EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE

1. INSTALL EXHAUST MANIFOLD

   
   

   1. Install a new exhaust manifold to head gasket onto the cylinder head sub-assembly.

   2. Install the exhaust manifold with the 8 nuts.

      Torque:

      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

2. INSTALL COMPRESSOR INLET ELBOW SUB-ASSEMBLY

   
   

   1. Install a new compressor inlet gasket onto the compressor inlet elbow sub-assembly.

   2. Install the compressor inlet elbow sub-assembly onto the turbocharger sub-assembly with the 3 nuts.

      Torque:

      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

3. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

   
   

   1. Install a new No. 1 turbo oil outlet gasket onto the cylinder block.

   2. Temporarily install the turbo oil inlet pipe sub-assembly onto the cylinder block with the 2 nuts.

4. INSTALL TURBOCHARGER SUB-ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Turbocharger side
      *b	Compressor side

      Install a new turbo oil inlet gasket onto the turbocharger sub-assembly.

   2. Install a new turbo to exhaust manifold gasket onto the exhaust manifold.

   3. Install the turbocharger sub-assembly onto the exhaust manifold with the 3 nuts.

      Torque:

      53 N*m  { 540 kgf*cm, 39 ft.*lbf }

      Note

      Simultaneously connect the turbo oil inlet pipe sub-assembly, taking care to ensure that the gasket does not fall off.

   4. Connect the 2 connectors of the turbocharger sub-assembly.

5. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

   
   

   1. 

      Install the turbo oil inlet pipe sub-assembly onto the turbocharger sub-assembly with the 2 nuts (A).

      Torque:

      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

   2. Tighten the 2 nuts (B).

      Torque:

      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

6. INSTALL MANIFOLD STAY

   
   

   1. Install the manifold stay with the 2 bolts.

      Torque:

      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

7. INSTALL TURBOCHARGER STAY

   
   

   1. 

      Temporarily install the turbocharger stay with the 2 bolts and nut.

   2. Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:

      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

8. INSTALL NO. 1 AIR HOSE

   
   
   1. 

      Text in Illustration

      *a	View A
      *b	View B
      *c	Upper Side
      *d	Rear Side
      *e	Clamp installation range

      Install the No. 1 air hose onto the turbocharger sub-assembly with the 2 hose clamps.

      Torque:

      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

9. INSTALL NO. 1 AIR CLEANER HOSE

   
   
   1. 

      Text in Illustration

      *a	View A
      *b	View B
      *c	Front Side
      *d	Rear Side
      *e	Clamp installation range

      Install the No. 1 air cleaner hose onto the compressor inlet elbow sub-assembly with the hose clamp.

   2. Connect the ventilation hose to the cylinder head cover sub-assembly with the hose clamp.

   3. Engage the clamp and connect the 2 fuel hoses to the No. 1 air cleaner hose.

   4. Connect the No. 1 air cleaner hose to the air cleaner cap with the hose clamp.

      Torque:

      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

10. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)

    Click here

11. TEMPORARILY TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)

    
    

    1. Install a new turbine outlet elbow gasket onto the turbocharger sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly onto the turbocharger sub-assembly with 3 new nuts.

12. TEMPORARILY TIGHTEN MANIFOLD SUPPORT BRACKET (w/o DPF)

    
    

    1. Temporarily install the manifold support bracket onto the exhaust manifold converter sub-assembly with the 3 bolts.

13. TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)

    
    

    1. Tighten the 3 nuts.

       Torque:

       26 N*m  { 265 kgf*cm, 19 ft.*lbf }

14. TIGHTEN MANIFOLD SUPPORT BRACKET (w/o DPF)

    
    

    1. 

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

       Torque:

       37 N*m  { 375 kgf*cm, 27 ft.*lbf }

15. INSTALL NO. 1 TURBO INSULATOR (w/o DPF)

    Click here

16. INSTALL WIRE HARNESS CLAMP BRACKET (w/o DPF)

    Click here

17. INSTALL NO. 2 ENGINE COVER BRACKET (w/o DPF)

    Click here

18. INSTALL NO. 1 ENGINE COVER (w/o DPF)

    Click here

19. INSTALL OUTER COWL TOP PANEL (w/o DPF)

    Click here

20. INSTALL INNER COWL TOP TO COWL BRACE (w/o DPF)

    Click here

21. INSTALL FRONT NO. 1 VENTILATOR SEAL (w/o DPF)

    Click here

22. INSTALL FRONT AIR SHUTTER SEAL RH (w/o DPF)

    Click here

23. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (w/o DPF)

    Click here

24. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o DPF)

    Click here

25. INSPECT FOR EXHAUST GAS LEAK (w/o DPF)

26. CLEAR DTC (P0046)

    
    

    1. When a new turbocharger is installed, DTC P0046 is likely to occur. It should be cleared by the special method Click here.