RM3660EC _51 Engine / Hybrid System _080791 NR Series INTAKE / EXHAUST _0392518 TURBOCHARGER A

NR Series INTAKE / EXHAUST  TURBOCHARGER  INSTALLATION  


CAUTION / NOTICE / HINT

NOTICE:

Before installing the turbocharger sub-assembly, be sure to read Maintenance Precaution.

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PROCEDURE

Hide 1.INSTALL STUD BOLT

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.


a.
A351386C03
0.583,0.25 0.906,0.479 0.323,0.229 10 false *1 1.823,1.771 2.125,1.99 0.302,0.219 10 false *2 0.26,0.448 0.583,0.677 0.323,0.229 10 false *1 1.25,1.854 1.573,2.083 0.323,0.229 10 false *1 1.531,1.313 1.76,1.51 0.229,0.198 10 true *1 2.24,0.625 2.479,0.802 0.24,0.177 10 true *2
*1 Stud Bolt (A)
*2 Stud Bolt (B)


Using an E10 "TORX" socket wrench, install the 4 stud bolts (A) to the turbocharger sub-assembly.

Torque:
19.5 N*m (199 kgf*cm, 14 ft.*lbf)


b.

Using an E6 "TORX" socket wrench, install the 2 stud bolts (B) to the turbocharger sub-assembly.

Torque:
5.0 N*m (51 kgf*cm, 44 in.*lbf)


Hide 17201 2.INSTALL TURBOCHARGER SUB-ASSEMBLY

a.
A351385C02
2.354,1.219 2.948,1.208 2.948,1.208 2.375,1.438 true 1.594,1.208 0.406,1.229 0.406,1.229 1.594,1.427 true 2.99,1.135 3.302,1.333 0.313,0.198 10 false *a 0.198,1.156 0.51,1.354 0.313,0.198 10 false *a
*a Claw


Install a new turbocharger gasket to the turbocharger sub-assembly.

HINT:

Make sure that the claws of the turbocharger gasket are facing the turbocharger sub-assembly.



b.
A351384N03
1.01,0.26 1.146,0.427 0.135,0.167 10 true 2 2.396,0.354 2.531,0.521 0.135,0.167 10 true 3 2.406,0.896 2.563,1.104 0.156,0.208 10 true 1

Temporarily install the turbocharger sub-assembly to the cylinder head sub-assembly with the 3 bolts in the order shown in the illustration.

HINT:

Tighten the bolt by hand until it contacts the surface of the cylinder head sub-assembly.



c.
A351382C02
1.708,0.917 0.948,0.802 0.948,0.802 1.406,1.063 true 1.781,1.333 2.135,1.646 2.135,1.646 1.26,1.604 true 2.229,0.635 2.833,1.063 2.833,1.063 1.958,1.021 true 2.896,1.01 3.24,1.219 0.344,0.208 10 false *a 2.188,1.604 2.531,1.813 0.344,0.208 10 false *a 0.76,0.719 1.104,0.927 0.344,0.208 10 false *a
*a Claw


Install a new inlet turbo oil gasket to the inlet turbo oil pipe sub-assembly.

NOTICE:

Make sure that the inlet turbo oil gasket is installed in the correct direction.


HINT:

Make sure that the claws of the inlet turbo oil gasket are facing the inlet turbo oil pipe sub-assembly.



d.
A355596C02
1.396,1.365 1.854,1.885 1.854,1.885 1.917,1.521 true 1.875,1.26 1.323,0.708 1.323,0.708 1.396,1.115 true 1.198,0.521 1.469,0.74 0.271,0.219 10 true *a 1.771,1.906 2.021,2.104 0.25,0.198 10 true *a
*a Claw


Install a new outlet No. 1 turbo oil gasket to the stiffening crankcase assembly.

HINT:

Make sure that the claws of the outlet No. 1 turbo oil gasket are facing the stiffening crankcase assembly.



e.
A353527C02
2.833,0.927 3.031,1.094 0.198,0.167 10 true *1 2.135,1.563 2.333,1.729 0.198,0.167 10 true *3 1.177,1.26 1.375,1.427 0.198,0.167 10 true *3 2.177,0.313 2.375,0.479 0.198,0.167 10 true *2 1.594,1.021 1.792,1.188 0.198,0.167 10 true *2
*1 Union Bolt
*2 Bolt (A)
*3 Bolt (B)


Install a new gasket to the inlet turbo oil pipe sub-assembly.


f.

Temporarily install the inlet turbo oil pipe sub-assembly to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts (A) and union bolt.


g.
A351384N02
1.01,0.26 1.146,0.427 0.135,0.167 10 true 2 2.396,0.354 2.531,0.521 0.135,0.167 10 true 3 2.406,0.896 2.677,1.104 0.271,0.208 10 true 1, 4

Tighten the 3 bolts in the order shown in the illustration.

Torque:
35 N*m (357 kgf*cm, 26 ft.*lbf)


h.

Tighten the 2 bolts (A).

Torque:
12 N*m (122 kgf*cm, 9 ft.*lbf)


i.

Temporarily tighten the union bolt.


j.

Temporarily install the 2 bolts (B).


k.

Tighten the union bolt.

Torque:
36 N*m (367 kgf*cm, 27 ft.*lbf)

NOTICE:

If the link that connects the gaskets is broken, remove the link by using side cutters or a similar tool.



l.

Tighten the 2 bolts (B).

Torque:
12 N*m (122 kgf*cm, 9 ft.*lbf)


m.

Connect the intake air control valve (air by-pass valve assembly) connector.


Hide 16027 3.CONNECT NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

a.

Set a new water by-pass gasket.


b.

Temporarily install the No. 1 turbo water pipe sub-assembly with the 2 nuts.


c.

Temporarily install the bolt.


d.
A351383N02
1.229,0.271 1.385,0.448 0.156,0.177 10 true 1 0.875,1.198 1.031,1.375 0.156,0.177 10 true 2 1.969,1.594 2.125,1.771 0.156,0.177 10 true 3

Tighten the 2 nuts and bolt in the order shown in the illustration.

Torque:
12 N*m (122 kgf*cm, 9 ft.*lbf)