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8) Remove bolts which install the lower side of turbocharger upper cover.
CAUTION:
Be careful, turbocharger and exhaust pipe are
hot.
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1) Set the vehicle on the lift.
2) Disconnect battery ground cable.
3) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
4) Remove intercooler bracket.
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9) Lower the vehicle.
10) Remove turbocharger upper cover.
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5) Lift-up the vehicle.
6) Remove under cover.
7) Remove universal joint bolts and then remove universal joint (RHD model only).
CAUTION:
Scribe alignment marks on universal joint so that it can be reassembled at the original serration.
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11) Remove bolts which install the upper side of turbocharger lower cover, and remove it.
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12) Separate center exhaust pipe from turbo-charger.
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17) Remove intercooler bracket.
18) Remove bolt which holds center exhaust pipe to hanger bracket.
CAUTION:
Be careful not to pull down center exhaust
pipe.
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13) Lift-up the vehicle.
14) Disconnect connector from rear oxygen sensor.
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19) Remove center exhaust pipe.
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15) Separate center exhaust pipe from rear exhaust pipe.
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CAUTION:
Replace gaskets with new ones.
1) Install center exhaust pipe and temporarily tighten bolt which holds center exhaust pipe to hanger bracket.
2) Temporarily tighten bolt which holds center pipe to transmission.
3) Connect center exhaust pipe to turbocharger.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
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16) Remove bolt which holds center exhaust pipe bracket to transmission.
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4) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
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7) Tighten bolt which holds center exhaust pipe to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26 ft-lb)
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5) Connect connector to rear oxygen sensor.
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8) Tighten bolts which hold intercooler bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
9) Lower the vehicle.
10) Place turbocharger lower cover, and tighten bolts which install the upper side of lower cover.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
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6) Tighten bolt which holds center exhaust pipe bracket to transmission.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
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11) Place turbocharger upper cover, and tighten bolts which install the upper side of upper cover.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
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13) Tighten bolts which install the under side of turbocharger upper cover.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
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17) Install intercooler bracket.
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18) Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.>
19) Align center of roll connector. (With airbag model) <Ref. to AB-11, ROLL CONNECTOR, INSPECTION, Inspection Locations After a Collision.>
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14) Install universal joint (RHD model only).
(1) Align bolt hole on the long yoke side of universal joint with the cutout at the serrated section of shaft end, and insert universal joint.
(2) Align bolt hole on the short yoke side of universal joint with the cutout at the serrated section of gearbox assembly. Lower universal joint completely.
(3) Temporarily tighten bolt on the short yoke side. Raise universal joint to make sure the bolt is properly passing through the cutout at the serrated section.
(4) Tighten bolt on the long yoke side, then that on the short yoke side.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
• Make sure that universal joint bolts are tightened through notches in shaft serration.
• Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation.
Standard clearance between gearbox to DOJ: Over 15 mm (0.59 in)
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15) Install under cover.
16) Lower the vehicle.
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