TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

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.

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

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].)

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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.

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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.

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

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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.

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(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.

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

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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].)

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

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

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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

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

Step 2

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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 (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
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.

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Vacuum hose No.1 installation note

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

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Oil hose No.2 installation note

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

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Oil pipe No.4 installation note

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

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2.  Tighten bolt (1).

3.  Tighten bolt (2).

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).

4.  Tighten bolt (3).

Oil pipe No.1 installation note

1.  Install the gaskets as shown in the figure.

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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.

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3.  Tighten the nut to the specified torque again.