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Twinscroll Turbocharger Removal/Installation: Notes

CAUTION:
  • If the intake-air system, exhaust system, or the engine is damaged, fragments of the damaged part may be remaining in the intake-air system or exhaust system. If the turbocharger is replaced without removing fragments of the damaged part, it could cause turbocharger damage or malfunction. Before replacing the turbocharger, verify that no fragments remain in the parts to be reused.
  1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [H3T] .)
  2. Switch to the maintenance mode. (See MAINTENANCE MODE .)
  3. Remove the wheel and tire. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  4. Remove the capsule cover. (See CAPSULE COVER REMOVAL/INSTALLATION [H3T] .)
  5. Complete the "HIGH VOLTAGE PART INSPECTION AND REMOVAL/INSTALLATION NOTES ". (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  6. Remove the cowl grille cover assembly (RH). (See COWL GRILLE REMOVAL/INSTALLATION .)
  7. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  8. Remove the cowl grille cover assembly (LH). (See COWL GRILLE REMOVAL/INSTALLATION .)
  9. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION (L.H.D.) ).
  10. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
  11. Remove the side cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
  12. Remove the cowl grille bracket. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  13. Remove the windshield wiper motor and link. (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION .)
  14. Remove the strut tower bar. (See DRIVER-SIDE STRUT TOWER BAR REMOVAL/INSTALLATION .) (See PASSENGER-SIDE STRUT TOWER BAR REMOVAL/INSTALLATION .)
  15. Remove the engine compartment insulator (Upper). (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  16. Remove the air cleaner assembly. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  17. Recover the refrigerant. (See REFRIGERANT RECOVERY .)
  18. Remove the front under cover No. 2. (See REMOVE FRONT UNDER COVER NO. 2 .)
  19. Remove the front under cover No. 1. (See REMOVE FRONT UNDER COVER NO. 1 .)
  20. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  21. Drain the water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  22. Remove the front under cover No. 3. (See REMOVE FRONT UNDER COVER NO. 3 .)
  23. Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION .)
  24. Perform the high voltage handling. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  25. Disconnect the ground plate. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  26. Partially peel back the front over fender. (See FRONT OVER FENDER REMOVAL/INSTALLATION .)
  27. Remove the front mudguard. (See FRONT MUDGUARD REMOVAL/INSTALLATION .)
  28. Remove the front deflector. (See FRONT DEFLECTOR REMOVAL/INSTALLATION .)
  29. Remove the front splash shield. (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
  30. Remove the edge rubber. (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)
  31. Remove the latch cover. (See FRONT BUMPER REMOVAL/INSTALLATION .)
  32. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .)
  33. Remove the center seal plate. (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  34. Remove the bracket (bumper upper side). (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  35. Remove the intake air guide (upper). (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  36. Remove the seal plate. (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION .)
  37. Remove the radiator mount bracket. (See RADIATOR REMOVAL/INSTALLATION [H3T] .)
  38. Remove the middle pipe. (See MIDDLE PIPE REMOVAL/INSTALLATION [H3T] .)
  39. Remove the exhaust system insulator. (See EXHAUST SYSTEM INSULATOR REMOVAL/INSTALLATION [H3T] .)
  40. Remove the engine under cover bracket. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  41. Remove the M hybrid boost battery bracket. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  42. Remove the tunnel member. (See REAR PROPELLER SHAFT REMOVAL/INSTALLATION .)
  43. Remove the rear propeller shaft. (See REAR PROPELLER SHAFT REMOVAL/INSTALLATION .)
  44. Disconnect quick release connector (fuel system) No. 2. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [H3T] .)
  45. Disconnect quick release connector (fuel system) No. 3. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [H3T] .)
  46. Disconnect the heater hose. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  47. Disconnect the sub radiator hose. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  48. Remove the member bracket. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [AWD] .)
  49. Remove the transverse member. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [AWD] .)
  50. Perform the Procedure Before Lowering Engine Component. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  51. Remove the engine assembly. (See ENGINE REMOVAL/INSTALLATION [H3T] .)
  52. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [H3T] .)
  53. Remove the air fuel ratio (A/F) sensor. (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [H3T] .)
  54. Remove the heated oxygen sensor (HO2S). (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [H3T] .)
  55. Remove the catalytic converter. (See CATALYTIC CONVERTER REMOVAL/INSTALLATION [H3T] .)
  56. Remove the turbocharger air outlet pipe No. 1 assembly. (See CYLINDER HEAD COVER REMOVAL/INSTALLATION [H3T] .)
  57. Remove in the order indicated in the table.
    Fig 1: Twinscroll Turbocharger Components Location With Torque Specifications
    G16702185Courtesy of MAZDA MOTORS CORP.
    TIGHTENING TORQUE SPECIFICATIONS

    Step Part name
    1 Breather hose - -
    2 Bolt - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    3 Ventilation pipe -  
    4 Gasket Replacement part -
    5 Water hose - -
    6 Bolt - 11 N.m {110 kgf.cm, 95 in.lbf}
    7 Bolt - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    8 Oil pipe - -
    9 Gasket Replacement part -
    10 Bolt
    (See Bolt installation note ).    		 Replacement part 11 N.m {110 kgf.cm, 95 in.lbf}
    11 Water hose - -
    12 Bolt - 11 N.m {110 kgf.cm, 95 in.lbf}
    13 Water pipe - -
    14 Gasket Replacement part -
    15 Bolt - 9.5 N.m {97 kgf.cm, 84 in.lbf}
    16 Harness bracket - -
    17 Connector - -
    18 Nut Replacement part 24.5 N.m {2.5 kgf.m, 18.05 ft.lbf}
    19 Twinscroll turbocharger - -
    20 Gasket Replacement part -
  58. Install in the reverse order of removal.
  59. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [H3T] .)
  60. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  61. Refill the water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  62. Perform air bleeding of engine coolant. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  63. Perform air bleeding of water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  64. Inspect for engine coolant leakage. (See ENGINE COOLANT REPLACEMENT [H3T] .)
  65. Inspect for water-cooled charge air cooler coolant leakage. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [H3T] .)
  66. End the maintenance mode. (See MAINTENANCE MODE .)
  67. Charge the refrigerant. (See REFRIGERANT CHARGING .)
  68. Inspect the refrigerant pressure. (See REFRIGERANT PRESSURE CHECK .)
  69. Inspect the refrigerant system performance. (See REFRIGERANT SYSTEM PERFORMANCE TEST .)
  70. Perform the 360° view monitor system aiming. (See 360° VIEW MONITOR SYSTEM AIMING .)
  71. Perform the radar sensor (front) aiming. (See FRONT RADAR SENSOR AIMING .)
  72. Perform the radar sensor (front side) aiming. (See FRONT SIDE RADAR SENSOR AIMING .)
  73. Perform the radar sensor (rear side) aiming. (See REAR SIDE RADAR SENSOR AIMING .)
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