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REMOVAL AND INSTALLATION


Pre-removal operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51, Under Cover .)
  • Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement .)
  • Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement .)
  • Engine Upper Cover Removal (Refer to GROUP 16, Ignition System - Ignition Coil .)
  • Charge Air Cooler Intake Hose A Removal (Refer to .)
  • Air Cleaner Assembly and Air Cleaner Intake Hose Removal (Refer to .)
  • Front Exhaust Pipe Removal (Refer to .)
  • Strut Tower Bar Removal (Refer to GROUP 42A, Strut Tower Bar .)
  • Cowl Top Panel Removal (Refer to GROUP 42A, Loose Panel .)

 Post-installation operation
  • Cowl Top Panel Installation (Refer to GROUP 42A, Loose Panel .)
  • Strut Tower Bar Installation (Refer to GROUP 42A, Strut Tower Bar .)
  • Front Exhaust Pipe Installation (Refer to .)
  • Air Cleaner Assembly and Air Cleaner Intake Hose Installation (Refer to .)
  • Charge Air Cooler Intake Hose A Installation (Refer to .)
  • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement .)
  • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement .)
  • Engine Upper Cover Removal (Refer to GROUP 16, Ignition System - Ignition Coil .)
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51, Under Cover .)




Removal steps


1.
 Dash panel heat protector


2.
 Exhaust manifold cover


3.
 Emission vacuum control hose connection


4.
 Turbocharger air outlet fitting


5.
 Turbocharger air outlet fitting gasket


6.
 Emission vacuum control hose connection


7.
 Turbocharger water return hose connection


8.
 Turbocharger water feed hose


9.
 Turbocharger water feed pipe


10.
 Gasket


11.
 Transfer heat protector


12.
 Drive shaft heat protector


13.
 Steering gear and linkage heat protector


14.
 Turbocharger protector A


15.
 Turbocharger protector B

>>E<<
 16.
 Turbocharger exhaust outlet fitting bracket


17.
 Turbocharger exhaust outlet fitting


18.
 Turbocharger exhaust outlet fitting gasket

>>B<<
 19.
 Turbocharger bracket and turbocharger assembly coupling bolt


20.
 Turbocharger oil feed tube connection


21.
 Gasket


22.
 Turbocharger oil return tube

>>D<<
 23.
 Turbocharger oil return tube gasket


24.
 O-ring

>>C<<
 25.
 Exhaust manifold and turbocharger assembly coupling bolt and nut


26.
 Exhaust manifold


27.
 Exhaust manifold gasket


28.
 Turbocharger gasket


29.
 Turbocharger seal ring


30.
 Turbocharger assembly


·
 Transfer assembly (Refer to GROUP 22C, Transfer Assembly )

>>B<<
 31.
 Turbocharger bracket




Removal steps
<<A>>
32.
 Turbocharger oil feed tube


33.
 Gasket


34.
 Turbocharger water return pipe


35.
 Gasket

>>A<<
 36.
 Turbocharger


40.
 Gasket
Required Special Tools:

REMOVAL SERVICE POINT

<<A>> TURBOCHARGER OIL FEED TUBE REMOVAL
caution Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the turbocharger oil feed tube is removed.

INSTALLATION SERVICE POINTS

>>A<< TURBOCHARGER INSTALLATION
1.Clean the fitting between turbocharger oil tube and turbocharger water pipe, the inside of eye bolts, the inside of tube and the inside of pipe for clogs.
2.
caution Take care not to allow foreign objects to get into the turbocharger.
Clean or use compressed air to remove any carbon particles stuck to the oil passage of the turbocharger.
3.Refill new engine oil at the turbocharger oil feed tube fitting hole of the turbocharger.

>>B<< TURBOCHARGER BRACKET/TURBOCHARGER BRACKET AND TURBOCHARGER ASSEMBLY COUPLING BOLT INSTALLATION

1.Check that the turbocharger bracket is in close contact with the turbocharger assembly and with the cylinder block. Then, temporarily tighten the turbocharger bracket mounting bolts, the turbocharger bracket and the turbocharger assembly coupling bolts.
2.Tighten the turbocharger bracket mounting bolts to the specified torque.
Tightening torque: 51 ± 7 N·m (38 ± 5 ft-lb)
3.Tighten the turbocharger bracket and turbocharger assembly coupling bolt to the specified torque.
Tightening torque: 64 ± 5 N·m (48 ± 3 ft-lb)

>>C<< EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY COUPLING BOLT AND NUT INSTALLATION


1.Tighten the bolts and nuts according to the procedure below.
(1) Install two washers with their identification holes facing outside as shown in the figure.
(2) Tighten the bolts and nuts to the specified torque.
Tightening torque: 29 ± 2 N·m (22 ± 1 ft-lb)
(3)
caution
  • When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
  • When the tightening angle is larger than the specified tightening angle, remove the bolt and nut to start from the beginning again according to the procedure.
Use special tool MB991614 to tighten bolts and nuts 65 ± 5 degrees angle.

>>D<< TURBOCHARGER OIL RETURN TUBE GASKET INSTALLATION

Install the gasket as its protrusion is in the direction shown.Install the gasket so that its protrusion faces in the direction shown in the illustration.

>>E<< TURBOCHARGER EXHAUST OUTLET FITTING BRACKET INSTALLATION

1.Check that the turbocharger exhaust outlet fitting bracket is in close contact with the turbocharger exhaust outlet fitting and with the cylinder block, and then temporarily tighten the turbocharger exhaust outlet fitting bracket mounting bolts.
2.Tighten the bolt of the cylinder block side to the specified torque.
Tightening torque: 51 ± 7 N·m (38 ± 5 ft-lb)
3.Tighten the bolt of the turbocharger exhaust outlet fitting bracket side to the specified torque.
Tightening torque: 64 ± 5 N·m (48 ± 3 ft-lb)