TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2]


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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 turbocharger initialization 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
Perform turbocharger initialization procedure.
2
Switch the ignition off.
3
Wait for 20 s.
4
Switch the ignition ON (engine off).
5
Perform KOEO self-test procedure.
6
Start the engine.
7
Verify that the check engine light does not illuminate.
8
Perform KOER self-test procedure.
9
Switch the ignition off.


Turbocharger Removal/Installation

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

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. (See TRANSFER REMOVAL/INSTALLATION [GW6AX-EL].)

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
3
Turbocharger bracket (2WD)
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
12
Oil pipe No.2
13
Oil pipe No.3
14
Oil pipe No.4
15
Turbocharger insulator No.3
16
Water pipe No.2
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).

Water pipe No.2 (turbocharger side) tightening torque
40—52 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}
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2.  Measure the distance shown in the figure and verify that water pipe No.2 is installed correctly.

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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.

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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.

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