Installation Procedure
- Clean the sealing surfaces.
- Replace the connect fittings on the turbocharger coolant feed pipe and the turbocharger coolant return pipe. Refer to Turbocharger Assemble .
- Install the turbocharger assembly (1) with a NEW turbocharger gasket (2).
- Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
- Install the 8 NEW turbocharger fasteners (1).
- Install the NEW 8 exhaust manifold fasteners (1).
- Tighten the 8 turbocharger fasteners in a sequence as shown to 8 (71 lb in).
- Connect the turbocharger coolant return hose (6) to the oil cooler coolant inlet pipe and install the turbocharger coolant return pipe bolt (7) to the oil cooler. Tighten the turbocharger coolant return pipe bolt to 8 N.m (71 lb in).
- Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
- Install the turbocharger oil feed pipe hollow screw (4) in compound with 2 NEW seal rings (1) and (3).
- Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten to 10 N.m (89 lb in).
- Tighten the turbocharger oil feed pipe hollow screw to 30 N.m (22 lb ft).
- Install the EN-49942 holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.
- Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 20 (15 lb ft).
- Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
- Install the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement (LUJ, LUV) or Air Conditioning Compressor Bracket Replacement (2H0) .
- Lower the vehicle.
- Install the catalytic converter. Refer to Catalytic Converter Replacement (2HO) .
- Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (1) and unclip the wiring harness from the retainer clip (2).
- Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV) .
- Install the charge air bypass valve tube (1) to the charge air bypass valve (2).
- Connect the positive crankcase ventilation pipe to the turbocharger. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
- Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
- Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
- Fill the coolant system. Refer to Cooling System Draining and Filling .
- Check and fill the engine oil.
- Close the hood.
NOTE:
Do not damage the turbocharger oil return pipe.
CAUTION:
Refer to Fastener Caution .
CAUTION:
Refer to Torque-to-Yield Fastener Caution .
NOTE:
Never re-use the old turbocharger fasteners.
NOTE:
The EN-49942 holding wrench (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twisting of the turbocharger coolant feed pipe during the fastening procedure.
NOTE:
EN-49942 holding wrench (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe while the fastening procedure.