Turbocharger installation (RZ4E-TC)

1. Component views

Turbocharger

Part name

  1. Nut
  2. Bolt
  3. Water feed and return pipe
  4. Turbocharger
  5. Nut
  6. Turbocharger heat protector
  7. Bolt
  8. Nut
  9. Bolt
  10. Turbocharger oil pipe
  11. Bolt
  12. Bolt
  13. Bolt
  14. Turbocharger bracket
  15. Bolt
  16. Bolt
  17. Nut
  18. Bolt
  19. Catalytic converter
  20. Catalytic converter bracket
  21. Bolt

Tightening torque

1: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8: 52 N・m { 5.3 kgf・m / 38 lb・ft }

9: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

11: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12: 22.5 N・m { 2.3 kgf・m / 17 lb・ft }

13: 25 N・m { 2.5 kgf・m / 18 lb・ft }

15: 52 N・m { 5.3 kgf・m / 38 lb・ft }

16: 52 N・m { 5.3 kgf・m / 38 lb・ft }

17: 52 N・m { 5.3 kgf・m / 38 lb・ft }

18: 52 N・m { 5.3 kgf・m / 38 lb・ft }

21: 52 N・m { 5.3 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) 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 }

2) Feed 1 cc (approximately 20 drops) of engine oil into the oil feed port.

3) Install the turbocharger and gasket to the exhaust manifold.

Caution

  • Do not reuse the gasket.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

4. Turbocharger heat protector installation

1) Install the turbocharger heat protector to the turbocharger.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

5. Turbocharger bracket installation

1) Temporarily tighten the turbocharger bracket to the turbocharger and cylinder block in the order shown in the diagram.

2) Final tighten the turbocharger bracket to the turbocharger and cylinder block in the order shown in the diagram.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

6. Turbocharger oil pipe installation

1) Install the gasket to the turbocharger oil pipe.

Caution

  • Do not reuse the gasket.

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

  1. Turbocharger
  2. Gasket
  3. Turbocharger oil pipe

3) Install the turbocharger oil pipe (feed side) to the cylinder block.

Caution

  • Do not reuse the gasket.

Tightening torque: 22.5 N・m { 2.3 kgf・m / 17 lb・ft } Eyebolt

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Bolt

Legend

  1. Turbocharger oil pipe (feed side)
  2. Bolt
  3. Eyebolt

4) Install the turbocharger oil pipe (return side) and gasket to the cylinder block.

Caution

  • Do not reuse the gasket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Legend

  1. Turbocharger oil pipe (return side)
  2. Bolt

7. Turbocharger water hose connect

1) Connect the turbocharger water return hose to the water feed pipe and return pipe.

2) Connect the turbocharger water feed hose to the water feed pipe and return pipe.

Legend

  1. Turbocharger water feed hose
  2. Turbocharger water return hose

8. Exhaust pipe installation

1. Except for Euro4 specifications

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) exhaust pipe installation".

9. Catalytic converter installation

1. Euro4 specifications

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter installation".

10. Vacuum hose installation

1) Install the vacuum hose to the turbocharger and vacuum pipe.

11. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Legend

  1. Air cleaner
  2. MAF and IAT sensor
  3. Barometric pressure sensor

2) Connect the connector to the barometric pressure sensor.

3) Connect the connector to the MAF and IAT sensor.

12. Intake hose installation

1) Install the intake hose to the turbocharger and air pipe.

Caution

  • Align the marks on the pipe side and hose side.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp

Legend

  1. Turbocharger
  2. Intercooler
  3. Intake hose
  4. Clamp

13. Air duct installation

1) Align the air duct with the air cleaner and turbocharger.

Legend

  1. Air duct

2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

Legend

  1. Alignment mark

3) Install the PCV hose to the cylinder head cover and air duct.

Caution

  • Align the marks on the pipe side and hose side.

Legend

  1. PCV hose
  2. Clamp

4) Install the intake air duct to the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

14. Engine cover installation

1) Install the engine cover to the engine.

Legend

  1. Engine cover

15. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

16. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

17. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution

  • Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.

Note

  • Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant lowers.

Caution

  • Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

Legend

  1. Radiator reserve tank
  2. MAX line
  3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution

  • Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note

  • If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note

  • Touch the radiator upper hose, and confirm that it has become warm.
  • If it has not become warm, go back to Step 11.

Caution

  • Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution

  • If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
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