NOTICE: After replacing the turbocharger assembly, pour approx. 20 cc (1.2 cu in.) of new oil into the oil inlet and turn the impeller wheel by hand to splash oil on the bearing.
1. INSTALL TURBINE OUTLET ELBOW
Install a new gasket and the outlet elbow with the six nuts.
2. INSTALL SIDE BEARING HOUING PLATE
Install a new gasket and the housing plate with the two nuts.
3. INSTALL TURBO WATER PIPE
Install a new gasket and the water pipe with the two nuts and two bolts.
4. INSTALL TURBO OIL PIPE
(a) Align the oil holes of the a new gasket and the turbocharger housing.
(b) Install the gasket and oil pipe with the two nuts. Do not torque the nuts yet.
5. INSTALL TURBOCHARGER
(a) Install a new gasket and the turbocharger with the four nuts. Do not torque the nuts.
(b) Install the oil pipe with the bolt, two new gaskets and union bolt. Do not torque the bolt and union bolt.
(c) Tighten the four nuts holding the turbocharger to the exhaust manifold.
(d) Tighten the two nuts holding the oil pipe to the turbocharger.
(e) Tighten the union bolt holding the oil pipe to the cylinder block.
(f) Tighten the union bolt holding the oil pipe to the cylinder block.
6. INSTALL TURBOCHARGER STAY
Install the turbocharger stay with the three bolts. Torque:
To turbocharger 705 kg-cm (51 ft-lb, 69 N-m) To cylinder block 600 kg-cm (43 ft-lb, 59 N-m)
7. CONNECT HOSES
(a) Water hose from water inlet housing
(b) Water by-pass hose from water by-pass pipe
(c) Vacuum hose from actuator
(d) Oil hose from turbo oil pipe
8. INSTALL HEAT INSULATORS OF TURBINE OUTLET ELBOW
(a) Install the RH heat insulator with the three bolt.
(b) Install the LH heat insulator with the two bolt.
(c) Install the oil dipstick gauge.
9. INSTALL OXYGEN SENSOR
(a) Install a new gaskets and the oxygen sensor with the two nuts.
(b) Connect the oxygen sensor connector.
10. INSTALL TURBOCHARGER HEAT INSULATOR
Install the heat insulator with the three bolt.
(b) Install the air tube stay with the four bolts. Torque: 195 kg-cm (14 ft-lb, 19 N-m)
12. INSTALL AIR BY-PASS VALVE
(a) Install a new 0-ring to the air by-pass valve.
(b) Apply soapy water on the O-ring.
(c) Install the air by-pass valve with the bolt. Torque: 195 kg-cm (14 ft-lb, 19 N-m)
13. INSTALL CLAMPS OF AIR BY-PASS HOSE AND VTV
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