Part B - Installation of New Components

21. Replace the original heater return pipe with the new heater return pipe using the new heater return pipe bracket (see Figure 9).



22. Disassemble the water outlet, thermostat, thermal vacuum valve (TVV), water temperature sensor, thermal transmitter, and stud from the old thermostat housing. Mark the position of the water outlet on the old thermostat housing prior to removal (see Figure 10).
23. Clean the gasket surface of the original water outlet. Install the water outlet with the original thermostat and a new gasket to the new thermostat housing. Install the stud, thermal transmitter, water temperature sensor, and thermal vacuum valve (TVV) to the new thermostat housing (see Figure 10).



24. Clean the thermostat housing surface on the cylinder head and install the new thermostat housing with a new gasket to the cylinder head. Do not fully tighten the mounting bolts. These bolts will be used to attach the oil line clamp and the EGR/heater return pipe bracket.

25. Loosely install the new oil delivery tube to the back of the engine block (see Figure 11).



26. Using the new exhaust manifold gasket, install the exhaust manifold (with turbocharger attached) and heatshield covers to the cylinder head (see Figure 12).



27. Using the new turbo outlet gasket, install the exhaust outlet (with catalytic converter attached) to the turbocharger exhaust (see Figure 13).



28. Install the new turbocharger water outlet tube assembly from the heater return pipe to the turbocharger (see Figure 14).
NOTE: The eyebolt used at the turbocharger has a large (7mm) hole.



29. Complete the installation of the turbocharger oil delivery tube by tightening the connections at the turbocharger and engine block (see Figure 15).



30. Install the original EGR tube and EGR tube/heater return pipe bracket to the thermostat housing (see Figure 16).






31. Install the oil tube and water tube bracket to the thermostat housing (see Figure 17).


32. Install the turbocharger oil return hose to the turbocharger oil return tube (see Figure 14).

33. Install the starter motor (automatic transmission models only).

34. Install the new air inlet pipe and hose from the intake manifold to the turbocharger using the new turbo inlet gasket.



35. Assemble the turbocharger water inlet tube assemblies (A and B) as shown in Figure 18.



36. Install the assembled turbocharger water inlet tube assemblies (A and B) to the thermostat housing. Install water inlet tube assembly C to the turbocharger and to tube assemblies A and B (see Figure 19).

NOTE: The eyebolt used at the thermostat housing has the small (2mm) hole.
37. Install the guides for the spark plug high tension leads.

38. Connect the upper radiator hose to the radiator.

39. Connect the electrical connectors to the thermal transmitter and water temperature sensor at the thermostat housing. Connect the vacuum hoses to the TVV valve at the thermostat housing.

40. Install the air duct hose, air pipe and air inlet hose.

41. Install the new distributor and spark plug high tension leads to the spark plugs. Route the spark plug high tension leads through the guides. Reconnect the distributor power lead.
42. Reconnect the O2 sensor and install the turbocharger temperature sensor at the turbocharger outlet.

43. Install the radiator reservoir tank.

44. Connect the exhaust pipe to the catalytic converter and reinstall the front exhaust pipe hanger.

45. Install the catalytic converter gussets and heat shield cover.

46. Install the turbocharger heat shield cover.

47. Install the oil dipstick.

48. Connect the battery ground cable and refill the radiator with engine coolant.

NOTE: Prior to starting the engine, turn the ignition key to the ON position and determine that the oil pressure light comes ON. After starting the engine, the oil pressure light should go OFF within two or three seconds. If it doesn't go OFF, check the engine oil dipstick level and for possible oil leaks.

49. Start and run the engine. Check for possible oil or water leaks. Check the distributor initial timing. Reset to specification if required.

CAUTION: After starting the engine, do not operate the engine above normal idle speed for at least 2 to 3 minutes.