Dimax Turbo

Turbocharger removal (4JK1-TCY) Page 1 of 22
Turbocharger removal (4JK1-TCY)
1. Component views
Low pressure turbocharger
Part name
1. Low pressure turbocharger

2. Low pressure turbocharger water feed and return pipe
3. Low pressure turbocharger heat protector
4. Oil drain pipe
5. Turbocharger bracket
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
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2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 25 N・m { 2.5 kgf・m / 18 lb・ft }
6: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 51 N・m { 5.2 kgf・m / 38 lb・ft }
High pressure turbocharger
Part name
1. High pressure turbocharger water feed and return pipe

2. High pressure turbocharger
3. High pressure turbocharger heat protector
4. Low pressure turbocharger
5. High pressure turbocharger oil return pipe
Tightening torque
1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
2: 52 N・m { 5.3 kgf・m / 38 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
5: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
2. Preliminary and post procedures
1. Preliminary procedures
1) Open the engine hood.
2) Disconnect the battery cable from the battery negative terminal.
Caution
• After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
• The ECM may malfunction if the battery cable is disconnected within 1 minute.
• If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.
• Steering angle sensor setting

• Setting for front door power window switch with AUTO UP/AUTO DOWN function
3. Underguard removal
Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".
4. Coolant drain
Warning
• Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
• When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.
1) Remove the radiator cap from the radiator.
2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.
1. Drain plug
4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.
5) Tighten the drain plug on the cylinder block.
Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }
6) Tighten the radiator drain plug.
5. Engine cover removal
1) Remove the engine cover from the engine.
1. Engine cover
6. Intake hose removal
1) Remove the intake hose from the intake air bypass valve and intercooler.
7. Intake air bypass valve removal
1) Disconnect the vacuum hose from the intake air bypass valve.
2) Remove the vacuum pipe from the intake air bypass valve.
3) Remove the intake air bypass valve and gasket from the turbocharger.
4) Remove the intake hose from the intake air bypass valve.
5) Remove the bracket from the front engine hanger bracket.
8. Blow-by hose disconnect
1) Disconnect the blow-by hose from the cylinder head cover.
9. Air cleaner removal
1) Disconnect the connector from the MAF and IAT sensor.
2) Disconnect the connector from the barometric pressure sensor.
3) Disconnect the vacuum hose from the air cleaner.
4) Disconnect the intake pipe from the turbocharger.
5) Remove the air cleaner from the vehicle.
1. Air cleaner
2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor
10. High pressure turbocharger heat protector removal
1) Remove the high pressure turbocharger heat protector from the high pressure turbocharger.
11. Turbocharger feed oil pipe removal
1) Remove the high pressure turbocharger feed oil pipe from the high pressure turbocharger and oil cooler.
2) Remove the oil feed pipe from the high pressure turbocharger and low pressure turbocharger.
12. Water feed and return pipe removal
1) Disconnect the high pressure turbocharger water feed hose from the high pressure turbocharger water feed and
return pipe.
2) Disconnect the high pressure turbocharger water return hose from the high pressure turbocharger water feed
and return pipe.
1. High pressure turbocharger water return hose

2. High pressure turbocharger water feed hose
3) Disconnect the low pressure turbocharger water return hose from the water intake pipe.
4) Remove the low pressure turbocharger water feed and return pipe from the low pressure turbocharger.
13. EGR cooler removal
1) Disconnect the high pressure turbocharger water return hose from the high pressure turbocharger.
2) Disconnect the vacuum hose from the low pressure turbocharger.
3) Disconnect the vacuum hose from the low pressure turbocharger vacuum pipe.
4) Remove the low pressure turbocharger vacuum pipe from the EGR cooler heat protector.
5) Remove the EGR cooler heat protector from the EGR cooler.
6) Disconnect the low pressure turbocharger vacuum pipe from the low pressure turbocharger.
7) Remove the low pressure turbocharger vacuum pipe from the EGR cooler.
8) Disconnect the EGR cooler water feed hose from the EGR cooler.
9) Disconnect the EGR cooler water return hose from the EGR cooler.
10) Remove the EGR cooler and gasket from the cylinder head and exhaust manifold.
14. Low pressure turbocharger heat protector removal
1) Remove the low pressure turbocharger heat protector from the low pressure turbocharger.
15. Exhaust differential pressure sensor removal
Refer to "1.Engine 1Z.Engine Electrical Control(4JK1-TCY) exhaust differential pressure sensor removal".
16. Exhaust pipe removal
Refer to "1.Engine 1G.Exhaust(4JK1-TCY) exhaust pipe removal".
17. DPD removal
1) Disconnect the 2 differential pressure hoses from the differential pressure pipes.
Caution
• Do not reuse the differential pressure hose clip.
• Place markings on the differential pressure hoses to prevent its incorrect assembly.
2) Disconnect the connector from Exhaust gas temperature sensor 1.
3) Remove the DPD hanger rubber from the DPD.
4) Remove the DPD and gasket from the catalytic converter.
1. DPD hanger rubber

2. DPD
3. Differential pressure hose
18. Catalytic converter removal
1. 2WD models
1) Disconnect Exhaust gas temperature sensor 3 from the catalytic converter.
1. Exhaust gas temperature sensor 3
3) Remove the exhaust pipe bracket from the catalytic converter and crankcase.
4) Remove the catalytic converter and gasket from the turbocharger.
2. 4WD models
3) Remove the mounting bracket from the frame.
1. Mounting bracket
4) Remove the exhaust pipe bracket from the catalytic converter and crankcase.
5) Remove the catalytic converter and gasket from the turbocharger.
Note
• The catalytic converter is removed after removing the low pressure turbocharger.
19. Turbocharger removal
1. 2WD models
1) Disconnect the high pressure turbocharger oil drain hose from the oil drain pipe.
2) Remove the high pressure turbocharger and gasket from the low pressure turbocharger.
3) Remove the oil drain pipe and gasket from the high pressure turbocharger.
4) Remove the high pressure turbocharger water feed and return pipe from the high pressure turbocharger.
5) Remove the low pressure turbocharger bracket from the bracket and low pressure turbocharger.
6) Remove the oil drain pipe mounting bolts and nuts from the low pressure turbocharger.
Note
• Remove the oil drain pipe after removing the low pressure turbocharger.
7) Remove the low pressure turbocharger and gasket from the exhaust manifold.
8) Remove the oil drain pipe from the vehicle.
2. 4WD models
1) Disconnect the high pressure turbocharger oil drain hose from the oil drain pipe.
2) Remove the high pressure turbocharger and gasket from the low pressure turbocharger.
3) Remove the oil drain pipe and gasket from the high pressure turbocharger.
4) Remove the high pressure turbocharger water feed and return pipe from the high pressure turbocharger.
5) Remove the low pressure turbocharger bracket from the bracket and low pressure turbocharger.
6) Remove the oil drain pipe mounting bolt and nut from the low pressure turbocharger and crankcase.
Note
• Remove the oil drain pipe after removing the low pressure turbocharger.
7) Remove the low pressure turbocharger and gasket from the exhaust manifold.
8) Remove the oil drain pipe from the vehicle.
9) Remove the catalytic converter from the vehicle.

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Turbocharger removal (4JK1-TCY) Page 1 of 22

Turbocharger removal (4JK1-TCY)

Low pressure turbocharger

1. Low pressure turbocharger

1: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7: 51 N・m { 5.2 kgf・m / 38 lb・ft }

High pressure turbocharger

1. High pressure turbocharger water feed and return pipe

1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2: 52 N・m { 5.3 kgf・m / 38 lb・ft }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2. Preliminary and post procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

• Steering angle sensor setting

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

1) Remove the radiator cap from the radiator.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

5. Engine cover removal

1) Remove the engine cover from the engine.

6. Intake hose removal

7. Intake air bypass valve removal

5) Remove the bracket from the front engine hanger bracket.

8. Blow-by hose disconnect

1) Disconnect the blow-by hose from the cylinder head cover.

9. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Disconnect the vacuum hose from the air cleaner.

4) Disconnect the intake pipe from the turbocharger.

5) Remove the air cleaner from the vehicle.

10. High pressure turbocharger heat protector removal

11. Turbocharger feed oil pipe removal

12. Water feed and return pipe removal

1. High pressure turbocharger water return hose

13. EGR cooler removal

2) Disconnect the vacuum hose from the low pressure turbocharger.

14. Low pressure turbocharger heat protector removal

15. Exhaust differential pressure sensor removal

16. Exhaust pipe removal

Refer to "1.Engine 1G.Exhaust(4JK1-TCY) exhaust pipe removal".

17. DPD removal

2) Disconnect the connector from Exhaust gas temperature sensor 1.

3) Remove the DPD hanger rubber from the DPD.

4) Remove the DPD and gasket from the catalytic converter.

1. DPD hanger rubber

18. Catalytic converter removal

1) Disconnect Exhaust gas temperature sensor 3 from the catalytic converter.

1. Exhaust gas temperature sensor 3

2) Disconnect Exhaust gas temperature sensor 2 from the catalytic converter.

1. Exhaust gas temperature sensor 2

4) Remove the catalytic converter and gasket from the turbocharger.

1) Disconnect Exhaust gas temperature sensor 3 from the catalytic converter.

1. Exhaust gas temperature sensor 3