EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

CAUTION / NOTICE / HINT

Note

w/ DPF:

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.

PROCEDURE


  1. INSTALL NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 2)


    1. B001ZIIE02

      Temporarily install a new gasket and the No. 2 inlet turbo oil pipe with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL NO. 2 TURBO OIL PIPE (for Bank 2)


    1. Install a new gasket and the No. 2 turbo oil pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Tech Tips

      The gasket claws should face the pipe.

  3. INSTALL NO. 2 INLET COMPRESSOR ELBOW (for Bank 2)


    1. Install a new gasket and the No. 2 inlet compressor elbow with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Install the No. 2 inlet compressor elbow with the "L" mark facing toward the outside of the vehicle.

  4. INSTALL NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH (for Bank 2)


    1. Install a new gasket to the No. 2 turbocharger.

    2. Install the exhaust manifold LH to the No. 2 turbocharger with 3 new nuts.

      Torque:
      69 N*m  { 704 kgf*cm, 51 ft.*lbf }

      Tech Tips

      The gasket claw should face toward the outside of the vehicle.

    3. w/ DPF:


      1. Install 2 new gaskets to the No. 2 exhaust manifold pipe.

        Tech Tips

        The gasket claws should face the No. 2 exhaust manifold pipe.

      2. B001VUH

        Temporarily install the No. 2 exhaust manifold pipe with the 4 bolts.

        Tech Tips

        Install the No. 2 exhaust manifold pipe so that it is oriented as shown in the illustration.

      3. Tighten the 4 bolts.

        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Install a new gasket to the cylinder head LH.

    5. Install the No. 2 turbocharger with exhaust manifold LH and 10 collars to the cylinder head LH with 10 new nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      B001ZRGE03
      Text in Illustration
      *A w/ DPF *B w/o DPF

      Tech Tips

      Install the collars with the colored side facing the nuts.

    6. B001XSB

      Install a new gasket and the No. 2 inlet turbo oil pipe to the No. 1 oil pan with the union bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    7. Connect the 2 connectors to the turbocharger.

  5. INSTALL NO. 2 VENTILATION TUBE SUB-ASSEMBLY (for Bank 2)


    1. Temporarily install a new gasket and the No. 2 ventilation tube with the union bolt and bolt.

      B001XQ5E02
      Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Clean and remove any oil in the area labeled 1 in the illustration.

    3. Connect the hose.

  6. INSTALL NO. 2 TURBOCHARGER STAY (for Bank 2)


    1. Install the No. 2 turbocharger stay with the 2 bolts.

      Torque:
      49 N*m  { 495 kgf*cm, 36 ft.*lbf }

  7. INSTALL NO. 2 OUTLET TURBO OIL HOSE (for Bank 2)

    Tech Tips

    Align the white paint marks on the oil hose and pipe, and connect the hose.

    B001W6IE03
    Text in Illustration
    *1 Painted Mark

  8. INSTALL NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    1. B00200HE02

      Temporarily install a new gasket and the No. 2 turbo water pipe with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the water hose to the pipe.

  9. INSTALL FRONT WATER BY-PASS JOINT (for Bank 2)


    1. Install a new gasket and the front water by-pass joint.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  10. INSTALL NO. 3 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    1. B001XQRE02

      Temporarily install a new gasket and the No. 3 turbo water pipe with the union bolt and 2 bolts.

    2. Tighten the union bolt and 2 bolts in the order shown in the illustration.

      Torque:
      for union bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 2)


    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  12. INSTALL NO. 2 TURBO WATER HOSE (for Bank 2)

  13. INSTALL BREATHER PLUG LH (for Bank 2)


    1. Install the breather plug LH.

    2. w/o DPF:

      Attach the clamp.

    3. Connect the hose.

  14. INSTALL NO. 3 VENTILATION HOSE (for Bank 2)

  15. INSTALL NO. 1 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 1)


    1. B001ZSYE02

      Temporarily install a new gasket and the No. 1 inlet turbo oil pipe with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  16. INSTALL NO. 1 TURBO OIL PIPE (for Bank 1)


    1. Install a new gasket and the No. 1 turbo oil pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  17. INSTALL NO. 1 INLET COMPRESSOR ELBOW (for Bank 1)


    1. Install a new gasket and the No. 1 inlet compressor elbow with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Install the No. 1 inlet compressor elbow with the "R" mark facing toward the outside of the vehicle.

  18. INSTALL NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH (for Bank 1)


    1. Install a new gasket to the No. 1 turbocharger.

    2. Install the exhaust manifold RH to the No. 1 turbocharger with 2 new nuts and the bolt.

      Torque:
      69 N*m  { 704 kgf*cm, 51 ft.*lbf }

    3. w/ DPF:


      1. Install 2 new gaskets to the No. 1 exhaust manifold pipe.

        Tech Tips

        The gasket claws should face the No. 1 exhaust manifold pipe.

      2. B001Z85

        Temporarily install the No. 1 exhaust manifold pipe with the 4 bolts.

        Tech Tips

        Install the No. 1 exhaust manifold pipe so that it is oriented as shown in the illustration.

      3. Tighten the 4 bolts.

        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Install a new gasket to the cylinder head RH.

    5. Install the No. 1 turbocharger with exhaust manifold RH to the cylinder head RH with the 10 collars and 10 new nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      B001Z2OE01
      Text in Illustration
      *A w/ DPF *B w/o DPF

      Tech Tips

      Install the collars with the colored side facing the nuts.

    6. B001VYA

      Install a new gasket and the No. 1 inlet turbo oil pipe to the cylinder block with the union bolt.

      Torque:
      When "dry"
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      When "wet"
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note


      • The parts are "dry" when there is absolutely no engine oil on the union bolt and cylinder block bolt hole.

      • The parts are "wet" when there is engine oil on the union bolt and cylinder block bolt hole.

  19. INSTALL NO. 1 VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)


    1. B001ZZ0E02

      Temporarily install a new gasket and the No. 1 ventilation tube with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 in.*lbf }

      Note

      Clean and remove any oil in the area labeled 1 in the illustration.

    3. Connect the hose.

  20. INSTALL NO. 1 TURBOCHARGER STAY (for Bank 1)


    1. Temporarily install the No. 1 turbocharger stay with the 2 bolts.

    2. Tighten the 2 bolts.

      Torque:
      49 N*m  { 495 kgf*cm, 36 ft.*lbf }

  21. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 1)


    1. B001XZ7E03
      Text in Illustration
      *1 New Nut

      Install a new gasket and the No. 1 turbo water pipe with 2 new nuts and the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the water hose.

  22. CONNECT NO. 1 OUTLET TURBO OIL HOSE (for Bank 1)

  23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 1)


    1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  24. INSTALL NO. 2 TURBO WATER HOSE (for Bank 1)

  25. INSTALL BREATHER PLUG RH (for Bank 1)


    1. Install the breather plug RH and attach the clamp.

    2. Connect the hose.

  26. INSTALL NO. 2 VENTILATION HOSE (for Bank 1)

  27. INSTALL NO. 1 INTAKE AIR CONNECTOR PIPE (for Bank 1)


    1. Install the No. 1 intake air connector pipe with the bolt. Then tighten the hose clamp.

      Torque:
      for bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for hose clamp
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Connect the 4 connectors and attach the 5 wire harness clamps.

  28. INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE (for Bank 1)


    1. Apply a light coat of engine oil to a new O-ring and install it to the No. 1 engine oil level dipstick guide.

    2. Install the No. 1 engine oil level dipstick guide with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  29. INSTALL ENGINE ASSEMBLY

    Click here

  30. INSPECT FOR OIL LEAK

    Click here

  31. INSPECT FOR COOLANT LEAK

    Click here

  32. CHECK ENGINE OIL LEVEL

    Click here

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.


    1. Connect the cables to negative (-) main battery and sub-battery terminals.

  34. PERFORM TURBOCHARGER INITIALIZATION

    Click here