EXHAUST MANIFOLD W/ TURBOCHARGER

INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

Install a new gasket and the No. 1 turbo water pipe sub-assembly and bolt to the turbocharger sub-assembly with the 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 EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

Temporarily install a new gasket and the turbocharger sub-assembly to the exhaust manifold with 3 new nuts.

Tech Tips

It is easier to install the turbo oil inlet pipe sub-assembly if the 3 nuts are only loosely installed.
Set a new gasket on the engine and install the exhaust manifold with turbocharger sub-assembly, the 8 collars and the 8 plate washers with 8 new nuts.

Torque:

40 N*m { 408 kgf*cm, 30 ft.*lbf }

Note

Install the collars so that the side with the smaller external diameter faces the exhaust manifold.

Temporarily install the turbo oil inlet pipe sub-assembly to the turbocharger sub-assembly.

Tech Tips

Before installing the turbo oil inlet pipe sub-assembly, clean it.

Install a new gasket and the turbo oil inlet pipe sub-assembly with the 2 nuts, but only loosely install the nuts.

Note

The notch (narrow part) of the gasket must face the engine.
Install a new gasket and the turbo oil inlet pipe sub-assembly with the 2 bolts, but only loosely install the bolts.

Note

The claws of the gasket must face the pipe.

Install a new gasket and the turbo oil inlet pipe sub-assembly with the union bolt, but only loosely install the union bolt.

Text in Illustration
*1	Gasket	-	-
*a	Wide	*b	Narrow
*c	Claw	-	-
	Outside	-	-

Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts and nut.

Tighten the 3 nuts of the turbocharger sub-assembly.

Torque:

52 N*m { 530 kgf*cm, 38 ft.*lbf }
Tighten the 2 nuts labeled A.

Torque:

13 N*m { 133 kgf*cm, 10 ft.*lbf }
Tighten the union bolt labeled B.

Torque:

33 N*m { 337 kgf*cm, 24 ft.*lbf }
Tighten the 2 bolts labeled C.

Torque:

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Tighten the 2 bolts and nut of the turbocharger stay in the order shown in the illustration.

Torque:

38 N*m { 387 kgf*cm, 28 ft.*lbf }

INSTALL TURBINE OUTLET ELBOW

Install a new gasket and the turbine outlet elbow to the turbocharger sub-assembly with the 3 nuts.

Torque:

39 N*m { 398 kgf*cm, 29 ft.*lbf }

CONNECT NO. 1 TURBO WATER HOSE

Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clamp to secure the hose.

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Temporarily install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the bolt.

INSTALL NO. 1 TURBO INSULATOR

Temporarily install the No. 1 turbo insulator to the turbocharger sub-assembly with the 2 bolts.
Tighten the bolt of the No. 1 exhaust manifold heat insulator and the 2 bolts of the No. 1 turbo insulator.

Torque:

12 N*m { 122 kgf*cm, 9 ft.*lbf }

INSTALL COMPRESSOR INLET ELBOW

Install a new gasket and the compressor inlet elbow with the 2 nuts.

Torque:

19 N*m { 194 kgf*cm, 14 ft.*lbf }
Connect the No. 2 turbo water hose and No. 3 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clamp to secure the hose.
Connect the No. 3 turbo water hose and No. 3 turbo water hose to the No. 2 water by-pass pipe, and slide the clamp to secure the hose.
Connect the 2 connectors and attach the wire harness clamp.
Install the wire harness bracket to the water inlet with the bolt.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Attach the 3 wire harness clamps.

INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Install a new O-ring to the engine oil level dipstick guide.
Apply a small amount of clean engine oil to the O-ring.
Install the engine oil level dipstick guide to the cylinder block sub-assembly with the 2 bolts.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Install the engine oil level dipstick.

INSTALL VENTILATION PIPE

Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover to the cylinder head sub-assembly with the bolt.

Torque:

18 N*m { 184 kgf*cm, 13 ft.*lbf }
Type A

Connect the No. 3 turbo water hose and No. 4 turbo water hose to the ventilation pipe, and slide the 2 clamps to secure the hose.

INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

Click here

INSTALL GENERATOR BRACKET

Click here

INSTALL GENERATOR ASSEMBLY

Click here

CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

Click here

INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)

Click here

INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)

Click here

INSTALL COMPRESSOR OUTLET ELBOW

Install the compressor outlet elbow with the 2 bolts and tighten the hose clamp.

Torque:

for bolt

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

for hose clamp

6.5 N*m { 66 kgf*cm, 58 in.*lbf }
Install the wire harness bracket with the bolt.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Attach the 3 wire harness clamps.

INSTALL NO. 1 AIR HOSE

Click here

INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Install the air cleaner case sub-assembly with the 3 bolts.

Torque:

12 N*m { 122 kgf*cm, 9 ft.*lbf }

INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

Attach the 4 clamps to install the air cleaner cap sub-assembly.
except Cold Area Specification Vehicles:

Attach the 2 clamps and connect the mass air flow meter connector.
for Cold Area Specification Vehicles:

Attach the 3 clamps and connect the mass air flow meter connector.

INSTALL NO. 1 AIR CLEANER HOSE

Text in Illustration
*1	No. 1 Air Cleaner Hose	*2	Compressor Inlet Elbow
*3	Air Cleaner Cap	-	-
*a	Upper Side	*b	Front Side of Vehicle
*c	Protrusion	*d	Groove

Install the No. 1 air cleaner hose with the 2 hose clamps.
Note
- When installing the No. 1 air cleaner hose, align the protrusion of the No. 1 air cleaner hose with the protrusion of the compressor inlet elbow as shown in the illustration.
- When installing the No. 1 air cleaner hose, align the groove of the No. 1 air cleaner hose with the protrusion of the air cleaner cap as shown in the illustration.
Tighten the 2 hose clamps.

Torque:

5.0 N*m { 51 kgf*cm, 44 in.*lbf }

Note

When tightening the 2 hose clamps, make sure that they are positioned as shown in the illustration.