TURBOCHARGER INSTALLATION

INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY
1. Install a new gasket and the No. 1 turbo water pipe sub-assembly with the bolt and 2 nuts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf, for bolt }
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf, for nut }
INSTALL COMPRESSOR INLET ELBOW
1. Install a new gasket and the compressor inlet elbow with the 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
TEMPORARILY TIGHTEN TURBOCHARGER
1. Set the turbocharger in a safe location.
2. Install a new gasket to the cylinder block.
3. Install the No. 2 water by-pass pipe with the bolt and 2 nuts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf, for bolt }
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf, for nut }
4. Connect the 2 turbo water hoses with the 2 clips.
5. Install a new gasket to the turbocharger.
  
  Note
  
  Install the gasket in the correct direction.
6. Temporarily install the turbocharger with 3 new nuts.
CONNECT TURBO WATER HOSE
1. Connect the 2 turbo water hoses with the 2 clips.
TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY
1. Install a new gasket to the turbo oil inlet pipe sub-assembly.
  
  Note
  
  Install the gasket in the correct direction.
2. Temporarily install the turbo oil inlet pipe sub-assembly with the 2 bolts, 2 nuts and union bolt.
TEMPORARILY TIGHTEN TURBOCHARGER STAY
1. Temporarily install the turbocharger stay with the 2 bolts and new nut.
FULLY TIGHTEN TURBOCHARGER
1. Tighten the 3 nuts to the specified torque to install the turbocharger.
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
CONNECT TURBOCHARGER STROKE SENSOR CONNECTOR
1. Connect the turbocharger stroke sensor connector.
FULLY TIGHTEN TURBOCHARGER STAY
1. Tighten the 2 bolts and nut to the specified torque to install the turbocharger stay.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY
1. Tighten the 2 bolts, 2 nuts and union nut to install the turbo oil inlet pipe sub-assembly.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf, for bolt }
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf, for nut }
  
  26 N*m { 265 kgf*cm, 19 ft.*lbf, for union bolt }
INSTALL NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)
1. Install the clamp with the 2 bolts.
  
  Torque:
  
  71 N*m { 724 kgf*cm, 52 ft.*lbf, for bolt A }
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf, for bolt B }
INSTALL TURBINE OUTLET ELBOW
1. Install a new gasket and the turbine outlet elbow with 3 new nuts.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Temporarily install the No, 1 exhaust manifold heat insulator with the 2 bolts.
INSTALL TURBO INSULATOR
1. Temporarily install the turbo insulator with the 2bolts.
2. Tighten the 4 bolts to the specified torque to install the turbo insulator and No. 1exhaust manifold heat insulator.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL VENTILATION PIPE
1. Install a new O-ring to the ventilation pipe sub-assembly.
2. Apply a small amount of engine oil to the O-ring and install the ventilation pipe sub-assembly.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Temporarily install the compressor bracket with the 4 bolts.
  
  Tech Tips
  
  Make sure that the compressor bracket is in contact with the engine block.
2. Tighten the 4 bolts in the sequence shown in the illustration.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.
2. Tighten the compressor and magnetic clutch with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
INSTALL FAN AND GENERATOR V BELT
1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.
  
  Note
  
  Make sure that the fan and generator V belt is set properly on each pulley.
2. Check that the indicator mark of the V-ribbed belt tensioner Click here.
INSTALL COMPRESSOR OUTLET ELBOW
1. Install the compressor outlet elbow with the 2 hose clamps and bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL COMPRESSOR ELBOW STAY
1. Install the compressor elbow stay with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
CONNECT TURBOCHARGER MOTOR CONNECTOR
1. Connect the turbocharger motor connector.
INSTALL AIR TUBE ASSEMBLY
1. Install the air tube assembly with the 2 hose clamps and 2 bolts.
  
  Torque:
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf, for bolt A }
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf, for bolt B }
INSTALL NO. 1 AIR CLEANER HOSE
1. Install the air cleaner hose to the compressor inlet elbow.
  
  Note
  
  Pull the hose to make sure that it is locked and securely connected.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Inspect the compression spring.
  1. Using vernier calipers, measure the free length of the compression spring.
    
    Minimum length
    
    40.5 mm (1.594 in.)
    
    If the free length is less than the minimum, replace the compression spring.
2. Fully insert a new gasket into the exhaust manifold by hand.
3. Using a wooden block, uniformly strike the gasket so that the gasket and the exhaust manifold are properly fitted.
  Note
  - Install the gasket in the correct direction.
  - Do not damage the outer surface of the gasket.
  - Do not reuse the removed gasket.
  - Do not push in the gasket with the front exhaust pipe when connecting it.
4. Install the hanger and the front exhaust pipe.
5. Install the 2 bolts and the 2 compression springs.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
ADD ENGINE COOLANT
INSTALL BATTERY SERVICE HOLE COVER
INSPECT FOR ENGINE COOLANT LEAK
INSPECT FOR ENGINE OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSTALL FENDER APRON MUDGUARD SEAL RH
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the engine service hole sub cover with the 5 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT SEAT ASSEMBLY RH
1. Connect the front seat inner belt assembly connector and install the front seat assembly.
2. Align the front seat assembly adjuster pin with the holes in the body.
3. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.
5. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.
7. Move the front seat assembly to the rearmost position.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
9. Move the front seat assembly fully forward.
  
  Note
  
  Make sure that the front seat assembly is securely locked.
10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH