TURBOCHARGER INSTALLATION


  1. TEMPORARILY TIGHTEN TURBOCHARGER SUB-ASSEMBLY


    1. A01BBGO

      If replacing the turbocharger, add 20 cm3(1.2 cu in.) of fresh oil into the turbocharger oil inlet hole and turn the turbine wheel by hand to spread oil to the bearing.

    2. A01BEVR

      Install a new turbo to exhaust manifold gasket as shown in the illustration.

    3. A01BDQ8

      Temporarily tighten the turbocharger assembly with the 3 nuts to exhaust manifold.

  2. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BENBE01

      Install a new turbo oil inlet gasket (A) and an outlet gasket (B) and temporarily tighten the turbo inlet pipe with the 2 bolts and 2 nuts.

    2. A01BCS7

      Install a new gasket and temporarily tighten the turbo inlet pipe with the union bolt.

      Tech Tips

      Be sure to install the turbo oil inlet pipe with the turbo charger assembly temporarily tightened so that the positions of the turbo and cylinder block can be adjusted.

  3. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. A01BCVA

      Temporarily tighten the turbocharger stay with the 3 bolts.

  4. FULLY TIGHTEN TURBOCHARGER SUB-ASSEMBLY


    1. Tighten the turbocharger with the 3 nuts to align the turbocharger and turbo oil inlet pipe.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    2. Tighten the turbocharger stay.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    3. A01BF6SE02

      Tighten the turbo oil inlet pipe.

      Torque:
      Nut A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      Bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt C
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  5. INSTALL TURBINE OUTLET ELBOW


    1. Install a new gasket to the turbocharger.

    2. A01BF7G

      Install the turbine outlet elbow with 4 new bolts.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  6. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for Long Wheelbase)


    1. Inspect the compression spring.


      1. A01BCDO

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5mm (1.594 in.)

        Tech Tips

        If the free length is less than the minimum, replace the compression spring.

    2. A01BD65E03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the front exhaust manifold.

    3. Connect the exhaust pipe support, and install the exhaust pipe assembly front with the 4 bolts, 2 compression springs and 2 nuts.

      Torque:
      exhaust manifold side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      exhaust pipe assembly front side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front.

  7. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for Super Long Wheelbase)


    1. Inspect the compression spring.


      1. A01BCDO

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5mm(1.594 in.)

        Tech Tips

        If the free length is less than the minimum, replace the compression spring.

    2. A01BD65E03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the front exhaust manifold.

    3. Connect the exhaust pipe support, and install the exhaust pipe assembly front and a new gasket with the 4 bolts, 2 compression springs and 2nuts.

      Torque:
      Exhaust manifold side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Exhaust pipe assembly center side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front .

  8. INSTALL TURBO WATER PIPE SUB-ASSEMBLY NO.2 (for Water Cooled Turbocharger)


    1. Install a new gasket onto the turbocharger.

    2. A01BCMM

      Install the turbo water pipe No.2 with the bolt and 2 nuts to the turbocharger.

      Torque:
      Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  9. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY NO.2


    1. Water cooled turbocharger (w/ heater)


      1. Install a new gasket onto the cylinder block.

      2. A01BA8N

        Install the water by-pass pipe No.2 with the bolt and 2 nuts.

        Torque:
        Bolt
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }
        Nut
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

      4. Connect the water by-pass hose No.3 with the clip.

      5. Connect the heater water inlet hose with the clip.

    2. Water cooled turbocharger (w/o heater)


      1. Install a new gasket onto the cylinder block.

      2. A01BDH8

        Install the water by-pass pipe No.2 with the 2 nuts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      3. Install the turbo water pipe No.2 with the 2 bolts.

        Torque:
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      4. Connect the 2 water hoses with the 2 clips.

      5. Connect the water by-pass hose No.3 with the clip.

    3. Air cooled turbocharger (w/o heater)


      1. Install a new gasket onto the cylinder block.

      2. A01BBTX

        Install the water by-pass pipe No.2 with the 2 nuts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  10. INSTALL COMPRESSOR ELBOW STAY


    1. A01BA4S

      Install the compressor elbow stay with the bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 23 ft.*lbf }

  11. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BCJBE01

      Install the compressor outlet elbow with the 2 bolts and 2 clamps.

      Torque:
      Bolt (A)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  12. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. Install the air cleaner hose assembly with the clamp.

  13. INSTALL AIR TUBE ASSEMBLY


    1. Install the air tube assembly with the 2 clamps and 2 bolts.

  14. INSTALL VENTILATION PIPE


    1. A01BHMA

      Install the ventilation pipe with the bolt and clip.

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

  15. INSTALL COMPRESSOR BRACKET (w/ Air Conditioning)


    1. A01BFLCE02

      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. Install the compressor bracket by tightening the 4 bolts as shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  16. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)


    1. A01BFJ0

      Install 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.

  17. INSTALL FAN & 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.

  18. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs and fill the radiator reserve tank assembly with coolant to the top of the inlet.

    2. Loosen the bleeder plug of outlet housing.

    3. When air is bled and the coolant drains out, firmly install the bleeder plug.

    4. Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap.

      Coolant capacity
      Condition Capacity
      w/ rear heater 17.0 liters (18.0 US qts, 15.0 imp. qts)
      w/o rear heater 15.0 liters (15.9 US qts, 13.2 imp. qts)

    5. Warm up the engine.

    6. After the engine cools down check that the coolant level is between the LOW and FULL level marks.

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  20. INSTALL BATTERY SERVICE HOLE COVER (W/ SUB BATTERY)

  21. CHECK FOR ENGINE COOLANT LEAKS

    Click here

  22. INSTALL FENDER APRON MUDGUARD SEAL RH

  23. 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 }

  24. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  25. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  26. INSTALL FRONT DOOR SCUFF PLATE RH

  27. INSTALL ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)


    1. Install the engine under cover No.2 together with the engine side under cover LH and engine side under cover RH (for Wide Body).

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  28. INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

    Torque:
    13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  29. PERFORM INITIALIZATION

    Click here