TURBOCHARGER (w/o EGR Cooler) INSTALLATION


  1. CLEAN TURBOCHARGER SUB-ASSEMBLY

  2. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. A01DV39

      Temporarily install a new gasket and the turbocharger with 3 new nuts.

      Tech Tips

      When installing the turbo oil pipe, loosely tighten the 3 nuts so that the turbocharger and cylinder head can be aligned easily.

    2. Temporarily install the turbo oil pipe and manifold stay.

      Tech Tips

      Wash the oil pipe before installing it.


      1. A01DVX4

        Temporarily install a new gasket and the oil pipe with the 2 nuts, but only loosely install the nuts.

        Note

        The notch (wide part) of the gasket must face the engine.

      2. A01DWTJE03

        Temporarily install a new gasket and the oil pipe with the 2 bolts (labeled: A), but only loosely install the bolts.

        Note

        The claws of the gasket must face the pipe.

      3. Temporarily install a new gasket and the oil pipe with the union bolt (labeled: B), but only loosely install the union bolt.

      4. Temporarily install the stay with the 2 bolts.

        Tech Tips

        The stay's indented area must face the turbocharger.

    3. Tighten the bolts and nuts.


      1. Tighten the 3 nuts of the turbocharger.

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

      2. Tighten the 2 nuts of the oil pipe.

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

      3. Tighten the 2 bolts of the oil pipe.

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

      4. Tighten the union bolt.

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

      5. Tighten the 2 bolts of the stay.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }
        A01E18EE01

  3. INSTALL TURBINE OUTLET ELBOW

    A01DWHX

    1. Temporarily install a new gasket and the outlet elbow (with turbocharger stay) to the turbocharger with the 4 nuts.

    2. Temporarily install the stay with the 2 bolts.

    3. Tighten the 4 nuts of the turbocharger.

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

    4. Tighten the 2 bolts of the stay.

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

  4. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    A01E2CCE05

    1. Connect the pipe (with the 2 air hoses) and install the bolt.

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

    2. Tighten the 2 clamps of the No. 1 and No. 2 air hoses.

      Torque:
      6.5 N*m  { 66 kgf*cm, 57 in.*lbf }

    3. Connect the vacuum hose to the gas filter.

    4. Connect the manifold absolute pressure sensor connector.

  5. INSTALL VENTILATION HOSE HEAT INSULATOR


    1. Install the insulator with the 2 bolts.

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

  6. INSTALL AIR CLEANER ASSEMBLY


    1. w/o Mass Air Flow Meter:


      1. A01DV6E

        Connect the air cleaner hose.

      2. Install the air cleaner with the 2 bolts.

        Torque:
        14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      3. Tighten the clamp.

      4. Install the clamp and connect the intake air temperature sensor connector.

      5. Connect the ventilation hose.

      6. Slide the clamp to the connection of the hose.

    2. w/ Mass Air Flow Meter:


      1. Connect the air cleaner hose.

      2. A01DX6Z

        Install the air cleaner with the 2 bolts.

        Torque:
        14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      3. Connect the connector to the mass air flow meter.

      4. Tighten the hose clamp.

  7. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01DWJ9

      Using a vernier caliper, measure the free length of the compression spring.

      Minimum length
      40 mm (1.57 in.)

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

    2. Install the front pipe to the pipe support.

    3. A01DYGME01

      Install a new gasket to the outlet pipe.

      Note


      • Be careful with the installation direction of the gasket.


      • Do not reuse the gasket.


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

      Tech Tips

      Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.

    4. Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      CAUTION:

      Do not reuse the gasket.

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  9. CHECK FOR ENGINE OIL LEAKS

  10. CHECK FOR EXHAUST LEAKS

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

  11. INSTALL FRONT FENDER APRON SEAL UPPER


    1. Install the apron seal with the 5 clips.

  12. INSTALL FRONT FENDER SEAL


    1. Install the fender seal with the 5 clips.

  13. INSTALL FRONT WHEEL RH

  14. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  15. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.