Document Outline

• PRECAUTIONS
• TABLE OF CONTENTS
• PREPARATION
  • 1. SST (Special Service Tools)
  • 2. Lubricants / Liquids
• VEHICLE LIFT LOCATIONS
• PARTS
  • 1. Location
    • 1.1. Turbo charger
    • 1.2. Heat shield
    • 1.3. Exhaust manifold
    • 1.4. Intercooler
    • 1.5. Air intake
    • 1.6. Oil filter
    • 1.7. Oil pan and brackets
    • 1.8. Electric components
    • 1.9. Cooling fan
    • 1.10. Templates
    • 1.11. Heat insulation, stickers and sparkplugs
  • 2. Parts List
  • 3. Specified torque
• INSTALLATION PROCEDURES
  • 1. Introduction
    • 1.1. Si unit.
    • 1.2. Caution * notice * hint.
    • 1.3. Definition of symbols.
    • 1.4. Water hose and clamp.
    • 1.5. Air hose and clamp.
    • 1.6. Oil and coolant.
  • 2. Parts to be removed (see workshop manual for detailed instructions)
  • 3. Vehicle preparation
    • 1. Remove carbon canister.
    • 2. Remove harness clamps.
    • 3. Hole preparation.
    • 4. Harness fixation.
    • 5. Harness grommet hole.(interior)
  • 4. Airfilter box heat shield preparation
    • 1. Preparation heat shield.
  • 5. Oil-sump preparation
    • 1. Install oil return adapter.
    • 2. Cleaning.
  • 6. Underbody protection preparation
    • 1. Undercover preparation.
  • 7. Engine cover preparation
    • 1. Engine cover preparation.
  • 8. Cooling fan preparation
    • 1. Install cooling-fan.
    • 2. Install bracket to cover.
    • 3. Temperature sensor.
  • 9. Inlet pipe preparation
    • 1. Install vacuum hose adapter.
    • 2. Preparation of VSV.
    • 3. Install VSV.
  • 10. Intercooler preparation
    • 1. Install lower bracket.
    • 2. Install upper bracket.
  • 11. Pre-catalyser heat shield preparation
    • 1. Install pre-catalyser heat shield.
  • 12. Turbo control system preparation
    • 1. Turbo control system preparation.
    • 2. Install control-unit harness.
  • 13. Turbo preparation
    • 1. Turbo protection.
    • 2. Remove plate with pressure actuator.
    • 3. Turbo lubrication.
    • 4. Install water adapters.
    • 5. Install water outlet hose.
    • 6. Install water inlet tube.
    • 7. Install oil pressure tube.
    • 8. Install plate with pressure actuator.
    • 9. Install pressure actuator hose.
  • 14. Installation engine compartment
    • 1. Install exhaust manifold gasket.
    • 2. Install exhaust manifold.
    • 3. Position Turbo charger.
    • 4. Install turbo charger.
    • 5. Install Turbo charger bracket.
    • 6. Tightening Turbo charger.
    • 7. Install water inlet connection.
    • 8. Install water outlet connections.
    • 9. Waterhose fixation.
    • 10. Install protection cap throttle body housing.
  • 15. Installation engine compartment lower
    • 1. Apply liquid gasket to oil pan.
    • 2. Install oil pan.
    • 3. Install oil pressure switch extension.
    • 4. Install oil pressure switch extension bolt.
    • 5. Install oil pressure switch.
    • 6. Install Intercooler.
    • 7. Install intercooler inlet pipe.
    • 8. Install oil pressure tube.
    • 9. Install intercooler outlet pipe.
  • 16. Installation engine compartment upper
    • 1. Install turbo inlet pipe.
    • 2. Install turbo inlet pipe bracket.
    • 3. Install water hose clamp
    • 4. Install VSV t-junction.
    • 5. Modify engine ventilation hose.
    • 6. Install engine ventilation hose onto engine.
    • 7. Install engine ventilation hose onto turbo inlet pipe.
    • 8. Install VSV connections.
    • 9. Install air filter.
    • 10. Prepare air filter box cover.
    • 11. Install air filter box cover
    • 12. Install exhaust pipe pre-catalyser.
    • 13. Install exhaust pipe bracket.
    • 14. Install oil return pipe.
    • 15. Install oil return hose.
    • 16. Install wiring harness.
    • 17. Install cooling fan cover.
    • 18. Install lambda sensor No. 1
    • 19. Install exhaust manifold heat shield.
    • 20. Install lambda sensor No..2
    • 21. Spark plug exchange
  • 17. Install interior compartment
    • 1. Install control-unit assembly. (manual transmission only)
    • 2. Remove automatic transmission control-unit (automatic transmission only).
    • 3. Install control-unit assembly (automatic transmission only).
    • 4. Install ground connection.
    • 5. Connect wiring harness.
  • 18. Parts to be installed (see workshop manual for detailed instructions)