Removal and Installation
- Remove the engine cover.
(Refer to Engine and Transmission Assembly - "ENGINE COVER ")
- Disconnect the battery negative terminal.
- Remove the engine room under cover
(Refer to Engine and Transmission Assembly - "ENGINE ROOM UNDER COVER ")
- Drain the coolant
(Refer to Cooling System - "COOLANT ")
- Remove the air intake hose.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
- Disconnect the recirculation valve connector (A) and the vacuum hose (B).
- Remove the intercooler inlet hose and pipe (A).
Tightening torque
Nuts (B): 14.7 - 19.6 N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb-ft)
Nut (C): 14.7 - 19.6 N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb-ft)
- Remove the air intake hose (A).
Tightening torque:
2.8 - 4.8 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)
NOTE:- Remove the air intake hose after checking that the engine has cooled down.
- Do not apply excessive force when removing the air intake hose.
- Do not reuse the rubber seal when removing the air intake hose.
- Remove the heat protector (A).
Tightening torque:
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
- Remove the heated oxygen sensor.
(Refer to Engine Control/Fuel System - "HEATED OXYGEN SENSOR (HO2S) ")
- Remove the warm - up catalytic converter (WCC) heat protector (A).
Tightening torque:
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
- Remove the front muffler.
(Refer to Intake and Exhaust System - "MUFFLER ")
- Remove the warm - up catalytic converter (WCC) stay (A).
Tightening torque
Bolts (B):
18.6 - 27.5 N.m (1.9 - 2.8 kgf.m, 13.7 - 20.3 lb-ft)
Bolts (C):
52.0 - 57.9 N.m (5.3 - 5.9 kgf.m, 38.3 - 42.7 lb-ft)
- Remove the RH rear strut bar cover (A).
- Disconnect the heater hose (A).
- Remove the warm - up catalytic converter (WCC) (A) with gasket.
Tightening torque:
49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.7 lb-ft)
- Remove the turbocharger water feed pipe and hose (A).
Tightening torque:
26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.7 lb-ft)
- Remove the oil feed pipe (A).
Tightening torque:
11.8 - 17.6 N.m (1.2 - 1.8 kgf.m, 8.7 - 41.1 lb-ft)
Tightening torque:
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
- Disconnect the turbocharger water drain hose (A).
- Remove the turbocharger oil drain pipe (A)
Tightening torque:
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
- Remove the turbo manifold module stay (A).
Tightening torque
Bolts (B):
18.6 - 27.5 N.m (1.9 - 2.8 kgf.m, 13.7 - 20.3 lb-ft)
Bolts (C):
52.0 - 57.9 N.m (5.3 - 5.9 kgf.m, 38.3 - 42.7 lb-ft)
- Remove the turbo manifold module (A).
Tightening torque:
49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.7 lb-ft)
- Install in the reverse order of removal.NOTE:
- Always use the new turbo manifold module gasket.
- Always use the new turbo manifold module nuts.
- Take care whether the oil feed pipe & hose assembly is interfered with turbo manifold module and any surrounding parts.
- If the oil feed pipe & hose is damaged, engine oil is not supplied sufficiently to the turbocharger then it may damage the turbocharger. If the oil drain pipe & hose is damaged and clogged, engine oil is not drained smoothly then it may cause oil leaks from the turbocharger. Be care full the oil feed pipe & hose not to damage. (bent, crushed, torn or cracked).
- When installing, replace with a new gasket. When installing the turbo manifold module, tighten the nuts with pre - torque first, and then tighten the nuts with specified torque in the sequence shown.