

Tightening torque
8—11 N·m {82—112 kgf·m, 71—97 ft·lbf}

4.  Tighten bolt (3).

Tightening torque
8—11 N·m {82—112 kgf·m, 71—97 ft·lbf}


Oil pipe No.1 installation note

1.  Install the gaskets as shown in the figure.

ac5wzw00012040


Turbocharger component installation note

1.  Install the new stud bolts to the exhaust manifold.

2.  Tighten the nuts shown in the figure to the specified torque.

Turbocharger component installation nut tightening torque
44—57 N·m {4.5—5.8 kgf·m, 33—42 ft·lbf}
ac5wzw00012041

3.  Tighten the nut to the specified torque again.