EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. B001E5N

      Using an E10 "TORX" socket wrench, install the 3 stud bolts at the positions shown in the illustration.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }
    2. B001H0H

      Using an E8 "TORX" socket wrench, install the 4 stud bolts at the positions shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B001HQ7

      Using an E5 "TORX" socket wrench, install the 4 stud bolts at the positions shown in the illustration.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  2. INSTALL COMPRESSOR OUTLET ELBOW


    1. Install the hose clamp with the bolt.

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

    2. Install a new gasket.

    3. Install a new gasket and the compressor outlet elbow with the 2 nuts.

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

  3. INSTALL COMPRESSOR INLET ELBOW


    1. Install a new gasket.

    2. Using an E8 "TORX" socket wrench, install a new gasket and the compressor inlet elbow with the stud bolt.

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

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

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

    4. Install the compressor inlet elbow stay with the 2 bolts.

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

  4. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. Install a new gasket.

    2. Temporarily install the turbo water pipe sub-assembly with the bolt and 2 nuts.

    3. Tighten the bolt and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    4. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the 2 hose clips to secure the hoses.

  5. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. B001E1SE02
      Text in Illustration
      *a NG
      *b OK

      Install a new gasket as shown in the illustration.

      Note

      Do not install the gasket upside down.

    2. Temporarily install the turbo oil inlet pipe subassembly with the 2 nuts.

  6. TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. Install 2 new gaskets to the exhaust manifold and turbocharger sub-assembly.

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

    3. B001IKRE01
      Text in Illustration
      *1 Collar
      B001DEF Engine Side

      Temporarily install the exhaust manifold with turbocharger sub-assembly, 8 collars and the 8 plate washers to the cylinder head sub-assembly with 8 new nuts.

      Note

      Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

    4. Install a new gasket on the union bolt side to turbo oil inlet pipe sub-assembly.

    5. Temporarily install the union bolt.

  7. INSTALL TURBO OIL OUTLET PIPE


    1. Install a new gasket to the turbo oil outlet pipe.

      Note

      The claws of the gasket must face the turbo oil outlet pipe.

    2. Install the turbo oil outlet pipe with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the turbo oil outlet hose to the turbo oil outlet pipe, turbo oil inlet pipe and slide the 2 hose clips to secure the hoses.

  8. TEMPORARILY INSTALL TURBOCHARGER STAY


    1. for Type B:

      Temporarily install the turbocharger stay to the turbocharger sub-assembly, with 3 bolts and nut.

    2. for Type A:


      1. Temporarily install the turbocharger stay and stad bolt.

      2. Using an E8 "TORX" socket wrench, tighten the stud bolt.

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

      3. Temporarily install the 3 bolts and nut.

  9. TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. B001F5QE01

      Tighten the exhaust manifold with turbocharger sub-assembly, to the cylinder head sub-assembly with 8 nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      Tighten the nuts in the order shown in the illustration.

    2. Tighten the turbocharger sub-assembly, to the exhaust manifold with the 3 nuts.

      Torque:
      73 N*m  { 744 kgf*cm, 54 ft.*lbf }

    3. Tighten the 2 nuts and then union bolt of the turbo oil inlet pipe sub-assembly.

      Torque:
      for nut
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

      Note

      If the connecting part of the union bolt gasket is cracked, remove the connecting part.

  10. TIGHTEN TURBOCHARGER STAY


    1. B001EKXE02

      Tighten the 3 bolts and nut of the turbocharger stay in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  11. INSTALL VISCOUS HEATER NO.1 BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)

    B001C8TE03
    Text in Illustration
    B001CHY No. 1 Viscous Heater Bracket Bolt
    B001DEF No. 4 Engine Harness Bolt

    1. Temporarily install the No. 1 viscous heater bracket sub-assembly with 4 bolts.

    2. Tighten the 4 bolts and of the No. 1 viscous heater bracket sub-assembly in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Connect the No. 4 engine harness with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    4. Connect the wire harness.

  12. INSTALL OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMPBRACKET


    1. Connect the wire harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. for Automatic Transmission:

      Connect the oil cooler tube bracket with the bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 47 in.*lbf }

  13. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    Click here

  14. CONNECT TURBO WATER HOSE


    1. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the water outlet sub-assembly, engine water pump assembly and slide the 2 hose clips to secure the hoses.

      Note

      The turbocharger sub-assembly may be damaged if the No. 1 turbo water hose and No. 2 turbo water hose are connected to the wrong locations.

  15. CONNECT NO. 1 WATER BY-PASS PIPE

    Click here

  16. INSTALL PCV HOSE (except Cold Area Specification Vehicles)


    1. Attach the clamp and install the PCV hose.

    2. Slide the 2 hose clips to secure the hoses.

  17. INSTALL PCV PIPE (for Cold Area Specification Vehicles)


    1. Connect the PCV pipe to the compressor inlet elbow, cylinder head cover sub-assembly and slide the 2 hose clips to secure the hoses.

    2. Install the PCV pipe with the bolt to the compressor inlet elbow.

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

    3. Connect the No. 19 water by-pass hose to the compressor inlet elbow and slide the hose clip to secure the hoses.

    4. Install the No. 20 water by-pass hose to the PCV pipe and No. 1 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

  18. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Connect the 2 water hoses to the oil cooler assembly and No. 2 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

    2. Install the No. 3 water by-pass pipe with the bolt.

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

    3. for Cold Area Specification Vehicles:

      Install the water hose to the compressor inlet elbow and No. 3 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

  19. INSTALL WATER HOSE SUB-ASSEMBLY B (w/ Viscous Heater)

    Click here

  20. INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY

    Click here

  21. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. for Cold Area Specification Vehicles:

      Connect the wire harness clamps.

  22. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner case.

  23. CONNECT AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE


    1. Attach the 4 clips to install the air cleaner cap sub-assembly with air cleaner hose.

    2. Tighten the hose clamp.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the mass air flow meter connector and attach the 2 wire harness clamps.

  24. INSTALL FAN SHROUD

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  25. INSTALL RADIATOR RESERVOIR ASSEMBLY

    Click here

  26. INSTALL NO. 1 RADIATOR HOSE

    Click here

  27. INSTALL VANE PUMP OIL RESERVOIR SUB-ASSEMBLY

    Click here

  28. INSTALL NO. 2 INTERCOOLER AIR HOSE

    Click here

  29. INSTALL INTERCOOLER AIR HOSE

    Click here

  30. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  32. ADD ENGINE OIL

    Click here

  33. ADD ENGINE COOLANT

    Click here

  34. INSPECT FOR OIL LEAK

    Click here

  35. INSPECT ENGINE OIL LEVEL

    Click here

  36. INSPECT FOR COOLANT LEAK

    Click here

  37. INSPECT FOR EXHAUST GAS LEAK

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