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Home › Mazda › 2003 › MPV ES › Repair and Diagnosis › Engine Performance › Ignition System › Engine Controls [Removal & Installation] › Air Induction Systems › Turbocharger › Installation (From Completely Disassembled State)

Installation (From Completely Disassembled State)

  1. Install NEW turbocharger to exhaust manifold gasket.
  2. Position turbocharger to exhaust manifold, install NEW nuts to studs. See TORQUE SPECIFICATIONS .
  3. Install NEW turbine outlet gasket.
  4. Position turbo down pipe to turbocharger.
  5. Install turbocharger insulator. See TORQUE SPECIFICATIONS .
  6. Install NEW nuts to studs. See TORQUE SPECIFICATIONS .
  7. Install coolant return line at rear of turbo center section using NEW copper washers to banjo bolt.
  8. Install coolant feed line at front of turbo center section using NEW copper washers to banjo bolt.
  9. Install oil feed line to top of turbo center section.
    10. NOTE: Adjust line positions by loosening the connections first, then re-tightening after the adjustment is made.
  10. Attach line retaining clamp to secure oil feed line, water feed line and water return line.
  11. Install new "O" ring on to drain flange.
  12. Install flange retaining bolts and tighten.
  13. Install wastegate actuator rod and clip.
  14. Install NEW exhaust manifold gasket.
    15. NOTE: Make sure spring clamp for coolant return line is on the line before lowering assembly into location.
  15. Insert turbocharger coolant return line into return hose while positioning primary turbocharger assembly onto the exhaust manifold studs.
  16. Position EGR pipe to the exhaust manifold and hand tighten the EGR pipe nut.
  17. Install all exhaust manifold nuts and bolts. Tighten the fasteners in at least 2 steps using a center-to-outside circular pattern tightening sequence. See TORQUE SPECIFICATIONS .
  18. Tighten EGR pipe nut.
  19. Install coolant feed hose and clamp.
  20. Position clamp over coolant return line connection.
  21. Route oil feed line to rear of engine.
  22. Attach oil feed line to retaining clip.
  23. Tighten oil feed line fitting to three-way tee adapter.
  24. Reinstall intake manifold brace.
  25. Reinstall turbo down pipe bracket and bolts. See TORQUE SPECIFICATIONS .
  26. Install oil drain block to oil pan upper block using NEW gasket.
  27. Install front pipe to turbo down pipe using NEW gasket. See TORQUE SPECIFICATIONS .
  28. Position springs and nuts to catalyst pipe and install to front pipe. See TORQUE SPECIFICATIONS .
  29. Install front pipe insulator. See TORQUE SPECIFICATIONS .
  30. Install exhaust manifold insulator.
  31. Reconnect vacuum hose from the intake manifold vacuum port to the turbocharger wastegate actuator and position temporarily for air bypass valve. Install spring clumps at each hose connection points.
  32. Reinstall radiator with charge air cooler and cooling fan. Be sure that the harness connections to both cooling fans are properly connected. See CHARGE AIR COOLER .
  33. Connect lower radiator hose.
  34. Remove any caps or taping from openings of the turbocharger compressor, charge air cooler and throttle body.
  35. Position duct onto charge air cooler bottom end-tank and the throttle body. Tighten clamps at each end.
  36. Secure fuel line to bracket on duct.
  37. Install purge solenoid valve body to duct using original nut.
  38. Position duct onto turbocharger compressor inlet and Mass Airflow (MAF). Tighten clamps at each end.
  39. Install valve cover breather hose onto duct.
  40. Secure Reverse light wire and fuel line to bracket on duct.
  41. Reconnect plug for Reverse light, if disconnected.
  42. Install front HO2S to exhaust manifold. Connect sensor to vehicle harness.
  43. Secure HO2S wire to retaining clip.
  44. Position duct onto turbocharger compressor outlet and charge air cooler top end-tank. Tighten clamps at each end.
  45. Install upper radiator hose.
  46. Position air bypass valve route between the ducts. Tighten clamp at the end of bypass connection.
  47. Connect vacuum hose from the intake manifold vacuum port to air bypass valve actuator. Install spring clamp to the vacuum hose connection.
  48. Reconnect MAT and MAF sensor, if disconnected.
    49. NOTE: Be sure that the harness connections to both cooling fans are properly connected.
  49. Close radiator drain plug and refill radiator. Fill with coolant to specified level and specified mixture ratio.
  50. Check oil level. Adjust level as necessary.
  51. Connect the negative battery cable.
  52. Remove INJ or FIP fuse and crank engine 10 seconds. Wait 30 seconds, and repeat until engine oil pressure warning light turns off.
  53. Start engine. Inspect for any leaks.
  54. Shut off engine and check engine oil level.
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