1. Component views
Turbocharger
Part name
- Bolt
- Gasket
- Turbocharger
- Bolt
- Heat protector
- Bolt
- Water feed and return pipe
- Bolt
- Turbocharger oil pipe
- Nut
- Bolt
- Bolt
- Nut
- Turbocharger bracket
- Bolt
- Bolt
- Bolt
- Bracket
Tightening torque
1: 52 N・m { 5.3 kgf・m / 38 lb・ft }
4: 25 N・m { 2.5 kgf・m / 18 lb・ft }
6: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
8: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
10: 25 N・m { 2.5 kgf・m / 18 lb・ft }
11: 23 N・m { 2.3 kgf・m / 17 lb・ft }
12: 51 N・m { 5.2 kgf・m / 38 lb・ft }
13: 52 N・m { 5.3 kgf・m / 38 lb・ft }
15: 51 N・m { 5.2 kgf・m / 38 lb・ft }
16: 25 N・m { 2.5 kgf・m / 18 lb・ft }
17: 51 N・m { 5.2 kgf・m / 38 lb・ft }
2. Turbocharger safety information
1) Perform the following procedures before installing the turbocharger.
- If the original turbocharger has a malfunction and needs to be replaced, change the engine oil and replace the oil filter because there may be fragments or wear particles in the engine oil.
- Completely remove carbon and dirt on the tip of the oil pipe with compressed air, etc.
- Clean any dirt inside the intake duct and exhaust manifold connected to the turbocharger.
- For the initial lubrication inside the turbocharger, fill the turbocharger oil feed port with 1 cc (approximately 20 drops) of engine oil.
2) After installing the turbocharger, warm up the engine at idle.
Caution
- Do not increase the engine speed immediately after the engine is started.
- If the turbocharger is operated with poor lubrication, the bearings inside the turbocharger may be burned.
3. Turbocharger installation
1) Feed 1 cc (approximately 20 drops) of engine oil into the oil feed port.
Legend
- Oil feed port
2) Install the turbocharger oil pipe and gasket to the turbocharger.
Caution
- Do not reuse the gasket.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
Legend
- Turbocharger oil pipe
- Bolt
3) Install the water feed and return pipe, as well as the gasket to the turbocharger.
Caution
- Do not reuse the gasket.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
4) Install the following parts as a set to the exhaust manifold.
- Turbocharger
- Turbocharger oil pipe
- Water feed and return pipe
Caution
- Do not reuse the gasket.
Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }
5) Connect the connector to the turbocharger.
4. Turbocharger bracket installation
1) Temporarily tighten the turbocharger upper bracket to the turbocharger and turbocharger lower bracket.
2) Final tighten the turbocharger upper bracket to the turbocharger and turbocharger lower bracket.
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }
5. Turbocharger oil pipe connect
1) Connect the turbocharger oil pipe to the oil cooler and crankcase.
Caution
- Do not reuse the gasket.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Crankcase side
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } Oil cooler side
Legend
- Turbocharger oil pipe
6. Turbocharger water hose connect
1) Connect the turbocharger water return hose to the water feed and return pipe.
2) Connect the turbocharger water feed hose to the water feed and return pipe.
Legend
- Turbocharger water feed hose
- Turbocharger water return hose
7. Intake hose installation
1) Install the intake hose to the intercooler and turbocharger.
Caution
- Align the marks on the pipe side and hose side.
Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
Legend
- Clamp
- Intake hose
8. DPD installation
1) Temporarily tighten the DPD and exhaust pipe bracket to the crankcase in the order shown in the diagram.
2) Temporarily tighten the DPD bracket to the following parts in the order shown in the diagram.
- DPD
- Oil cooler side bracket
- Turbocharger lower bracket
- Turbocharger upper bracket
3) Temporarily tighten the DPD to the turbocharger using a V-band.
Caution
- Do not reuse the gasket.
- Assemble with the gasket yellow paint section facing toward the DPD.
Legend
- Yellow paint section
V-band assembly direction
Legend
- Top
- RH
4) Final tighten the DPD and exhaust pipe bracket to the crankcase in the order shown in the diagram.
Tightening torque: 94 N・m { 9.6 kgf・m / 69 lb・ft }
5) Final tighten the DPD bracket to the following parts in the order shown in the diagram.
- DPD
- Oil cooler side bracket
- Turbocharger lower bracket
- Turbocharger upper bracket
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
6) Align the markings, and then connect the differential pressure hoses to the DPD.
Caution
- Install the differential pressure hose clip securely so that there is no gas leakage.
- Do not use cracked hoses.
- If there is gas leakage from connections, the sensor may malfunction.
- After starting the engine, verify that there is no gas leakage.
Legend
- White paint
- Green paint
7) Final tighten the V-band to the DPD and turbocharger.
Note
- Turn the V-band bolt, pushing it into the joint pin.
Caution
- Tighten in 2 stages.
Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }
Legend
- V-band bolt
- Joint pin
8) Install the heat protector to the turbocharger.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Legend
- Heat protector
9. Exhaust pipe installation
10. Steering shaft connect
1) Install the lower second steering shaft to the second steering shaft according to the alignment marks placed during removal.
Caution
- Install while it makes contact with the yoke.
- Tighten the bolt by hand until seated and final tighten.
- Tighten the tire while it is in contact with the ground.
Tightening torque: 31 N・m { 3.2 kgf・m / 23 lb・ft }
Legend
- Yoke
- Alignment mark
2) Connect the universal joint to the power steering unit according to the alignment marks placed during removal.
Tightening torque: 31 N・m { 3.2 kgf・m / 23 lb・ft }