Installation

Installation Procedure





1. Install the turbocharger oil drain pipe and NEW gasket to the turbocharger.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the turbocharger oil drain pipe bolts.
^ Tighten the oil drain pipe bolts to 21 Nm (16 ft. lbs.).
3. Install the turbocharger inlet coolant hose to the turbocharger.





4. Install the turbocharger oil supply hose to the engine block.
5. Install the turbocharger oil supply hose eye bolt and washers.
^ Tighten the turbocharger oil supply hose eye bolt to 42 Nm (31 ft. lbs.).
6. Install the turbocharger lower heat shield to the engine block.





7. Install the turbocharger to the engine.
8. Install the turbocharger three mounting bolts.
^ Tighten the turbocharger mounting bolts to 108 Nm (80 ft. lbs.).





9. Install a NEW gasket for the oil drain pipe.
10. Install the turbocharger oil drain pipe nuts.
^ Tighten the turbocharger drain pipe nuts to 21 Nm (15 ft. lbs.).





11. If installing a new turbocharger, pour about 120 - 150 cc (4 - 5 oz) of clean engine oil in the turbocharger, supply hose opening while rotating the impeller.
12. Using NEW sealing washers, install the oil supply hose and bolt to the turbocharger,
^ Tighten the oil supply hose eye bolt to 42 Nm (31 ft. lbs.).





13. Position the left exhaust pipe. The pipe flanges are different. Ensure the proper pipe flange is towards the turbocharger.
14. Install the left exhaust pipe to the turbocharger with NEW gasket. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.
^ Tighten the left exhaust pipe to turbocharger bolts (1) to 53 Nm (39 ft. lbs.).
15. Position the left exhaust pipe heat shield, but do not install the bolts.





16. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.
17. Install the right exhaust pipe to, turbocharger bolts (2).
^ Tighten the right exhaust pipe to turbocharger bolts to 53 Nm (39 ft. lbs.).





18. Install the exhaust outlet with a NEW gasket to the turbocharger.
19. Install the exhaust outlet bolts and nuts.
^ Tighten the exhaust outlet bolts and nuts to 53 Nm (39 ft. lbs.).





20. Install the exhaust outlet heat shield.
21. Install the upper 2 exhaust outlet heat shield bolts (1, 3).
^ Tighten the exhaust outlet heat shield bolts to 8 Nm (71 inch lbs.).





22. Install the turbocharger heat shield.
23. Install the turbocharger heat shield bolts.
^ Tighten the turbocharger heat shield bolts to 9 Nm (80 inch lbs.).





24. Connect the PCV hose to the upper left valve rocker arm cover.





25. Connect the turbocharger outlet coolant hose to the turbocharger.





26. Connect the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
27. Install the inlet air heater relay.

Notice: Refer to Fastener Notice in Service Precautions.

28. Connect the wire terminal and the nut to intake air heater.
^ Tighten the intake air heater nut to 4 Nm (35 inch lbs.).





29. Position the A/C compressor.
30. Install the A/C compressor mounting bolts.
^ Tighten the A/C compressor mounting bolts to 50 Nm (37 ft. lbs.).
31. Install the drive belt.
32. Connect the A/C cut out switch electrical connector.
33. Connect the A/C clutch electrical connector.





34. Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.
35. Position the clamp as shown for proper clearance.
^ Tighten the clamp to 6 Nm (53 inch lbs.).





36. Install the hose to the charged air cooler outlet duct to intake manifold tube.
The hose is marked DUCT which connects to the charged air cooler outlet duct.
The hose is marked ENG which connects to the turbocharger.
Align the marks on the hose with the alignment marks on the pipe and tube.
37. Position the clamps as shown for proper clearance.
^ Tighten the clamps to 6 Nm (53 inch lbs.).





38. Install the air cleaner outlet duct to the air cleaner.





39. Install the air cleaner outlet duct to turbocharger.
Align the duct to the air cleaner.
^ Tighten the air cleaner outlet duct clamps to 6 Nm (53 inch lbs.).





40. Raise the vehicle.
41. Install the lower bolt (2) for the exhaust outlet heat shield.
^ Tighten the exhaust outlet heat shield bolt to 8 Nm (71 inch lbs.).





42. Install the right exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
43. Install the right exhaust pipe bolts (2).
^ Tighten the exhaust pipe to exhaust manifold bolts to 53 Nm (39 ft. lbs.).





44. Install the left exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
45. Install the left exhaust pipe bolts (1).
^ Tighten the exhaust pipe to exhaust manifold bolts to 53 Nm (39 ft. lbs.).





46. Position the left exhaust pipe heat shield.
47. Install the left exhaust pipe heat shield bolts.
^ Tighten the left exhaust pipe heat shield bolts to 8 Nm (71 ft. lbs.).





48. Install the exhaust heat shield (3) to left front of the dash panel.
49. Install the shield nuts (2).
^ Tighten the shield nuts to 9 Nm (80 ft. lbs.).





50. If equipped position the transmission fluid fill tube.
51. Install the transmission fluid fill tube nuts.
^ Tighten the transmission fluid fill tube nuts to 18 Nm (13 ft. lbs.).





52. Install the exhaust outlet to exhaust pipe clamp.
To assist in positioning the clamp on the flanges use a suitable screw jack to hold the exhaust pipe in position.
^ Tighten the exhaust pipe clamp to 40 Nm (30 ft. lbs.).
53. Lower the vehicle.
54. Fill the cooling system.





55. Install the upper intake manifold sight shield.
^ Tighten the upper intake manifold shield bolt to 9 Nm (80 inch lbs.).





56. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).
^ Tighten the hood hinge bolts to 25 Nm (18 ft. lbs.).
57. Connect both battery negative cables.
58. road test the vehicle for normal operation.
59. Inspect for coolant, oil, or exhaust leaks.