4
10. Intercooler preparation ...........................................................................................................................40
1. Install lower bracket. ............................................................................................................................ 40
2. Install upper bracket. ........................................................................................................................... 40
11. Pre-catalyser heat shield preparation ............................................. ......................................................41
1. Install pre-catalyser heat shield. ................................................ .... ... ...................................................41
12. Turbo control system preparation ......................................................................................................... 42
1. Turbo control system preparation. ....................................................................................... ....... .........42
2. Install control-unit harness. .................................................................................................................. 42
13. Turbo preparation ...................................................................................................................................43
1. Turbo protection. ................................................................................................................................. 43
2. Remove plate with pressure actuator. .................................................................................................43
3. Turbo lubrication. .................................................................................................................................43
4. Install water adapters. ......................................................................................................................... 43
5. Install water outlet hose. ................................................................... ...................................................44
6. Install water inlet tube. ......................................................................... ................................................44
7. Install oil pressure tube. ....................................................................................................................... 44
8. Install plate with pressure actuator. .............................. .......................................................................44
9. Install pressure actuator hose. ............................................................................................................ 45
14. Installation engine compartment ........................................................................................................... 46
1. Install exhaust manifold gasket. .......................................................................................................... 46
2. Install exhaust manifold. ......................................................................................................................46
3. Position Turbo charger. ................... ....................................................................................................46
4. Install turbo charger. ............................................................................................................................46
5. Install Turbo charger bracket. .............................................................................................................. 47
6. Tightening Turbo charger. ................................................................................................................... 47
7. Install water inlet connection. .............................................................................................................. 47
8. Install water outlet connections. .......................................................................................................... 48
9. Waterhose fixation. ..............................................................................................................................48
10. Install protection cap throttle body housing. ............ ..........................................................................48
15. Installation engine compartment lower ................................................................................................49
1. Apply liquid gasket to oil pan. ........................................... ...................................................................49
2. Install oil pan. .......................................................................................................................................49
3. Install oil pressure switch extension. ............... ....................................................................................49
4. Install oil pressure switch extension bolt. ............................................................................................49
5. Install oil pressure switch. .................................................................................................................... 50
6. Install Intercooler. ................................................................................................................................50
7. Install intercooler inlet pipe. ................................................. ................................................................50
8. Install oil pressure tube. ....................................................................................................................... 51
9. Install intercooler outlet pipe. ............................................................................................................... 51
16. Installation engine compartment upper ................................................................................ ................53
1. Install turbo inlet pipe. .................................................................................................................... ......53
2. Install turbo inlet pipe bracket. ....................................................................... ......................................53
3. Install water hose clamp ......................................................... ... ..........................................................53
4. Install VSV t-junction. ..........................................................................................................................53
5. Modify engine ventilation hose. ................. ..........................................................................................54
6. Install engine ventilation hose onto engine. ......................................................................................... 54
7. Install engine ventilation hose onto turbo inlet pipe. ................................................................... .........54
8. Install VSV connections. ......................................................................................................................55
9. Install air filter. ..................................................................................................................................... 55
10. Prepare air filter box cover. ............................................................................................................... 55
11. Install air filter box cover ....................................................................................................... .............55
12. Install exhaust pipe pre-catalyser. .................................................. ...................................................56
13. Install exhaust pipe bracket. ................................................. .............................................................56
14. Install oil return pipe. ......................................................................................................................... 56
15. Install oil return hose. ........................................................................................................................ 57
16. Install wiring harness. ................................................. .......................................................................57
17. Install cooling fan cover. ................................................. ...................................................................58
18. Install lambda sensor No. 1 .................................................. .............................................................59
19. Install exhaust manifold heat shield. .................................................................................................. 59
20. Install lambda sensor No..2 .................................................. .............................................................59
21. Spark plug exchange ......................................................................................... ................................60