3
TABLE OF CONTENTSTABLE OF CONTENTS ...................................... .... ... ... ... ... ......................................................................................3
PRECAUTIONS ........................................................................................................................................... ...........6
PREPARATION ........................................................................................................................................... ...........7
1. SST (Special Service Tools) ..................................................................... ..................................................7
2. Lubricants / Liquids ....................................................................................................................................7
VEHICLE LIFT LOCATIONS .................................................................................................................................. 8
PARTS ..................................................................................................................................................... ...............9
1. Location .......................................................................................................................................................9
1.1. Turbo charger ........................................................................................................... ...........................9
1.2. Heat shield........ ................................................................................................................................. 10
1.3. Exhaust manifold ...................................................................................................... .........................11
1.4. Intercooler................................................................................................................................. .........12
1.5. Air intake.. .......................................................................................................................................... 13
1.6. Oil filter .......................................... ....................................................................................................14
1.7. Oil pan and brackets.......................................................................................................... ................15
1.8. Electric components .................................................................... ......................................................16
1.9. Cooling fan ........................................... .............................................................................................17
1.10. Templates.............................................................................................. ..........................................18
1.11. Heat insulation, stickers and sparkplugs............ .............................................................................19
2. Parts List ................................................................................................................................................. ...20
3. Specified torque ........................................................................................................ ................................24
INSTALLATION PROCEDURES ................................................................................................................ .........26
1. Introduction ...............................................................................................................................................26
1.1. Si unit............. .................................................................................................................................... 26
1.2. Caution * notice * hint........................................... .............................................................................26
1.3. Definition of symbols. ........................................................................................................................ 26
1.4. Water hose and clamp.................................................................................................................... ...26
1.5. Air hose and clamp......................................................................... ...................................................27
1.6. Oil and coolant...................................................................................................................................27
2. Parts to be removed (see workshop manual for detailed instructions) ...............................................28
3. Vehicle preparation ................................................................................................................................... 30
1. Remove carbon canister. ........................................... ..........................................................................30
2. Remove harness clamps. ....................................................................................................................30
3. Hole preparation. ........................................................................................................ .........................31
4. Harness fixation. .................................................................................................................................. 31
5. Harness grommet hole.(interior) ..........................................................................................................31
4. Airfilter box heat shield preparation ....................................................................................................... 32
1. Preparation heat shield. ....................................................................................................... ................32
5. Oil-sump preparation ................................................................................................................................ 33
1. Install oil return adapter. .................................. ....................................................................................33
2. Cleaning. ............................................................................................................................................. 33
6. Underbody protection preparation ..........................................................................................................34
1. Undercover preparation. ...................................................................................................................... 34
7. Engine cover preparation ............... ..........................................................................................................37
1. Engine cover preparation. ...................................................................................................................37
8. Cooling fan preparation ............................................... .............................................................................38
1. Install cooling-fan. ................................................................................................................................ 38
2. Install bracket to cover. ........................................................................................ ................................38
3. Temperature sensor. ..................................................................... ......................................................38
9. Inlet pipe preparation ................................................ ................................................................................39
1. Install vacuum hose adapter. ............................................................................................ ...................39
2. Preparation of VSV. ............................................................................................................. ................39
3. Install VSV. ..........................................................................................................................................39