Toyota Yaris: Turbocharger / Installation

INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

(a) Using an E8 "TORX" socket wrench, install the stud bolt to the turbocharger sub-assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL TURBO WATER PIPE GASKET

(a) Install the new turbo water pipe gasket to the turbocharger sub-assembly.

3. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

(a) Install the No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

4. CONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY

(a) Install a new gasket to the turbo water pipe sub-assembly.

(b) Install the turbo water pipe sub-assembly to the turbocharger sub-assembly with the bolt.

Torque:

35 N·m {357 kgf·cm, 26 ft·lbf}

5. CONNECT COMPRESSOR INLET ELBOW

(a) Install a new gasket to the compressor inlet elbow.

(b) Install the compressor inlet elbow to the turbocharger sub-assembly with the bolt and nut.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

6. INSTALL STUD BOLT

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7. INSTALL EXHAUST MANIFOLD TO HEAD GASKET

(a) Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

8. INSTALL TURBOCHARGER SUB-ASSEMBLY

(a) Install the collar to the turbocharger sub-assembly with the red side facing the rear of the vehicle.

*a	Color(Red)
	Rear Side
	Front Side

(b) Tighten the 7 nuts in the order shown in the illustration.

Torque:

44.3 N·m {452 kgf·cm, 33 ft·lbf}

9. CONNECT WIRE HARNESS

(a) Connect the connector to the turbocharger sub-assembly.

10. CONNECT NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

(a) Install a new gasket to the inlet No. 1 turbo water pipe sub-assembly.

(b) Install the No. 1 turbo water pipe sub-assembly to the cylinder block sub-assembly with the bolt and union bolt.

Torque:

Bolt :

13 N·m {133 kgf·cm, 10 ft·lbf}

Union Bolt :

35 N·m {357 kgf·cm, 26 ft·lbf}

(c) Connect the turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

11. INSTALL TURBO OIL INLET PIPE UNION BOLT

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

(b) Install the inlet turbo oil pipe sub-assembly to the cylinder block sub-assembly with the union bolt.

Torque:

35 N·m {357 kgf·cm, 26 ft·lbf}

12. INSTALL NO. 2 VACUUM TRANSMITTING HOSE

(a) Connect the No. 2 vacuum transmitting hose.

13. INSTALL NO. 2 AIR HOSE

(a) Install the new No. 2 air hose to the turbocharger sub-assembly and tighten the hose clamp. Torque: 6.0 N·m {61 kgf·cm, 53 in·lbf}

*a Right of Vehicle *b Top of Vehicle *c 30° *d 25°

14. CONNECT TURBO OIL OUTLET PIPE

(a) Install a new gasket to the outlet turbo oil pipe.

(b) Install the outlet turbo oil pipe to the turbocharger sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

15. INSTALL NO. 1 TURBO INSULATOR

(a) Install the No. 1 turbo insulator to the turbocharger sub-assembly with the 3 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

16. INSTALL NO. 1 AIR INLET DUCT

(a) Install the No. 1 air inlet duct to the compressor inlet elbow and tighten the hose clamp. Torque: 3.0 N·m {31 kgf·cm, 27 in·lbf}

*a Upper Side *b Lower Side *c Rear of Vehicle *d Top of Vehicle *e Left of Vehicle *f 30°

(b) Install the No. 1 air inlet duct to the No. 1 air hose and tighten the hose clamp.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the No. 1 air inlet duct to the cylinder head sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the ventilation hose to the No. 1 air inlet duct and slide the clip to secure it.

17. INSTALL INTAKE AIR RESONATOR

(a) Install the intake air resonator to the No. 1 air hose and tighten the hose clamp.

Torque:

3.0 N·m {31 kgf·cm, 27 in·lbf}

(b) Install the intake air resonator to the air cleaner hose assembly and tighten the hose clamp.

Torque:

3.0 N·m {31 kgf·cm, 27 in·lbf}

(c) Install the intake air resonator to the cylinder head sub-assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

18. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Engage the 3 grommets and pin to install the air cleaner case sub-assembly.

(b) Engage the 6 clamps.

(c) Connect the 3 connector.

19. CONNECT NO. 1 AIR CLEANER HOSE

(a) Connect the No. 1 air cleaner hose to the air cleaner case sub-assembly and tighten the hose clamp.

Torque:

3.0 N·m {31 kgf·cm, 27 in·lbf}

20. INSTALL NO. 1 AIR CLEANER INLET

(a) Install the No.1 air cleaner inlet with 2 clips

21. INSTALL DASH PANEL HEAT INSULATOR

(a) Install the dash panel heat insulator to the vehicle body with the 3 nuts and clamp.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

22. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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23. INSTALL NO. 1 FRONT VENTILATOR SEAL

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24. INSTALL WATER GUARD PLATE RH

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25. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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26. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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27. ADD ENGINE COOLANT

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28. INSPECT FOR COOLANT LEAK

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29. ADD ENGINE OIL

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30. CHECK ENGINE OIL LEVEL

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31. INSPECT FOR ENGINE OIL LEAK

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32. CHECK ENGINE OIL LEVEL

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