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REMOVAL AND INSTALLATION


Pre-removal operation
  • Engine Room Under Cover Front A, B, Engine Room Under Cover Center 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 and Charge Air Cooler Intake Pipe 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 ).
  • Charge Air Cooler Intake Hose A and Charge Air Cooler Intake Pipe A Installation (Refer to ).
  • Air Cleaner Assembly and Air Cleaner Intake Hose 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 Installation (Refer to GROUP 16, Ignition System - Ignition Coil ).
  • Engine Room Under Cover Front A, B, Engine Room Under Cover Center and Engine Room Side Cover (RH) Installation (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
<<A>>
 >>F<<
 6.
 Turbocharger compressor bracket


7.
 Turbocharger air inlet fitting


8.
 Turbocharger air inlet fitting gasket


9.
 Turbocharger water feed hose


10.
 Turbocharger water feed pipe


11.
 Gasket


12.
 Turbocharger water return hose

>>E<<
 13.
 Turbocharger exhaust outlet fitting bracket


14.
 Transfer heat protector


15.
 Drive shaft heat protector


16.
 Steering gear and linkage heat protector


17.
 Turbocharger protector A


18.
 Turbocharger protector B


19.
 Emission vacuum control hose connection


20.
 Turbocharger pin
<<B>>
21.
 Waste gate actuator


22.
 Turbocharger exhaust outlet fitting


23.
 Turbocharger exhaust outlet fitting gasket

>>C<<
 24.
 Turbocharger bracket and turbocharger assembly coupling bolt


25.
 Turbocharger oil feed tube connection


26.
 Gasket


27.
 Turbocharger oil return tube connection


28.
 O-ring

>>D<<
 29.
 Exhaust manifold and turbocharger assembly coupling bolt and nut


30.
 Exhaust manifold


31.
 Exhaust manifold gasket


32.
 Turbocharger gasket


33.
 Turbocharger assembly


·
 Transfer assembly (Refer to GROUP 22A, Transfer Assembly <M/T>), (Refer to GROUP 22C, Transfer Assembly <TC-SST>)

>>C<<
 34.
 Turbocharger bracket




Removal steps
<<C>>
35.
 Turbocharger oil feed tube


36.
 Gasket


37.
 Turbocharger oil return tube

>>B<<
 38.
 Turbocharger oil return tube gasket


39.
 Turbocharger water return pipe


40.
 Gasket

>>A<<
 41.
 Turbocharger
Required Special Tools:

REMOVAL SERVICE POINTS

<<A>> TURBOCHARGER COMPRESSOR BRACKET REMOVAL

Use special MB992274 to remove the turbocharger compressor bracket mounting bolt (cylinder block side).

<<B>> WASTE GATE ACTUATOR REMOVAL

caution Never loosen the locking nuts and adjusting rod of the waste gate actuator.

<<C>> 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 turbocharger oil feed tube, turbocharger water feed pipe and turbocharger water return pipe fitting, the inside of eye bolts, and individual 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 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.

>>C<< 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, and then temporarily tighten the turbocharger bracket.
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 turbocharger bracket and the turbocharger assembly coupling bolt to the specified torque.
Tightening torque: 64 ± 5 N·m (48 ± 3 ft-lb)

>>D<< 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 29 ± 2 N·m (22 ± 1 ft-lb) in the order of number shown in the figure.
(3) Use special tool MB991614 to tighten bolts and nuts 65 ± 5 degrees angle.

>>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.
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)

>>F<< TURBOCHARGER COMPRESSOR BRACKET INSTALLATION



1.Check that the turbocharger compressor bracket is in close contact with the turbocharger assembly and with the cylinder block, and then temporarily tighten the turbocharger compressor bracket.

2.Use special tool MB992274 to tighten the turbocharger compressor bracket mounting bolt (cylinder block side) to the specified torque.
Tightening torque: 51 ± 7 N·m (38 ± 5 ft-lb)
3.Tighten the bolt of the turbocharger assembly side to the specified torque.
Tightening torque: 51 ± 7 N·m (38 ± 5 ft-lb)