TURBOCHARGER INSTALLATION


  1. 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 }

  2. 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 }

  3. TEMPORARILY INSTALL TURBOCHARGER


    1. Set the turbocharger in a safe location.

    2. 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 }

    3. Connect the 2 turbo water hoses with the 2 clips.

    4. A01BC4ZE01

      Install a new gasket to the turbocharger.

      Note

      Install the gasket in the correct direction.

    5. Temporarily install the turbocharger with 3 new nuts.

  4. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BEFIE01

      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.

  5. TEMPORARILY INSTALL TURBOCHARGER STAY


    1. Temporarily install the turbocharger stay with the 2 bolts and a new nut.

  6. 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 }

  7. CONNECT TURBOCHARGER STROKE SENSOR CONNECTOR


    1. Connect the turbocharger stroke sensor connector.

  8. 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 }

  9. TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BG18E01

      Tighten the 2 bolts, 2 nuts and union nut 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 }

  10. INSTALL NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)


    1. A01BFAKE01

      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 }

  11. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install a new gasket and the exhaust manifold converter with 3 new nuts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  12. TEMPORARILY INSTALL TURBINE OUTLET ELBOW STAY


    1. Temporarily install the turbine outlet elbow stay with the 2 bolts and 2 new nuts.

    2. Tighten the 2 bolts.

      Tech Tips

      Tighten the nut after installing the front exhaust pipe.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  13. TEMPORARILY INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Temporarily install the No. 1 exhaust manifold heat insulator with the 3 bolts.

  14. 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 }

  15. 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.

  16. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  17. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BFLCE02

      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 }

  18. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BFP8E01

      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 }

  19. INSTALL COMPRESSOR ELBOW STAY


    1. Install the compressor elbow stay with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  20. CONNECT TURBOCHARGER MOTOR CONNECTOR


    1. Connect the turbocharger motor connector.

  21. INSTALL AIR TUBE ASSEMBLY


    1. A01BGL8E01

      Install the air tube with the 2 hose clamps and 2 bolts.

      Torque:
      for bolt A
      18 N*m  { 178 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 }

  22. 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.

  23. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A01BFJ0E01

    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.

  24. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)

  25. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

  26. 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.

  27. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01BD2W

      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. A01BDL4E01

      Fully insert a new gasket into the exhaust manifold converter pipe by hand.

    3. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold converter 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 the pipe.

    4. Connect the front exhaust pipe to 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 }

  28. TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01BEU2

      Tighten the 2 nuts to the exhaust manifold converter.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  30. ADD ENGINE COOLANT

  31. CHARGE REFRIGERANT (w/ Air Conditioning System)

  32. WARM UP ENGINE

  33. CHECK FOR REFRIGERANT LEAK (w/ Air Conditioning System)

  34. INSPECT FOR ENGINE COOLANT LEAK

  35. INSPECT FOR ENGINE OIL LEAK

  36. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  37. INSTALL FENDER APRON MUDGUARD SEAL RH

  38. 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 }

  39. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      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 }

  40. INSTALL FRONT DOOR SCUFF PLATE RH

  41. 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 }

  42. 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 }