TURBOCHARGER INSTALLATION

INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY
1. Install a new gasket and the No. 1 turbo water pipe with the bolt and 2 nuts.
  
  Torque:
  
  for bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  for nut
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
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 }
2. w/ DPF:
  
  Connect the No. 4 turbo water hose.
TEMPORARILY INSTALL TURBOCHARGER
1. w/ DPF:
  1. Set the turbocharger in a safe location.
  2. Temporarily install the exhaust manifold with the 8 plate washers, 8 new nuts and 8 new collars.
  3. Connect the 3 turbo water hoses.
2. w/o DPF:
  1. Install the No. 2 water by-pass pipe with the bolt and 2 nuts.
    
    Torque:
    
    for bolt
    
    19 N*m { 194 kgf*cm, 14 ft.*lbf }
    
    for nut
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  2. Connect the 2 turbo water hoses.
3. Install a new gasket to the turbocharger.
  
  Note
  
  Install the gasket in the correct direction.
4. Temporarily install the turbocharger with 3 new nuts.
TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY
1. Install a new gasket to the turbo oil inlet pipe.
  
  Note
  
  Install the gasket in the correct direction.
2. Temporarily install the turbo oil inlet pipe with the 2 bolts, 2 nuts and union bolt.
TEMPORARILY INSTALL TURBOCHARGER STAY
1. Temporarily install the turbocharger stay with the 2 bolts and a new nut.
TIGHTEN TURBOCHARGER
1. w/ DPF:
  
  Tighten the 8 nuts to the specified torque to install the exhaust manifold.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
2. 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
TIGHTEN TURBOCHARGER STAY
1. Tighten the 2 bolts and nut to the specified torque to install the turbocharger stay.
  
  Torque:
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY
1. Tighten the 2 bolts, 2 nuts and union bolt to install the turbo oil inlet pipe.
  
  Torque:
  
  for bolt
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  for nut
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  for union bolt
  
  26 N*m { 265 kgf*cm, 19 ft.*lbf }
INSTALL NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)
1. Install the clamp with the 2 bolts.
  
  Torque:
  
  for bolt A
  
  71 N*m { 724 kgf*cm, 52 ft.*lbf }
  
  for bolt B
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)
1. Install a new gasket and the exhaust manifold converter with 3 new nuts.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
TEMPORARILY INSTALL TURBINE OUTLET ELBOW STAY
1. w/ DPF:
  
  Temporarily install the turbine outlet elbow stay with the 2 bolts.
  
  Tech Tips
  
  The bolts are tightened after installing the catalytic with pipe converter assembly. The nuts are temporarily installed at that point and tightened after installing the front exhaust pipe.
2. w/o DPF:
  1. Temporarily install the turbine outlet elbow stay with the 2 bolts and 2 new nuts.
    
    Tech Tips
    
    The nuts are tightened after installing the front exhaust pipe.
  2. Tighten the 2 bolts.
    
    Torque:
    
    62 N*m { 632 kgf*cm, 46 ft.*lbf }
TEMPORARILY INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Temporarily install the No. 1 exhaust manifold heat insulator with the 3 bolts.
INSTALL TURBO INSULATOR
1. Temporarily install the turbo insulator with the 2 bolts.
2. Tighten the 5 bolts to the specified torque to install the turbo insulator and No. 1 exhaust manifold heat insulator.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL TURBINE OUTLET ELBOW (w/ DPF)
1. Temporarily install the turbine outlet elbow and a new gasket with 3 new nuts.
2. Temporarily install the No. 3 fuel pipe and a new gasket with the union bolt.
3. Tighten the 3 nuts of the turbine outlet elbow.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
INSTALL NO. 2 FUEL PIPE CLAMP (w/ DPF)
1. Temporarily install the No. 2 fuel pipe clamp with the 2 bolts.
2. Tighten the 2 bolts of the No. 2 fuel pipe clamp and the union bolt of the No. 3 fuel pipe.
  
  Torque:
  
  for bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  for union bolt
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
3. Connect the No. 4 water by-pass pipe to the No. 13 water by-pass hose.
4. Install a new gasket to the turbine outlet elbow with the union bolt.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL CATALYTIC WITH PIPE CONVERTER ASSEMBLY (w/ DPF)
1. Install a new gasket and the catalytic with pipe converter with 3 new nuts.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
2. Temporarily install 2 new nuts.
  
  Tech Tips
  
  The nuts are tightened after installing the front exhaust pipe.
3. Tighten the 2 bolts of the turbine outlet elbow stay.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)
1. Install the No. 3 exhaust manifold heat insulator with the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)
1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Attach the 3 wire harness clamps.
INSTALL VENTILATION PIPE
1. Install the ventilation pipe with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect to the 2 ventilation hoses.
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Temporarily install the No. 1 compressor mounting bracket with the 4 bolts.
  
  Tech Tips
  
  Make sure that the No. 1 compressor mounting bracket is in contact with the cylinder 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 OUTLET ELBOW
1. Install the compressor outlet elbow with the 2 hose clamps and bolt.
  
  Torque:
  
  for bolt
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  for hose clamp A
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
  
  for hose clamp B
  
  6.0 N*m { 61 kgf*cm, 53 in.*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
INSTALL AIR TUBE ASSEMBLY
1. Install the air tube with the 2 hose clamps and 2 bolts.
  
  Torque:
  
  for bolt A
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
  
  for bolt B
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
  
  for hose clamp
  
  4.5 N*m { 46 kgf*cm, 40 in.*lbf }
INSTALL NO. 1 AIR CLEANER HOSE
1. Install the No. 1 air cleaner hose to the compressor inlet elbow.
  
  Note
  
  Pull the hose to make sure that it is locked and securely connected.
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.
CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)
INSTALL FAN AND GENERATOR V BELT (w/ Air Conditioning System)
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 NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transmission)
1. Install the transmission control cable bracket with the 2 bolts.
  
  Torque:
  
  72 N*m { 729 kgf*cm, 53 ft.*lbf }
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)
1. Install 2 new clips to the No. 1 transmission control cable bracket.
2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket.
  Note
  - Make sure that A claws of the clips are firmly installed into the bracket grooves.
  - Make sure that the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.
3. Align the matchmarks on the control cable assembly and the shift outer lever.
4. Align the matchmarks on the control cable assembly and the select outer lever.
5. Install the transmission control cable assembly to the shift outer lever with the nut.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
6. Install the transmission control cable assembly to the select outer lever with the nut.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ DPF)

Click here
INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o DPF)
1. Inspect the compression spring.
  1. Using vernier calipers, measure the free length of the compression spring.
    
    Minimum length
    
    40.5 mm (1.59 in.)
    
    If the free length is less than the minimum, replace the compression spring.
2. Fully push a new gasket onto the exhaust manifold converter pipe by hand.
3. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold converter fit together properly.
  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 the pipe.
4. Connect the front exhaust pipe to the No. 4 exhaust pipe support.
5. Install the front exhaust pipe and 2 compression springs with the 2 bolts and 2 nuts.
  
  Torque:
  
  for bolt
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  for nut
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)
1. Tighten the 2 nuts to the exhaust manifold converter.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
ADD ENGINE COOLANT
CHARGE REFRIGERANT (w/ Air Conditioning System)
WARM UP ENGINE
CHECK FOR REFRIGERANT LEAK (w/ Air Conditioning System)
INSPECT FOR COOLANT LEAK
INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
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
INSTALL NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)
1. Install the No. 2 engine under cover with the 6 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)
1. Install the No. 1 engine under cover with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }