Removal And Installation

WARNING: This page is about a different variant/trim than selected.

Disconnect the battery negative terminal.
Tightening torque:

3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 Ib-ft)

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Remove the engine cover.

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Remove the air duct (A).

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Remove the air cleaner assembly.

Disconnect the RCV hose (A).
Disconnect the breather hose (B).
Disconnect the intake air hose (C).
Disconnect the air flow sensor (AFS) connector (D).

Remove the air cleaner assembly (E).

Tightening torque:

Hose Clamp: 2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)

Air Cleaner Assembly: 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 Ib-ft)

G14524549

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NOTE:

When install the intake hose, match the alignment marks (A).

G14524550

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Remove the battery.

Open the "+" cable cover (A).

G14524551

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Loosen the "+" cable mounting nut (B).

Tightening torque:

7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)

G14524552

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Remove the battery mounting bracket (C), and then remove the battery.

Tightening torque:

18.6 - 29.4 N.m (1.9 - 3.0 kgf.m, 13.7 - 21.7 lb-ft)

G14524553

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Disconnect the ECM connector (A).

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Remove the ECM & battery tray (A).
Tightening torque:

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

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Remove the intercooler inlet hoses & pipe.

Disconnect the main wiring (A), connector (B) from intercooler inlet pipe.

G14524556

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Remove the intercooler inlet hose & pipe (C).

Tightening torque:

Mounting Blot: 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

Clamp Bolt: 4.9 - 6.9 N.m 0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

G14524557

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Loosen the drain plug, and drain the coolant.
(Refer to Cooling System - "COOLANT ")
Disconnect the reservoir tank hose (A).

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Disconnect the turbo charger outlet hose (A).

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Remove the warm up catalytic converter (WCC) upper stay bracket (A).
Tightening torque:

49.1 - 54.0 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

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NOTE:
- When installing, temporarily tighten the nut in picture order.
  
  Fig 1: Warm Up Catalytic Converter (WCC) Upper Stay Bracket Nuts Tightening Sequence
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Remove the front muffler.
(Refer to Intake and Exhaust Manifold - "FRONT MUFFLER ")
Remove the warm up catalytic converter (WCC) lower stay bracket (A).
Tightening torque:

49.1 - 54.0 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

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NOTE:
- When installing, temporarily tighten the nut in picture order.
  
  Fig 2: Warm Up Catalytic Converter (WCC) Lower Stay Bracket Nuts Tightening Sequence
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Remove the EGR cooler pipe mounting bolt (A).
Tightening torque:

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

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NOTE:
- When installing, replace with a new gasket.
Remove the warm up catalytic converter (WCC) (A).
Tightening torque:

35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.4 lb-ft)

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NOTE:
- When installing, replace with a new gasket.
Disconnect the turbo charger outlet hose (A), and then remove the water pipe (B).
Tightening torque:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

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Remove the turbo charger inlet hose & pipe (A).

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NOTE:
- When installing, replace with a new gasket.
Remove the turbo charger oil drain pipe (A).
Tightening torque:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

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NOTE:
- When installing, replace with a new gasket.
Remove the turbo charger heat protect (A).
Tightening torque:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

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Remove the turbo charger oil feed pipe (A).
Tightening torque:

Oil feed pipe: 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

Oil feed pipe bracket bolt: 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

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NOTE:
- When installing, replace with a new gasket.
Remove the differential Pressure hose mounting bolt (A).
Tightening torque:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

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Disconnect the Differential Pressure hose (A) and breather hose (B).

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Disconnect the EGR hose (A).

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Remove the turbo charger heat protectors (A).
Tightening torque:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

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Remove the exhaust manifold & turbo charger (A).
Tightening torque:

49.1 - 54.0 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

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NOTE:
- When installing, replace with a new gasket.
CAUTION:
- When installing the exhaust manifold tighten the nuts with specified torque in the sequence shown.
  
  Fig 3: Exhaust Manifold Nuts Tightening Sequence
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Install in the reverse order of removal.