REMOVAL AND INSTALLATION


Pre-removal Operation
  • Engine Cover Removal (Refer to GROUP 11E - Engine Assembly ).
  • Breather Hose Removal (Refer to GROUP 11E - Rocker Cover Assembly ).
  • Air Cleaner Assembly Removal (Refer to ).
  • Air hose A Removal (Refer to ).
  • Catalytic Converter Removal (Refer to GROUP 17 - Emission Control, Catalytic Converter ).

 Post-installation Operation
  • Catalytic Converter Installation (Refer to GROUP 17 - Emission Control, Catalytic Converter ).
  • Air hose A Installation (Refer to ).
  • Air Cleaner Assembly Installation (Refer to ).
  • Breather Hose Installation (Refer to GROUP 11E - Rocker Cover Assembly ).
  • Engine Oil Check (Refer to GROUP 12 - Engine Oil Check ).
  • Engine Cover Installation (Refer to GROUP 11E - Engine Assembly ).




Removal steps


1.
 Turbocharger cover
<<A>>
 >>H<<
 2.
 Oil pipe


3.
 Gasket


4.
 Oil return pipe

>>G<<
 5.
 Oil return pipe gasket


6.
 Oil return hose


7.
 Turbocharger stay


·
 Exhaust manifold cover (Refer to ).


8.
 Turbocharger bracket


·
 Water hose G connection (Refer to GROUP 14 - Water Hose and Water Pipe ).


9.
 Bolt, nut and washer


10.
 Water pipe D, air inlet fitting and turbocharger assembly

>>F<<
 11.
 Turbocharger gasket




Removal steps


12.
 Water pipe D

>>E<<
 13.
 Water pipe gasket


14.
 Air inlet fitting

>>D<<
 15.
 Air inlet fitting gasket

>>C<<
 16.
 Turbocharger assembly

>>B<<
 17.
 Stud

>>A<<
 18.
 Stud

REMOVAL SERVICE POINT

<<A>> OIL PIPE REMOVAL
caution Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the oil pipe is removed.

INSTALLATION SERVICE POINTS

>>A<< STUD INSTALLATION
The stud should protrude 24 to 26 mm from the end of the turbocharger.

>>B<< STUD INSTALLATION
The stud should protrude 26 to 28 mm from the end of the turbocharger.

>>C<< TURBOCHARGER ASSEMBLY INSTALLATION
1.Check the internal surface, the eye bolt and the mating surface of the oil pipe and water pipe for clogging, and clean if necessary.
2.
caution Be careful not to allow foreign material to enter the turbocharger.
If deposits of carbon are accumulated on the turbocharger oil passage, remove them and clean using the compressed air.
3.Add clean engine oil through the oil feed pipe port on the turbocharger.

>>D<< AIR INLET FITTING GASKET INSTALLATION

Install the air inlet fitting gasket as its projection is in the direction shown.

>>E<< WATER PIPE GASKET INSTALLATION

The tab on the water pipe gasket should be position as shown.

>>F<< TURBOCHARGER GASKET INSTALLATION

Install the turbocharger gasket as its projection is in the direction shown.

>>G<< OIL RETURN PIPE GASKET INSTALLATION

The tab on the oil return pipe gasket should be position as shown.

>>H<< OIL PIPE INSTALLATION
1.Tighten the eye bolt by hand.
2.Tighten the oil pipe clamp mounting bolts by hand.
3.Tighten the eye bolt to the specified torque, being careful not to deform the oil pipe.
Tightening torque: 17 ± 2 N·m
4.Tighten the oil pipe clamp mounting bolt to the specified torque.
Tightening torque: 28 ± 1 N·m