EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

    Only perform this procedure when replacement of the stud bolt is necessary.


    1. Using "TORX" socket wrench E10, install the 2 stud bolts to the turbocharger sub-assembly.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    2. Using "TORX" socket wrench E5, install the 2 stud bolts to the turbocharger sub-assembly.

      Torque:
      7.0 N*m  { 67 kgf*cm, 58 in.*lbf }

    3. Using a double nut, install the 3 stud bolts to the turbocharger sub-assembly.

      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }

    4. Using "TORX" socket wrench E6, install the 3 stud bolts to the turbocharger sub-assembly.

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

    5. Using "TORX" socket wrench E10, install the stud bolt to the turbocharger sub-assembly.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    6. Using "TORX" socket wrench E10, install the stud bolt to the exhaust manifold.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD (w/o DPF)


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

    2. Install the exhaust manifold to the cylinder head sub-assembly with the 8 nuts.

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

  3. INSTALL EXHAUST MANIFOLD (w/ DPF)


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

    2. A01VH4PE01

      Temporarily install the No. 2 manifold support bracket to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

    3. Temporarily install the exhaust manifold to the cylinder head sub-assembly with the 8 nuts.

    4. Fully tighten the 2 bolts and 8 nuts in the sequence shown in the illustration.

      Torque:
      Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Nut
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  4. INSTALL COMPRESSOR INLET ELBOW SUB-ASSEMBLY


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

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

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

  5. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. Install a new No. 1 turbo oil outlet gasket to the cylinder block sub-assembly.

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

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

    4. Install a new turbo to exhaust manifold gasket to the exhaust manifold.

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

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

      Note


      • When installing the turbocharger sub-assembly, do not hold it by the electric actuator rod.

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

    6. Connect the 2 turbocharger sub-assembly connectors.

    7. A01VGXYE01

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

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

    8. Fully 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 to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts.

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

  7. INSTALL TURBOCHARGER STAY


    1. A01VEM8E02

      Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder head sub-assembly with the 2 bolts and nut.

    2. Fully tighten the 2 bolts and nut in the sequence shown in the illustration.

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

  8. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ DPF)


    1. Install a new gasket and No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the 4 bolts.

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

  9. INSTALL NO. 2 TURBO WATER HOSE (w/ DPF)


    1. Connect the No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the hose clip to secure it.

  10. INSTALL NO. 1 TURBO WATER HOSE (w/ DPF)


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

  11. INSTALL NO. 1 AIR HOSE (w/o DPF)


    1. A01VFFTE01
      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 to the turbocharger sub-assembly and No. 1 air tube and tighten the 2 hose clamps.

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

  12. INSTALL NO. 1 AIR CLEANER HOSE


    1. A01VILPE03
      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 to the compressor inlet elbow sub-assembly and slide the hose clip to secure it.

    2. Connect the ventilation hose to the cylinder head cover sub-assembly and slide the hose clip to secure it.

    3. Engage the clamp to connect the No. 1 fuel hose sub-assembly to the No. 1 air cleaner hose.

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

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

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

    Click here

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


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

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

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


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

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


    1. Tighten the 3 nuts.

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

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


    1. A01VGNJE01

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

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

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

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

  29. 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.