Intake and Exhaust

1399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download 15-1 GROUP 15 INTAKE AND = EXHAUST CONTENTS GENERAL INFORMATION ....... 15-2 ‘, 15-8 INTERCOOLER REMOVAL AND INSTALLATION SERVICE SPECIFICATION(S) .... . 15-2 15-12 45-3. INLETMANIFOLD . cee 15-45 INLET MANIFOLD REMOVAL AND INSTALLATION 45-3 15-15 INLET MANIFOLD INSPECTION 15-18 SPECIAL TOOL(S) ON-VEHICLE SERVICE. ... TURBOCHARGER BOOST PRESSURE CHECK 15-3 TURBOCHARGER WASTE GATE ACTUATOR EXHAUST MANIFOLD AND CHECK 154 TURBOCHARGER... sees 1549 VARIABLE GEOMETRY ACTUATOR CHECK EXHAUST MANIFOLD AND TURBOCHARGER 15.5 REMOVAL AND INSTALLATION VARIABLE GEOMETRY SOLENOID VALVE CHECK 15-49 15.5 EXHAUST MANIFOLD AND TURBOCHARGER REMOVAL AND INSTALLATION . 15.21 AIR CLEANER........... |. 15:6 EXHAUST MANIFOLD AND TURBOCHARGER ‘AIR CLEANER REMOVAL AND INSTALLATION INSPECTION 15:28 156 EXHAUST PIPE AND MAIN MUFFLER INTERCOOLER . 158 15.24 INTERCOOLER REMOVAL AND INSTALLATION EXHAUST PIPE AND MAIN MUFFLER 18-24 hitpsticardiagn.comvintake-and-exhaust-2012-12001 11251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download 15-2 INTAKE AND EXHAUST GENERAL INFORMATION GENERAL INFORMATION vserocr0r860 The exhaust pipe is divided into three parts SERVICE SPECIFICATIONS srocesozt99 Item ‘Standard value | Limit Turbocharger supercharging pressure KPa /ExceptEuroS |178.9- 7882 |— Euro S-low power |194.9- 2335 |_ engine Euro 5-normal 199.4 - 237.6 _ power engine Euro S-high 2031-2386 |- power engine Initial activation pressure of waste gate actuator (atthe stroke of [1326-1436 |— approximately 1 mm) kPa Initial activation vacuum of variable geometry actuator (at the stroke |45.4— 49.2 - approximately 1.5 mm from full close) kPa Variable geometry solenoid vaive coil resistance (at 20°C) G7 q q = ‘B991827-—~ else rene aise) \ @ ASS \ Wy rie fs > JA ~ AUF @ a Ca MB991627 ARsO02TTAB 2. Turn the ignition switch to "LOOK" (OFF) position, and connect the diagnosis connector to the MU-TAIL 3. Use the data list function named "Item No. 6" boost pressure sensor of the M.U.T-IIl to check the supercharging pressure when the engine speed increases to approximately 3,000 r/min or more by driving at full acceleration in 2nd. Standard valu 178.9 — 188.2 kPa 194.9 — 233.5 kPa 199.4 — 237.6 kPa hitpsticardiagn.comvintake-and-exhaust-2012-12001 203.1 - 238.6 kPa 4. If the supercharging pressure deviates from the standard value, check the following items for possible cause. + Malfunction of the waste gate actuator Malfunction of the variable geometry actuator Malfunction of the variable geometry solenoid valve Malfunction of the variable nozzle Malfunction of the boost pressure sensor Leakage of supercharging pressure Malfunction of the turbocharger 5. When the indicated supercharging is more than standard value, supercharging control may be faulty, therefore check the followings. * Disconnection or cracks of the waste gate actuator rubber hose Malfunction of the waste gate actuator Malfunction of the waste gate valve Malfunction of the variable geometry actuator Malfunction of the variable geometry solenoid valve Malfunction of the variable nozzle Malfunction of the manifold absolute pressure sensor WASTE GATE ACTUATOR CHECK antstootaooera 1. Connect a manual pump (pressure-application type) to nipple. AX CAUTION In order to avoid damage to the diaphragm, do not apply a pressure of 159 kPa or higher. 2. While gradually applying pressure, check the pressure that begins to activate (approximately 1 mm stroke) the waste gate actuator rod 425,1399122, 9:27 INTAKE AND EXHAUST INTAKE AND EXHAUST - 2012 L200 | Paf Download 15-5 ON-VEHICLE SERVICE, Standard valu 132.6 - 143.6 kPa 3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace actuator or turbocharger assembly if necessary. VARIABLE GEOMETRY ACTUATOR CHECK ntstoro0024e geometry (VG) actuator. Connect the hand ‘vacuum pump to the nipple. Bl elelas| AX CAUTION In order to avoid damage to the diaphragm, do not apply a vacuum of 60 kPa or higher. 2. By applying the vacuum pressure until the VG actuator link touches the stopper bolt, fully shrink the actuator rod. The vacuum pressure is approximately 55 kPa at that time. 3. Leak the vacuum pressure gradually as much as possible to check the vacuum pressure when the \VG actuator rod moves approximately 1.5 mm in the extension direction. Standard value: Approximately 45.4 ~ 49,2 kPa hitpsticardiagn.comvintake-and-exhaust-2012-12001 4, If the vacuum pressure significantly deviates from the standard value, check the actuator or the variable nozzle. Replace the turbocharger assembly if necessary. VARIABLE GEOMETRY SOLENOID VALVE CHECK I = Variable geometry control solenoid valve atstornrocan2 1. Disconnect the vacuum hoses from the variable geometry solenoid valve NOTE: When disconnecting the vacuum hose, always make sure that it can be reconnected at its original position. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the variable geometry solenoid vaive. 4. As described in the chart below, check alrtightness by applying a vacuum with voltage applied directly from the battery to the variable geometry solenoid valve, and without applying voltage. Battery positive | Nipple (B) _ [Normal voltage ndition | condition Applied Vacuum leaks | Closed )Vacuum maintained Not applied ‘Open ‘Vacuum maintained 51251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download INTAKE AND EXHAUST 15-6 AIR CLEANER - Standard value: 10 - 14 02 (at 20°C) = 6. Replace the solenoid ifairtightness or resistance — is out of specification. 5. Measure the resistance between the terminals of the variable geometry solenoid valve. AIR CLEANER REMOVAL AND INSTALLATION nteronzr03se 0.7 £04. Nm “ 9.01.0Nm 9.021.0Nm “13 9.021.0Nm hitpsticardiagn.comvintake-and-exhaust-2012-12001 6251399122, 9:27 INTAKE AND EXHAUST - 2012 L200 | Paf Download INTAKE AND EXHAUST 5 AIR CLEANER, 15-7 SoAc< 9, 10, "1 12. 13. Removal steps Air cleaner element Air flow sensor connector connection Air flow sensor Air flow sensor O-ring Hamess clamp Air cleaner cover Breather hose connection Blow-by hose heater connector ‘ ‘Vacuum hose connection Air intake hose Radiator condenser tank hose connection Air cleaner intake duct Air cleaner body hitpsticardiagn.comvintake-and-exhaust-2012-12001 INSTALLATION SERVICE POINTS >>A<< VACUUM HOSE CONNECTION Arintake hose Vacuum hose ACoD0N6AB Clamp vacuum hose with clip of air intake hose beside white marking as shown, 75,1399122, 9:27 15-8 A\ CAUTION INTAKE AND EXHAUST - 2012 L200 | Paf Download INTAKE AND EXHAUST INTERCOOLER. INTERCOOLER REMOVAL AND INSTALLATION vanistonzeor208 * Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent. + As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocar- bon. * Working area should be airy and kept from flame. Pre-removal Operation * Air Cleaner Intake Duct Removal (Refer to P.15-6), Post-installation Operation ‘= Air Cleaner Intake Duct Installation (Refer to P.15-6) peace peace >>hec >>Be< pohc< aoc oO Removal steps Intercooler inlet air hose Intercooler outlet alr hose Front bumper reinforcement (Refer to GROUP 51 - Front Bumper Assembly ). Intercooler inlet air pipe and intercooler assembly Intercooler inlet air pipe Intercooler inlet air pipe gasket Intercooler assembly Intercooler outiet air hose Intercooler outiet air pipe hitpsticardiagn.comvintake-and-exhaust-2012-12001 021.0Nm 6.021.0Nm 7.021.0Nm 6.02 4.0.Nm 9 2 9.021.0Nm Aceouonae INSTALLATION SERVICE POINTS >>A<< INTERCOOLER OUTLET AIR PIPE/INTER- COOLER OUTLET AIR HOSE/INTERCOOLER INLET AIR PIPE/INTERCOOLER OUTLET AIR HOSE/INTERCOOLER INLET AIR HOSE INSTAL- LATION 1. Ifthe oil adheres to the insertion area of the intercooler air hose or the intercooler air pipe, degrease it. 8251399122, 9:27 INTAKE AND EXHAUST - 2012 L200 | Paf Download INTAKE AND EXHAUST 15-9 INTERCOOLER ‘NC compressor 7> essampy suction pipe isiching a mene Tubocharger aching Vow A inet f ew 8 me / ( a ( inlet air hose Power steering \ Intercooler ohne i hitpsticardiagn.comvintake-and-exhaust-2012-12001 Matching Intercooler outiet air hose Intercooler outlet air pipe Matching Intercooler outlet air hose Intercooler ‘assembly 9n5,1399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download =! INTAKE AND EXHAUST 15-10 INTERCOOLER. Intercooler Inlet air hose 15mm or more Radiator upper hose ‘NIC compressor ‘suction pipe \) 7] ie 20 mm or more 9 mm or enore lJ View B 2. Install the intercooler air hose to the intercooler air pipe with the matching marks aligned as shown in the figure. 3. When installing the intercooler air hose to the throttle body assembly or the turbocharger assembly, install the intercooler air hose with its, matching mark located as shown in the figure. 4. After installing the intercooler outlet air hose, check that the clearance between the intercooler ‘outlet air hose and the radiator upper hose is 15 mm or more (View A). hitpsticardiagn.comvintake-and-exhaust-2012-12001 Power steering \ i suction nose 5. No re U Intercooler outlet ar hose \ View A After installing the intercooler inlet air hose, check that the clearance between the intercooler inlet air hose and the A/C compressor suction pipe is 20 mm or more (View B). After installing the intercooler inlet air hose, check that the clearance between the intercooler inlet air hose and the power steering suction hose is 20 mm or more (View B). 10751399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download INTAKE AND EXHAUST 4 INTERCOOLER. 15-11 7. Insert intercooler air hose to stopper end and not overlap with stopper. 8, Place the hose clamp as shown in the figure so that it does not overlap with the bulge and the stopper end. When installing the hose clamp to the intercooler air pipe or intercooler assembly, Intercodter Dsesccter set the hose clamp 5 + 1 mm away from the air hose air pipe stopper end. When installing the hose clamp to ioee Loe the throttle body assembly or turbocharger P ACTI205308 assembly, set the hose clamp 4 +1 mm away from the stopper end, Stopperend 544mm Bulge & >>Bc< INTERCOOLER INLET AIR PIPE GASKET Intercooler INSTALLATION Intorcooter outlet assembly. ( air hose xk J Hose clamp ‘Stopper acri2084as]| csosaesac| Install the intercooler inlet air pipe gasket as its pro- trusion is in the direction shown. outlet \ air hose Throttle body Lave damp [assembly ACEONDEAB intercooler 1/7 tbocharser inlet air ( (C) assombly hose Hose clamp’ Aceoscoraa| hitpsticardiagn.comvintake-and-exhaust-2012-12001 9281399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download \- INTAKE AND EXHAUST 15-12 INTERCOOLER, REMOVAL AND INSTALLATION a Z A CAUTION + Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent. * As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocar- bon. + Working area should be airy and kept from flame. Pre-removal Operation Post-nstallation Operation + Air Cloanor Intake Duct Removal (Refer to P.15-6), ‘Air Cleaner Intake Duct Installation (Refer to P.15-6), 4 6.021.0Nm 1842Nm 6021.0Nm 3 6 7.021.0Nm = 6.02 4.0 Nm 1222Nm 8 7 Removal steps INSTALLATION SERVICE POINTS S2A5¢ Jj, Intemcociariniet sir hose >>A<< INTERCOOLER OUTLET AIR PIPE/INTER- mrAcs 2, lereooler out aichose | COOLER OUTLET AIR HOSE/INTERCOOLER + ftom bumper reaforoment INLET AIR PIPE/INTERCOOLER OUTLET AIR Burger Al bh HOSE/INTERCOOLER INLET AIR HOSE INSTAL- per Assombly ) inece 3. _ Intercooler inlet air pipe and intercooler assembly 1. If the oil adheres to the insertion area of the >>A< 4, _ Intercooler inlet air pipe intercooler air hose or the intercooler air pipe, >>Bc< 5, _ Intercooler inlet air pipe gasket degrease it 6. Intercooler assembly >>Ac< 7. Intercooler outit airhose >>Ac< 8. Intercooler outlet air pipe hitpsticardiagn.comvintake-and-exhaust-2012-12001 12751399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download INTAKE AND EXHAUST 4 INTERCOOLER. 15-13 Throttle body assembly Matching Turbocharger mark ‘assembly ‘watching ‘mark Intercooler outlet air hose Intercooler Inlet air nose: Intercooler utiet alr pipe Matching marks Matching marks Intercooler Intercooler inlet air pipe outlet air hose: Aceooee2As Intercooler outlet air hose Intercooler outlot air pipe Matching Matching Intercooler coutet air hose intercooler assembly hitpsticardiagn.comvintake-and-exhaust-2012-12001 13251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download =! INTAKE AND EXHAUST 15-14 INTERCOOLER. 2. Install the intercooler air hose to the intercooler air pipe with the matching marks aligned as shown in the figure. 3. When installing the intercooler air hose to the throttle body assembly or the turbocharger assembly, install the intercooler air hose with its, matching mark located as shown in the figure. J erooter ae pipe Intercooler air hose Hose ctamp ACT#205908 Stopper end 524 mm Bulge Intarooler Intercooler -__ outat assembly. ( air hose / Hose clamp Stopper neriscas 4e1mm put ‘Stopper end se Intercooler outlet air hose Throttle body Hose clamp lassombly Aceon “Turbocharger assembly ‘Stopper end Bulge. Intercooler inlet air hose Hose clamp hitpsticardiagn.comvintake-and-exhaust-2012-12001 4, Insert intercooler air hose to stopper end and not overlap with stopper. 5, Place the hose clamp as shown in the figure so that it does not overlap with the bulge and the stopper end. When installing the hose clamp to the intercooler air pipe or intercooler assembly, set the hose clamp § = 1 mm away from the stopper end. When installing the hose clamp to the throttle body assembly or turbocharger assembly, set the hose clamp 4 = 1 mm away from the stopper end. >>Bc< INTERCOOLER INLET AIR PIPE GASKET INSTALLATION acsossesac| Install the intercooler inlet air pipe gasket as its pro- trusion is in the direction shown. 1425,1399122, 9:27 INTAKE AND EXHAUST INTAKE AND EXHAUST - 2012 L200 | Paf Download INLET MANIFOLD. INLET MANIFOLD REMOVAL AND INSTALLATION 15-15 vanrsroa200sess -removal Operation Throttle Body Removal (Refer to GROUP 13A - Throttle Body EGR Valve and EGR Pipe Removal (Refer to GROUP 17 = EGR Valve and EGR Cooler Windshield Wiper Removal (Rafer to GROUP 51 - Wind= shield Wiper). Cow Top Panel Front Removal Post-installation Operation ‘Cow Top Panel Front Installation Windshiald Wipor Installation (Refer to GROUP 81 — Windshield Wiper). EGR Valve and EGR Pipe Installation (Refer to GROUP 17 — EGR Valve and EGR Coole). ‘Trrottlo Body Installation (Refer to GROUP 13A - Thrattlo Body ). Air Bleeding from Fuel Line (Refer to GROUP 134 ~ On- ‘vehicle Servico, Evacuation of Air from Fuel Line ). hitpsticardiagn.comvintake-and-exhaust-2012-12001 15251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download 15-16 INTAKE AND EXHAUST INLET MANIFOLD 1 3 Caen \ A I ms\! -« \y 2423Nm Removal steps Removal steps (Continued) 4. Control wiring hares connection 9. Inlet manifold stay 2. Earth cable connection + Fuel injection pipe No.3, 4 clamp 3. Emission contro! hose mounting bolt (Refer to GROUP 4. _ Intake air temperature sensor 413A — Common Rail and Supply 5. _ Intake air temperature sensor Pump ) gasket >>B<< 10. Inlet manifold 6. Vacuum pump pipe 11. Inlet manifold gasket 7. Engine cover stay 12. Inlet manifold gasket 8. Fuel inlet pipe mounting bott hitpsticardiagn.comvintake-and-exhaust-2012-12001 16251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download INTAKE AND EXHAUST INLET MANIFOLD. 15-17 aw es Removal steps Removal steps (Continued) 4. Control wiring harness connection + Fuel injection pipe No.3, 4 clamp 2. Earth cable connection ‘mounting bolt (Refer to GROUP 3. Emission control hose 413A — Common Rall and Supply <> 4. EGR gas temperature sensor Pump ) 5. Vacuum pump pipe >>Bee 9. Inlet manifold 6. Engine cover stay 10. Inlet manifold gasket 7. Fuel inlet pipe mounting bolt >>Ace 11. Inlet manifold gasket 8. Inlet manifold stay hitpsticardiagn.comvintake-and-exhaust-2012-12001 17281399122, 9:27 15-18 REMOVAL SERVICE POINT <> EGR GAS TEMPERATURE SENSOR REMOVAL A\CAUTION Do not use the EGR gas temperature sensor which dropped. NO’ Flare nut (14) socket (MB982682) acaos74ias Use the recommended too! flare nut (14) socket (MB992692) to remove the EGR gas temperature sensor. INSTALLATION SERVICE POINTS. >>A<< INLET MANIFOLD GASKET INSTALLA- TION Position the projection as shown in the illustration, hitpsticardiagn.comvintake-and-exhaust-2012-12001 INTAKE AND EXHAUST - 2012 L200 | Paf Download INTAKE AND EXHAUST INLET MANIFOLD. >>B<< INLET MANIFOLD ASSEMBLY INSTALLATION Inlet —Y@e manifold aceon 1. As shown in the illustration, temporarily tighten to 6.5 + 1.5 Nem the bolts located at side A 2. As shown in the illustration, tighten the bolts and nuts located at side B to the specified torque. Tightening torque: 24.£3 Nm 20 + 2. Nem 3. As shown in the illustration, tighten the bolts located at side A to the specified torque. Tightening torque: 24 = 3 Nm INSPECTION ntsroa2t00e8 Check the following points; replace the part if @ prob- Jem is found. INLET MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Clogging of the negative pressure (vacuum) outlet port. 3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less 18251399122, 9:27 INTAKE AND EXHAUST INTAKE AND EXHAUST - 2012 L200 | Paf Download 15-19 EXHAUST MANIFOLD AND TURBOCHARGER EXHAUST MANIFOLD AND TURBOCHARGER REMOVAL AND INSTALLATION ants r00@001253 Pre-removal Operation Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP $1 — Under Cover } Engine Coolant Draining (Refer to GROUP 14 - On-vehi- le Service, Engine Coolant Replacement). Air Claanar Assembly Ramoval (Rear to P.15-6). Battery and Battery Box Removal (Refer to GROUP S4A, = Battery) Intercooler Init Air Hose Removal (Refer to P.15-8), Catalytic Converter Removal (Refer to GROUP 17 Cat- alytic Converter). Post-installation Operation ‘+ Catalytic Converter Installation (Refer to GROUP 17 — Catalytic Converter) ‘Intercooler Inlet Air Hose Installation (Refer to P.15-8). ‘+ Battery and Battery Box Installation (Refer to GROUP, ‘S4A — Battery ). «© Air Cleaner Assembly Installation (Rear to P.16-6). ‘+ Under Skid Plato and Engine Room Under Cover installae tion (Refer to GROUP 51 - Under Cover ) ‘+ Engine Coolant Refilling (Refer to GROUP 14 - On-vehi- dle Service, Engine Coolant Replacement), stetnm — 7#2Nem 5327Nm 9.02 1.0.Nm m2 59210Nm 1 9.01.0 Nm Removal steps 1. Turbocharger oil feed pipe 2. Turbocharger cll feed pipe gasket 3. Turbocharger water return hose connection 4. Turbocharger water feed pipe 6. Turbocharger water feed pipe gasket hitpsticardiagn.comvintake-and-exhaust-2012-12001 1742Nm 20 1aetNm 121Nm Removal steps (Continued) 6. Turbocharger water feed hose connection 7. Turbocharger water return pipe 8. Turbocharger water return pipe gasket 9. Turbocharger oil retum pipe Turbocharger oil retum pipe gasket 1925INTAKE AND EXHAUST - 2012 L200 | Paf Download INTAKE AND EXHAUST EXHAUST MANIFOLD AND TURBOCHARGER 1319/22, 9:27 15-20 Removal steps (Continued) >>C<< 11. Turbocharger oil return pipe gasket 12, Nut and washer >>Be< 13. Turbocharger assembly >>Ac< 14. Turbocharger gasket 45. Exhaust manifold cover 46. Flange nut 47. Engine hanger 48. Nut and washer 49. Exhaust manifold 20. Exhaust manifold gasket REMOVAL SERVICE POINT <> OIL PIPE REMOVAL A\ CAUTION Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the oil pipe is removed. INSTALLATION SERVICE POINTS. >>A<< TURBOCHARGER GASKET INSTALLA- TION Section AA Projection Ia nearonss hitpsticardiagn.comvintake-and-exhaust-2012-12001 Position the projection as shown in the illustration. >>B<< TURBOCHARGER ASSEMBLY INSTALLATION 1. Check the internal surface, the eye bolt and the mating surface of the oil pipe and water pipe for clogging, and clean if necessary. A\ CAUTION Be careful not to allow foreign material to enter the turbocharger. 2. If deposits of carbon are accumulated on the turbocharger oil passage, remove them and clean using the compressed air. 3. Add clean engine cil through the oil feed pipe port cn the turbocharger. >>C<< OIL RETURN PIPE GASKET INSTALLATION ACs02086AB Position the projection as shown in the illustration. 20751399122, 9:27 INTAKE AND EXHAUST INTAKE AND EXHAUST - 2012 L200 | Paf Download 15-21 EXHAUST MANIFOLD AND TURBOCHARGER REMOVAL AND INSTALLATION nrstooagosee Pre-removal Operation + Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 61 - Under Cover ) + Engine Coolant Draining (Refer to GROUP 14 — On-vohi- cle Service, Engine Coolant Replacement). * Air Cleaner Assembly Removal (Refer to P.15-0) + Battery and Battery Box Removal (Refer lo GROUP 54A, = Battory). + Intercooler Inlet Air Hose Removal (Refer to P.15-12), * Catalytic Converter Removal (Refer to GROUP 17 ~ Cat- alytie Converter). Postinstallation Operation + Gataytic Converter installation (Refer to GROUP 17 — Catalytic Converter. + Intorcooiorinlot Ar Hoso instalation (Rofer to P.15-12). + Battory and Battory Box instalation (Refer to GROUP 54A_ Battery). » Air Cleaner Assembly Installation (Refer to P.15-6). {Under Skis Plata and Eng'ne Room Under Cover instalation (Refer to GROUP 51 ~ Under Cover) + Engine Coolant Retling (Refer to GROUP 14 ~ On-vei- ‘la Sonica, Engine Coclant Replacement) 14s1Nm rh, 2 \ / ga23nm sostovm —_O F wits, ewe 9 / 43. yea 24 2 3 Nm i nm SAY ta SO 1 um SP i x Removal steps Engine cover ‘Turbocharger heat protector Gil pipe Gasket Heat protector Heat protector bracket Water hose connection <<>> hitpsticardiagn.comvintake-and-exhaust-2012-12001 3.020.5Nm Aco00eas5ac Removal steps (Continued) 8. Water hose connection, 9. Oil retum hose 10. Vacuum hose connection 11. Nutand washer 12. Bolt and washer 1. Turbocharger, turbocharger water pipe and oil return pipe assembly 21125,1399122, 9:27 15-22 INTAKE AND EXHAUST - 2012 L200 | Paf Download INTAKE AND EXHAUST. EXHAUST MANIFOLD AND TURBOCHARGER Removal steps (Continued) >>D<< 14. Turbocharger gasket 15. Exhaust manifold heat protector A 16. Exhaust manifold heat protector B 17. Engine hanger 18. Nutand washer 19. Exhaust manifold 20. Exhaust manifold gasket Removal steps 21. Oil return pipe >>C<< 22. il return pipe gasket 23. Water hose 24. Turbocharger water pipe >>B<< 25. Turbocharger water pipe gasket >>Ac<< 26. Turbocharger assembly REMOVAL SERVICE POINT <> OIL PIPE REMOVAL ZX CAUTION Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the oil pipe is removed, INSTALLATION SERVICE POINTS. >>A<< TURBOCHARGER ASSEMBLY INSTALLA- TION 1. Check the internal surface, the eye bolt and the mating surface of the oil pipe and water pipe for Clogging, and clean if necessary. hitpsticardiagn.comvintake-and-exhaust-2012-12001 111Nm AcaosrriAc A\ CAUTION Be careful not to allow foreign material to enter the turbocharger. 2. If deposits of carbon are accumulated on the turbocharger oil passage, remove them and clean using the compressed air. 3. Add clean engine oll through the oll pipe port on the turbocharger. >>B<< TURBOCHARGER WATER PIPE GASKET INSTALLATION Projection [Turbocharger lassembly S 7 / Turbocharger 7 Pipe water pipe [gasket acansrze 0 | 22r51399122, 9:27 INTAKE AND EXHAUST INTAKE AND EXHAUST - 2012 L200 | Paf Download 15-23 EXHAUST MANIFOLD AND TURBOCHARGER Position the projection as shown in the illustration, >>C<< OIL RETURN PIPE GASKET INSTALLATION il return Ag ‘gasket Turbocharger assembly ai yy retum pipe aceosr72n8| Position the projection as shown in the illustration. >>D<< TURBOCHARGER GASKET INSTALLATION Turbocharger —| assembly = Projection Projection = hitpsticardiagn.comvintake-and-exhaust-2012-12001 Position the projection as shown in the illustration. INSPECTION istoneones? Check the following points; replace the part if a problem is found. EXHAUST MANIFOLD CHECK 41. Check for damage or cracking of any part. 2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface. ‘Standard value: 0.15 mm or less Li ).20 mm TURBOCHARGER ASSEMBLY CHECK 1. Visually check the turbine wheel and the compressor wheel for cracking or other damage. 2. Check whether the turbine wheel and the compressor wheel can be easily turned by hand. 3. Check for oil leakage from the turbocharger assembly, 4. Check whether or not the turbocharger waste gate regulating valve remains open. if any problem is found, replace the part after disassembly. OIL PIPE AND OIL RETURN PIPE CHECK Check the oil pipe and oil retum pipe for clogging, bending or other damage. If there is clogging, clean it 231251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download e INTAKE AND EXHAUST 15-24 EXHAUST PIPE AND MAIN MUFFLER EXHAUST PIPE AND MAIN MUFFLER REMOVAL AND INSTALLATION ‘urrs100e0008e6 Pre-removal Operation ‘Under Skid Plate and Engine Room Under Cover Removal (Refer io GROUP 51 ~ Under Cover ) Postinstallation Operation Undar Skid Plata and Engine Room Under Cover Installa- tion (Refer to GROUP 51 ~ Under Cover ) Removal steps Removal steps (Continued) 4. Front exhaust pipe 5. Exhaust pipe gasket 2. Exhaust pipe gasket 6. Exhaust main muffler 3. Seal ring 7. Dash heat protector panel 4. Centre exhaust pipe hitpsticardiagn.comvintake-and-exhaust-2012-12001 24251399122, 9:27 INTAKE AND EXHAUST - 2012 1200 | Paf Download INTAKE AND EXHAUST 15-25 EXHAUST PIPE AND MAIN MUFFLER A CAUTION When the DPF is replaced, use the M.U.T-III to e the learning value (Refer to GROUP 00 - Pre- cautions before Service, Initialisation Procedure for Learning Value in DPF System ). Pre-removal Operation ‘Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 51 ~ Under Cover ) Postinstallation Operation ‘© Under Skid Plato and Engine Room Under Cover Instlla- tion (Refer to GROUP 51 ~ Under Cover ) 10, 8.022.0Nm V7 3624Nm a 4925Nm Removal steps No.2 exhaust gas temperature sensor (Refer to GROUP 17 ~ Emission Control, DPF System Sensors ) Front exhaust pipe Exhaust pipe gasket Seal ring No.2 crossmember (Refer to GROUP 22 - Rear Engine Mounting ) <2WD> hitpsticardiagn.comvintake-and-exhaust-2012-12001 Removal steps (Continued) + No.3 exhaust gas temperature sensor (Refer to GROUP 17 - Emission Control, DPF System ‘Sensors ) Exhaust pressure hose connection Exhaust pressure pipe and DPF assembly Exhaust pressure pipe DPF Exhaust pipe gasket Exhaust main muffier }0._ Front floor heat protector panel 2525

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