Exhaust Manifold W/ Turbocharger Reassembly

Install a new turbocharger gasket to the compressor with bearing housing sub-assembly.

NOTICE:

1. Install the turbocharger gasket facing the direction shown in the illustration.
   

Install a new seal ring to the compressor with bearing housing sub-assembly.

NOTICE:

Do not reuse the seal ring.

Align the No. 2 turbocharger nozzle vane arm as shown in the illustration.

Text in Illustration

*1	No. 2 Turbocharger Nozzle Vane Arm
*2	No. 2 Turbocharger Nozzle Vane Control Link
	No. 2 Turbocharger Nozzle Vane Arm Fully Open
	No. 2 Turbocharger Nozzle Vane Control Link Fully Open

Install the turbocharger nozzle vane plate sub-assembly to the compressor with bearing housing sub-assembly.

HINT:

1. When installing the turbocharger nozzle vane plate sub-assembly, align the installation positions on the pin side and No. 2 turbocharger nozzle vane arm side.
   
2. Do not remove the No. 2 turbocharger nozzle vane plate and turbocharger nozzle vane spacer.
   

Install the turbocharger nozzle vane support plate to the turbocharger nozzle vane plate sub-assembly.

Text in Illustration

*1	Turbocharger Nozzle Vane Support Plate
	Upper

NOTICE:

If the turbocharger nozzle vane support plate is bent or twisted, replace it.

HINT:

Install the turbocharger nozzle vane support plate facing the direction shown in the illustration.

Temporarily install the turbine housing to the compressor with bearing housing sub-assembly with 5 new bolts and 5 new spacers.

HINT:

Align the matchmark as shown in the illustration to install the part.

Secure the flange of the turbine housing sub-assembly of the turbocharger sub-assembly in a vise between aluminum plates.

NOTICE:

Do not tighten the vise more than necessary, as doing so will damage the flange of the turbine housing sub-assembly.

Using a 10 mm union nut wrench, tighten the 5 bolts in the order shown in the illustration.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

NOTICE:

Move the turbocharger vane control link subassembly and check that the turbocharger nozzle vane plate sub-assembly smoothly operates.

HINT:

1. Text in Illustration

   *a	Torque Wrench Fulcrum Length

   Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
   
2. When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)
   

Install the turbocharger nozzle vane control actuator with the 3 bolts.

Torque:

12 N*m{125 kgf*cm, 9 ft.*lbf}

Install the turbocharger vane control rod sub-assembly.

Install 2 new E-washers to the variable nozzle vane motor assembly and turbocharger vane control link sub-assembly.

NOTICE:

Do not reuse the E-washer.