EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION


  1. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. A0117VL

      Install a new gasket.

    2. Install the turbocharger with the 3 nuts.

      Torque:
      53 N*m  { 540 kgf*cm, 39 ft.*lbf }

  2. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. A0117E1E01
      *1 Compressor Side

      Install a new gasket to the turbocharger.

    2. A011A40

      Install the inlet turbo oil pipe with the 2 nuts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  3. INSTALL TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD


    1. A0119LHE02

      Install 2 new gaskets to the cylinder head and cylinder block.

    2. Install the turbocharger with exhaust manifold with the 11 nut.

      Note

      Fully tighten the nuts to the exhaust manifold side before tightening the nuts to the turbo oil inlet pipe.

      Torque:
      Nut A
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Nut B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    3. A0119VP

      Connect the 2 turbocharger connectors.

  4. INSTALL MANIFOLD STAY


    1. A011BGB

      Install the manifold stay with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  5. INSTALL NO. 2 TURBOCHARGER STAY


    1. A011BTI

      Temporarily tighten the No. 2 turbocharger stay with the bolt and nut.

    2. Fully tighten the nut on the turbocharger side before tightening the bolt on the cylinder head side.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  6. INSTALL TURBOCHARGER STAY


    1. A011AE8

      Temporarily tighten the turbocharger stay with the 2 bolts and nut.

    2. Fully tighten the nut on the turbocharger side before tightening the bolts on the cylinder head side.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  7. INSTALL NO. 1 TURBO INSULATOR


    1. A0117JH

      Install No. 1 turbo insulator with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)


    1. A011BJ8

      Install a new gasket onto the turbocharger.

    2. Install the exhaust manifold converter with 3 new nuts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    3. A011A9I

      Engage the harness clamp and connect the connector.

  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


    1. A011BXE

      Install a new gasket onto the turbocharger.

    2. Install the exhaust manifold converter with 3 new nuts.

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

  10. INSTALL NO. 1 AIR HOSE


    1. A0118N0E01

      Install the No. 1 air hose with the 2 hose clamps.

      Tech Tips


      • Align the paint mark of the intercooler air hose with the location mark of the turbocharger.

      • Align the paint mark of the intercooler air hose with the location mark of No. 1 air tube.

      • Make sure that the hose clamp is at the correct angle when installing.

  11. INSTALL MANIFOLD SUPPORT BRACKET


    1. A01192RE01

      Temporarily tighten the manifold support bracket with the 2 bolts and nut.

    2. Fully tighten the 2 bolts and nut, as shown in the illustration.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  12. INSTALL NO. 2 MANIFOLD SUPPORT BRACKET


    1. A011BM4

      Install the No. 2 manifold support bracket with the bolt and nut.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  13. INSTALL TAIL EXHAUST PIPE ASSEMBLY


    1. Install the tail exhaust pipe assembly Click here.

  14. INSTALL TIE ROD END SUB-ASSEMBLY RH

    A011ABK

    1. Install the tie rod end onto the steering knuckle with a new castle nut.

      Torque:
      59 N*m  { 600 kgf*cm, 43 ft.*lbf }

      Note

      If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

    2. Install a new clip.

  15. INSTALL FRONT WHEEL RH

  16. INSTALL OIL LEVEL DIPSTICK GUIDE


    1. A0119YL

      Install the O-ring to the oil level dipstick guide.

    2. Install the oil level dipstick guide with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    3. Engage the harness clamp and install the oil level dipstick guide and wire harness with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  17. INSTALL NO. 2 TURBO INSULATOR


    1. A011B21

      Install the No. 2 turbo insulator with the bolt and nut.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 ft.*lbf }

  18. INSTALL AIR FUEL RATIO SENSOR


    1. A011BB9E01
      Text in Illustration
      *1 Fulcrum length

      Using SST, install the air fuel ratio sensor.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) Click here.

      • This torque value is effective when SST is parallel to the torque wrench.

    2. A0119BY

      Engage the 3 wire harness clamps and install the air fuel ratio sensor wire harness.

    3. Connect the air fuel ratio sensor connector.

  19. INSTALL ENGINE COVER ASSEMBLY


    1. A011ACJ

      Engage the 3 claws and install the engine cover.

  20. INSTALL AIR CLEANER HOSE ASSEMBLY

    A0119ZOE02
    Text in Illustration
    *1 Paint Mark

    1. Install the air cleaner hose.

      Note

      Position the clip so that the claws are centered over the paint mark on the hose.

  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A011AXX

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  22. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. A011BX8

      Install the air cleaner filter element.

      Note

      Engage the air cleaner filter element protrusion with the air cleaner case groove.

  23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A0119FRE01

      Engage the 2 claws and 2 clamps and install the air cleaner cap.

    2. Connect the connector and 2 wire harness clamps.

      Text in Illustration
      *1 Wire harness clamp
      *2 Clamp
    3. A0118S5E01

      Connect the air cleaner hose to the air cleaner cap.

      Tech Tips


      • The clamp should contact the air cleaner hose stopper.

      • Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.

  24. INSTALL FRONT WIPER MOTOR AND LINK


    1. Install the front wiper motor and link Click here.

  25. INSTALL EXHAUST PIPE (w/ Combustion Type Power Heater)


    1. Install the exhaust pipe Click here.

  26. INSPECT FOR OIL LEAK

  27. INSPECT FOR EXHAUST GAS LEAK

  28. CLEAR DTC (P0046)


    1. When a new turbocharger is installed, DTC P0046 is likely to occur. It should be cleared by the special method Click here.