EXHAUST MANIFOLD W/ TURBOCHARGER REASSEMBLY

PROCEDURE


  1. INSTALL TURBOCHARGER GASKET


    1. A01SJKVC01
      *1 Turbocharger Gasket
      B0068HS Upper

      Install a new turbocharger gasket to the compressor with bearing housing sub-assembly.

      Tech Tips


      • Install the turbocharger gasket facing the direction shown in the illustration.

      • Make sure to install the turbocharger gasket so that the white coating faces downwards.

  2. INSTALL SEAL RING


    1. Install a new seal ring to the compressor with bearing housing sub-assembly.

      Note

      Do not reuse the seal ring.

  3. INSTALL TURBOCHARGER NOZZLE VANE PLATE SUB-ASSEMBLY


    1. A01SHZ9C02
      *1 No. 2 Turbocharger Nozzle Vane Arm
      *2 No. 2 Turbocharger Nozzle Vane Control Link
      B0068HS No. 2 Turbocharger Nozzle Vane Arm Fully Open
      B006964 No. 2 Turbocharger Nozzle Vane Control Link Fully Open

      Align the No. 2 turbocharger nozzle vane arm as shown in the illustration.

    2. Install the turbocharger nozzle vane plate sub-assembly to the compressor with bearing housing sub-assembly.

      Note


      • When installing the turbocharger nozzle vane plate sub-assembly, align the installation positions on the pin side and No. 2 turbocharger nozzle vane arm side.

      • Do not remove the No. 2 turbocharger nozzle vane plate and turbocharger nozzle vane spacer.

      A01SJWEC02
      *a Bearing Housing Pin Side
      *b No. 2 Turbocharger Nozzle Vane Arm Side
      *c Installation Positions Pin Side
      *d Installation Positions No. 2 Turbocharger Nozzle Vane Arm Side
    3. A01SIBKC01
      *1 Turbocharger Nozzle Vane Support Plate
      B0068HS Upper

      Install the turbocharger nozzle vane support plate to the turbocharger nozzle vane plate sub-assembly.

      Note

      If the turbocharger nozzle vane support plate is bent or twisted, replace it.

      Tech Tips

      Install the turbocharger nozzle vane support plate facing the direction shown in the illustration.

  4. INSTALL TURBINE HOUSING


    1. Temporarily install the turbine housing to the compressor with bearing housing sub-assembly with 5 new bolts and 5 new spacers.

      Tech Tips

      Align the matchmark as shown in the illustration to install the part.

      A01SGIPC01
      *a Matchmark
    2. A01SBL5

      Secure the flange of the turbine housing sub-assembly of the turbocharger sub-assembly in a vise between aluminum plates.

      Note

      Do not tighten the vise more than necessary, as doing so will damage the flange of the turbine housing sub-assembly.

    3. A01SJZ1E01

      Using a 10 mm union nut wrench, tighten the 5 bolts in the order shown in the illustration.

      Torque:
      Specified tightening torque
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Move the turbocharger vane control link sub-assembly and check that the turbocharger nozzle vane plate sub-assembly smoothly operates.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      B0068F6C06
      *a Torque Wrench Fulcrum Length

  5. INSTALL TURBOCHARGER NOZZLE VANE CONTROL ACTUATOR


    1. Install the turbocharger nozzle vane control actuator with the 3 bolts.

      Torque:
      12.3 N*m  { 125 kgf*cm, 9 ft.*lbf }

  6. INSTALL TURBOCHARGER VANE CONTROL ROD SUB-ASSEMBLY


    1. Install the turbocharger vane control rod sub-assembly.

    2. Install 2 new E-washers to the variable nozzle vane motor assembly and turbocharger vane control link sub-assembly.

      Note

      Do not reuse the E-washer.