Removal and Installation Special Tool(s) | Remover/Installer, Coolant Hose Clamp 303-397 | | -
Drain the cooling system. For additional information, refer to: Cooling System Draining, Filling and Bleeding - 2.0L (303-03E, General Procedures). | | -
NOTE:Make sure that the windshield wiper motor is in the park position. Disconnect the battery ground cable. For additional information, refer to: Battery Disconnect (414-01, General Procedures). | | -
Remove the engine upper cover. | | -
Detach the brake fluid reservoir from the bulkhead extension panel. | | -
Remove the windshield wiper arms. | | -
Remove the cowl panel. - Detach the cowl panel from the retaining clips.
- Remove the cowl panel by detaching it from the windshield glass lower weatherstrip.
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Remove the bulkhead extension panel. - Remove the bulkhead extension panel retaining screws.
- Detach the bulkhead extension panel from the retaining clips.
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Disconnect the positive crankcase ventilation (PCV) breather hose from the intake manifold PCV valve. - Press in the release clip.
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Remove the turbocharger intake support bracket retaining bolt. | | -
Raise and support the vehicle. For additional information, refer to: Lifting (100-02, Description and Operation). | 11. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Turbocharger outlet pipe retaining clamps 6 - Catalytic converter support bracket 7 - Turbocharger support bracket retaining bolt 8 - Turbocharger support bracket 14 - Heater core coolant hose to coolant bypass pipe 16 - Coolant bypass hose to coolant bypass pipe 20 - Coolant bypass pipe seal 12. To install, reverse the removal procedure. NOTE:Before installation, make sure that the PCV hose quick release coupling is clean and free from any oil residue. | -
Vehicles with global closing, initialize the door window motors. For additional information, refer to: Door Window Motor Initialization (501-11, General Procedures). | Removal Details Item 3 : Catalytic converter retaining clamp | -
Make a note of the position of the catalytic converter retaining clamp before removal. | Item 5 : Catalytic converter | -
Detach the catalytic converter from the turbocharger and secure it to one side. | Item 9 : Turbocharger variable vane solenoid vacuum supply line | -
Detach the turbocharger variable vane solenoid vacuum supply line from the turbocharger intake pipe. | Item 10 : Turbocharger variable vane solenoid wiring harness | -
Detach the turbocharger variable vane solenoid wiring harness from the turbocharger intake pipe. | Item 12 : Engine support insulator retaining bolt | -
CAUTION:Take care not to crush or put excessive force on the components between the engine and radiator. Slide the engine towards the radiator. | Item 13 : Heater core coolant hose to coolant bypass pipe retaining clamp | -
Using the special tool, detach the heater core coolant hose to coolant bypass pipe retaining clamp. | Item 15 : Coolant bypass hose to coolant bypass pipe retaining clamp | -
Using the special tool, detach the coolant bypass hose to coolant bypass pipe retaining clamp. | Item 19 : Coolant bypass pipe CAUTION:Take care not to place excessive strain on the surrounding power steering lines, fuel lines and engine compartment wiring harness when removing the coolant bypass pipe. | -
With the aid of another technician, remove the coolant bypass pipe. | Installation Details Item 18 : Coolant bypass pipe retaining bolts | -
NOTE:Do not tighten the coolant bypass pipe retaining bolts at this stage. Install the coolant bypass pipe retaining bolts. | Item 17 : Coolant bypass pipe support bracket retaining bolt | -
NOTE:Do not tighten the coolant bypass pipe support bracket retaining bolt at this stage. Install the coolant bypass pipe support bracket retaining bolt. | | -
Tighten the coolant bypass pipe retaining bolts. | | -
Tighten the coolant bypass pipe support bracket retaining bolt. | | -
Slide the engine back to the original position and install the engine support insulator bolt. | Item 11 : Turbocharger intake pipe retaining bolts NOTE:Make sure that the inside of the turbocharger outlet pipe is clean and free from any oil residue, as this will reduce the installation grip of the pipe to the turbocharger and charge air cooler intake pipe. Item 4 : Catalytic converter retaining nuts | -
NOTE:Do not tighten the catalytic converter retaining nuts at this stage. Install the catalytic converter retaining nuts. | Item 3 : Catalytic converter retaining clamp CAUTION:Never use jointing compound forward of the catalytic converter. NOTE:The catalytic converter retaining clamp must be installed in the same position as removed. | -
Install the catalytic converter retaining clamp. | | -
Tighten the catalytic converter retaining nuts. | Item 2 : Turbocharger outlet pipe NOTE:Make sure that the inside of the turbocharger outlet pipe is clean and free from any oil residue, as this will reduce the installation grip of the pipe to the turbocharger and charge air cooler intake pipe. |