EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

PROCEDURE


  1. REMOVE EGR COOLER WITH PIPE ASSEMBLY

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  2. REMOVE TURBO OIL OUTLET PIPE


    1. A004UCEE01
      Text in Illustration
      *1 Nut

      Remove the 2 nuts, 2 bolts, turbo oil outlet pipe and 2 gaskets.

  3. REMOVE NO. 1 TURBO INSULATOR


    1. A004U5Y

      Remove the 2 bolts and No. 1 turbo insulator.

  4. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. A004SXH

      Remove the union bolt, gasket and No. 1 turbo water pipe sub-assembly.

  5. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A004QCC

      Slide the clamp and disconnect the No. 3 water by-pass hose from the No. 1 water by-pass pipe.

  6. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. A004U2IE01
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt and gasket.

    2. Remove the bolt and No. 2 turbo water pipe sub-assembly.

  7. REMOVE NO. 5 WATER BY-PASS PIPE (for Automatic Transaxle)


    1. A004NKO

      Remove the 2 bolts and No. 5 water by-pass pipe.

  8. REMOVE NO. 2 TURBO OIL PIPE


    1. A004O4OE04
      *1 for Upper Side:
      *2 for Lower Side:

      Disconnect the vacuum hose.

    2. Remove the 2 union bolts, 2 gaskets and No. 2 turbo oil pipe.

  9. REMOVE TURBOCHARGER STAY


    1. A004TIXE01
      Text in Illustration
      *1 Turbocharger Stay
      *2 Collar

      Remove the 2 nuts, turbocharger stay and 2 collars.

      Note

      Do not reuse the turbocharger stay.

  10. REMOVE TURBOCHARGER SUB-ASSEMBLY

    A004Q0SE03
    *1 for Manual Transaxle:
    *2 for Automatic Transaxle:

    1. Disconnect the vacuum hose.

    2. Remove the 3 nuts, turbocharger sub-assembly and gasket.

  11. REMOVE EXHAUST MANIFOLD


    1. A004SZKE05
      Text in Illustration
      *1 Collar

      Remove the 8 nuts, 8 collars and exhaust manifold.

    2. Remove the gasket from the cylinder head sub-assembly.

  12. REPLACE STUD BOLT (for Manual Transaxle)

    Tech Tips

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


    1. A004SG4E02
      Text in Illustration
      *a 32 mm (1.26 in.)
      *b 20 mm (0.787 in.)
      *c 10 mm (0.394 in.)

      For turbocharger:

      Using an E8 "TORX" wrench, replace the 3 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A004N80E02
      Text in Illustration
      *a 43 mm (1.69 in.)
      *b 16 mm (0.630 in.)
      *c 24.5 mm (0.965 in.)
      *d 12 mm (0.472 in.)
      *e 9.0 mm (0.354 in.)

      For turbocharger:

      Replace the 2 stud bolts labeled A shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. For turbocharger:

      Using an E5 "TORX" wrench, replace the 2 stud bolts labeled B shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A004MLSE02
      Text in Illustration
      *a 47 mm (1.85 in.)
      *b 14 mm (0.551 in.)
      *c 15 mm (0.591 in.)

      For turbocharger:

      Using an E8 "TORX" wrench, replace the stud bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A004O2EE02
      Text in Illustration
      *a 43 mm (1.69 in.)
      *b 16 mm (0.630 in.)

      For exhaust manifold:

      Replace the stud bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  13. REPLACE STUD BOLT (for Automatic Transaxle)

    Tech Tips

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


    1. A004Q6IE02
      Text in Illustration
      *a 32 mm (1.26 in.)
      *b 20 mm (0.787 in.)
      *c 10 mm (0.394 in.)

      For turbocharger:

      Using an E8 "TORX" wrench, replace the 3 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A004SQIE02
      Text in Illustration
      *a 43 mm (1.69 in.)
      *b 16 mm (0.630 in.)
      *c 24.5 mm (0.965 in.)
      *d 12 mm (0.472 in.)
      *e 9.0 mm (0.354 in.)

      For turbocharger:

      Replace the 2 stud bolts labeled A shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. For turbocharger:

      Using an E5 "TORX" wrench, replace the 2 stud bolts labeled B shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A004OJFE03
      Text in Illustration
      *a 47 mm (1.85 in.)
      *b 14 mm (0.551 in.)
      *c 15 mm (0.591 in.)

      For turbocharger:

      Using an E8 "TORX" wrench, replace the stud bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A004O2EE02
      Text in Illustration
      *a 43 mm (1.69 in.)
      *b 16 mm (0.630 in.)

      For exhaust manifold:

      Replace the stud bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }