Installation Steps

Components For Removal And Installation Of The Turbocharger (1 Of 2):

Components For Removal And Installation Of The Turbocharger (2 Of 2):

TURBOCHARGER INSTALLATION



NOTICE: After replacing the turbocharger assembly, pour approx. 20 cc (1.2 cu in.) of fresh oil into the oil inlet and turn the impeller wheel by hand to splash oil on the bearing.

1. INSTALL NO.1 TURBOCHARGER TO TURBINE OUTLET ELBOW.



- Install a new gasket and the turbocharger with 6 new nuts.
Torque: 25 Nm (18 ft.lb)

2. INSTALL NO.2 TURBOCHARGER TO TURBINE OUTLET ELBOW.
- Install a new gasket and the turbocharger with 6 new nuts.
Torque: 25 Nm (18 ft.lb)

3. INSTALL NO.1 TURBO WATER PIPE TO NO.1 TURBOCHARGER.



- Install a new gasket and the water pipe with the 2 nuts.
Torque: 8.8 Nm (78 in.lb)

4. INSTALL BEARING HOUSING SIDE PLATE TO NO.2 TURBOCHARGER.
- Install a new gasket and the housing plate with the 2 nuts.
Torque: 8.8 Nm (78 in.lb)

5. INSTALL NO.2 TURBO WATER PIPE TO NO.2 TURBOCHARGER.



- Install a new gasket and the water pipe with the 2 nuts.
Torque: 8.8 Nm (78 in.lb)

6. INSTALL BEARING HOUSING SIDE PLATE TO NO.1 TURBOCHARGER.
- Install a new gasket and the housing plate with the 2 nuts.
Torque: 8.8 Nm (78 in.lb)

7. INSTALL EXHAUST MANIFOLD PLATE TO TURBINE OUTLET ELBOW.



- Install the manifold plate with the 2 bolts.

8. INSTALL NO.2 AIR TUBE AND NO. 3 WATER BYPASS PIPE ASSEMBLY TO NO.2 TURBOCHARGER.
- Install a new gasket, the air tube and bypass pipe assembly with 2 bolts.
Torque: 21 Nm (15 ft.lb)

9. CONNECT AIR HOSES ON NO.1 VACUUM PIPE TO NO.2 TURBOCHARGER.



- Connect the 2 air hoses to the actuator for the exhaust bypass valve.

10. INSTALL TURBOCHARGERS AND TURBINE OUTLET ELBOW ASSEMBLY.



(a) Install 2 new gaskets to the exhaust manifold.
(b) Install the 2 turbochargers and turbine outlet elbow assembly with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 54 Nm (40 ft.lb)
(c) Connect the following hoses:



(1) heater hose (from No.3 water bypass pipe) to No.2 water bypass pipe
(2) water bypass hose (from No.2 turbo water pipe) to No.2 water bypass pipe

11. INSTALL NO.1 TURBO OIL PIPE.



(a) Connect the turbo oil hose to the turbo oil outlet on the No.1 oil pan.
(b) Align the oil holes of a new gasket and the turbocharger housing.
(c) Temporarily install the gasket and turbo oil pipe to the turbocharger with the 2 nuts.
(d) Install 2 new gaskets and the turbo oil pipe to the cylinder block with the union bolt.
Torque: 39 Nm (29 ft.lb)
(e) Tighten the 2 nuts holding the turbo oil pipe to the turbocharger.
Torque: 21 Nm (15 ft.lb)

12. INSTALL NO.2 TURBO OIL PIPE.
(a) Connect the turbo oil hose to the turbo oil outlet on the No.1 oil pan.
(b) Align the oil holes of a new gasket and the turbocharger housing.
(c) Temporarily install the gasket and turbo oil pipe to the turbocharger with the 2 nuts.
(d) Install 2 new gaskets and the turbo oil pipe to the cylinder block with the union bolt.
Torque: 39 Nm (29 ft.lb)
(e) Tighten the 2 nuts holding the turbo oil pipe to the turbocharger.
Torque: 21 Nm (15 ft.lb)

13. INSTALL NO.1 TURBOCHARGER STAY.



- Install the turbocharger stay with the bolt and nut.
Torque: 43 Nm (32 ft.lb)

14. INSTALL NO.2 TURBOCHARGER STAY.
- Install the turbocharger stay and No.1 turbo oil pipe clamp with the bolt and nut.
Torque: 43 Nm (32 ft.lb)

15. INSTALL EXHAUST GAS CONTROL VALVE.
(a) Install 2 new gaskets to the control valve.



(b) Install the control valve with 3 new nuts.
Torque: 69 Nm (51 ft.lb)
NOTICE: The control valve is ceramic. Do not drop or knock the control valve.

16. INSTALL MAIN HEATED OXYGEN SENSOR.



(a) Install a new gasket and the oxygen sensor with 2 new nuts.
(b) Connect the oxygen sensor connector.
Torque: 20 Nm (14 ft.lb)

17. INSTALL EXHAUST GAS CONTROL VALVE STAY.



- Install the control valve stay with the bolt and nut.
Torque: 43 Nm (32 ft.lb)

18. INSTALL EXHAUST BYPASS PIPE.



- Install 2 new gaskets and the bypass pipe with 4 new nuts.
Torque: 25 Nm (18 ft.lb)

19. INSTALL HEAT INSULATOR FOR TURBOCHARGER.



- Install the heat Insulator with the 4 bolts.

20. INSTALL AIR INLET DUCT.
- Install the air inlet duct and cable bracket with the bolt and 2 nuts.

21. INSTALL AIR TUBES AND INTAKE AIR CONNECTOR.
(a) Place the intake air connector and No.1 air tube assembly in position.
(b) Connect the following hoses.



(1) Air hose to No.2 air tube
(2) PCV hose to No.2 cylinder head cover




(c) Install a new gasket and the air control valve to the No.2 turbocharger with the 2 bolts.
Torque: 21 Nm (15 ft.lb)

(d) Place the No.4 air tube and air bypass valve assembly in position.
(e) Connect the following hoses.



(1) Air hose to No.4 air tube
(2) Air hose to intake air connector
(f) Install a new gasket and the No.4 air tube to the No.1 turbocharger with the 2 nuts.
Torque: 21 Nm (15 ft.lb)




(g) Install a new gasket and the No.1 air tube to the No.1 turbocharger with the 2 bolts.
Torque: 21 Nm (15 ft.lb)




(h) Install the No.2 turbo water pipe to the No.4 air tube with the bolt.

(i) Connect the following connector and hoses:



(1) Crankshaft position sensor connector to clamp
(2) Water bypass hose (from water pump) to No.1 turbo water pipe
(3) Water bypass hose (from water outlet) to No.1 turbo water pipe
(4) Water bypass hose (from water outlet) to No.2 turbo water pipe

22. INSTALL VSV ASSEMBLY.
(a) Install the VSV assembly with the 2 bolts.
(b) Connect the 2 VSV connectors.
(c) Connect the following hoses:



(1) Air hose to actuator for waste gate valve
(2) Air hose to actuator for exhaust gas control valve
(3) Air hose to hose clamp
(4) Engine wire to wire clamp

23. CONNECT NO.1 VACUUM PIPE FROM AIR TUBES.
(a) Install the the vacuum pipe with the 3 bolts.
(b) Connect the following hoses:



(1) Air hose to No.4 air tube
(2) Air hose to No.1 air tube
(3) Air hose (from VSV for waste gate valve) to vacuum pipe
(4) Air hose (from VSV for exhaust gas control valve) to vacuum pipe
(5) Vacuum hose (from air bypass valve) to No.1 air tube
(6) 2 air hoses (from VSV for exhaust bypass valve) to vacuum pipe
(7) Air hose (from No.2 air tube) to vacuum pipe
(8) Air hose to VSV for intake air control valve
(9) 2 air hoses (from pressure tank) to vacuum pipe

(c) Connect the following connectors:



(1) VSV connector for intake air control valve
(2) VSV connector for exhaust bypass valve
(d) Secure the engine wire with the 3 clamps.

24. CONNECT IAC VALVE PIPE TO NO.2 AIR TUBE.
(a) Connect the following hoses:



(1) Air hose (from No.1 vacuum pipe) to IAC valve pipe
(2) Air hose to No.2 air tube
(b) Install the IAC valve pipe to the clamp.
(c) Secure the engine wire with the clamp.

25. CONNECT THE FOLLOWING HOSES:



(1) Heater hose to No.3 water bypass pipe
(2) EVAP hose to No.1 vacuum pipe

26. INSTALL ENGINE WIRE PROTECTOR TO BODY.
- Install the wire protector with the 2 bolts, as illustrated above.

27. INSTALL AT OIL COOLER TUBES TO ENGINE.



(a) Install the tube bracket (rear side) to the cylinder block.
(b) Install the oil cooler tubes to the bracket (rear side) on the cylinder block with the tube clamp and bolt.
(c) Install the oil cooler tubes to the bracket (front side) on the generator with the tube clamp and bolt.

28. INSTALL HEAT INSULATOR FOR NO.2 FRONT EXHAUST PIPE.



- Install the heat insulator with the 2 bolts and 2 nuts.

29. INSTALL NO.2 FRONT EXHAUST PIPE.



(a) Install a new gaskets and the No.2 front exhaust pipe with 3 new nuts.
Torque: 62 Nm (46 ft.lb)

(b) Temporarily install the pipe support bracket to the transmission with the 2 bolts.



(c) Install a new gasket to front end of the front exhaust pipe, and connect the front exhaust pipe to the No.2 front exhaust pipe with the 2 bolts and nuts.
Torque: 58 Nm (43 ft.lb)
(d) Tighten the 2 bolts holding the pipe support bracket to the transmission.
Torque: 43 Nm (32 ft.lb)

30. INSTALL UPPER FRONT CROSSMEMBER EXTENSION.



- Install the crossmember extension with the 2 bolts and 2 nuts.
Torque:
29 Nm (22 ft.lb) for bolts
33 Nm (25 ft.lb) for nuts

31, INSTALL FRONT LOWER ARM BRACKET STAY.
- Install the arm bracket stay with the plate washer, nut and 2 bolts.
Torque:
44 Nm (33 ft.lb) for bolts
59 Nm (43 ft.lb) for nut




32. INSTALL THEFT DETERRENT HORN.

33. INSTALL AIR CLEANER AND MAF METER ASSEMBLY.



(a) Connect the air cleaner hose to the intake air connector.
(b) Install the air cleaner and MAF meter assembly with the 3 bolts.
(c) Tighten the hose clamp holding the air cleaner hose to the intake air connector.
(d) Connect the MAF meter connector.
(e) Secure the MAF meter wire with the clamp on the air cleaner case.

34. INSTALL AIR CLEANER DUCT.



(a) Connect the air cleaner duct to the air cleaner case.
(b) Install the air cleaner duct with the bolt.




35. INSTALL NO.1 AIR HOSE WITH THE 2 HOSE CLAMPS.




36. CONNECT CRUISE CONTROL ACTUATOR CABLE TO THROTTLE BODY.
37. FILL WITH ENGINE COOLANT.
38. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY.
39. START ENGINE AND CHECK FOR LEAKS.
40. CHECK ENGINE OIL LEVEL.
41. RECHECK ENGINE COOLANT LEVEL.
42. INSTALL ENGINE UNDER COVER.