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 STUD BOLT

    Note

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


    1. for Turbocharger Sub-assembly Side:


      1. Using an E10 "TORX" wrench, install the stud bolts to the turbocharger sub-assembly labeled A and B shown in the illustration below.

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

      2. Install the stud bolts to the turbocharger sub-assembly labeled C shown in the illustration below.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
        B00183YE02
        Text in Illustration
        *a 41.4 mm (1.63 in.) *b 18 mm (0.709 in.)
        *c 13 mm (0.512 in.) *d 39.5 mm (1.56 in.)
        *e 20 mm (0.787 in.) *f 14 mm (0.551 in.)
        *g 23 mm (0.906 in.) *h 9.0 mm (0.354 in.)

    2. for No. 2 Turbocharger Sub-assembly Side:


      1. B0018MOE02
        Text in Illustration
        *a 39.5 mm (1.56 in.)
        *b 20 mm (0.787 in.)
        *c 14 mm (0.551 in.)

        Using an E10 "TORX" wrench, install the stud bolts to the No. 2 turbocharger sub-assembly.

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

    3. for No. 2 Exhaust Manifold Side:


      1. B0018APE02
        Text in Illustration
        *A w/ DPF
        *B w/o DPF
        *a 39.5 mm (1.56 in.)
        *b 20 mm (0.787 in.)
        *c 14 mm (0.551 in.)

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

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

  2. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY LH (for Bank 2)


    1. B0019ZME03

      Temporarily install a new gasket and the turbo oil inlet pipe sub-assembly to the No. 2 turbocharger sub-assembly with the union bolt and bolt.

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

      Torque:
      for union bolt
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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


    1. Install a new gasket and the No. 2 turbo oil pipe to the No. 2 turbocharger sub-assembly with the 2 bolts.

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

      Tech Tips

      The gasket claws should face the No. 2 turbo oil pipe.

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


    1. Install a new gasket and the No. 2 compressor inlet elbow to the No. 2 turbocharger sub-assembly with the 2 bolts.

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

      Tech Tips

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

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


    1. Install a new gasket to the No. 2 turbocharger sub-assembly.

    2. Install the No. 2 exhaust manifold to the No. 2 turbocharger sub-assembly 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. Temporarily install the No. 2 exhaust manifold pipe to the No. 2 exhaust manifold with the 4 bolts.

        Tech Tips

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

        B00192A

      3. Tighten the 4 bolts.

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

    4. Install a new No. 2 exhaust manifold to head gasket to the cylinder head LH.

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

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      B0018HFE04
      Text in Illustration
      *A w/ DPF *B w/o DPF

      Tech Tips

      Install the collars with the colored side facing the nuts.

    6. Install a new gasket and the turbo oil inlet pipe sub-assembly LH to the oil pan sub-assembly with the union bolt.

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

    7. Connect the 2 connectors to the No. 2 turbocharger sub-assembly.

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


    1. Temporarily install a new gasket and the No. 2 ventilation tube sub-assembly to the No. 2 turbo oil pipe and No. 2 exhaust manifold with the union bolt and bolt.

      B0019M1E02
      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 No. 2 vacuum transmitting hose assembly to the No. 2 turbocharger sub-assembly.

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


    1. Install the No. 2 turbocharger stay to the No. 2 turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts.

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

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


    1. Install the No. 2 turbo oil outlet hose to the No. 2 turbo oil pipe and oil pan sub-assembly, and slide the 2 clamps to secure the hose.

      Tech Tips

      Align the white paint marks on the No. 2 turbo oil outlet hose and oil pan sub-assembly, and connect the No. 2 turbo oil outlet hose.

      B001AEKE04
      Text in Illustration
      *a Painted Mark

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


    1. B001AV9E03

      Temporarily install a new gasket and the No. 2 turbo water pipe sub-assembly to the No. 2 turbocharger sub-assembly 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 No. 3 water by-pass hose to the No. 2 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

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


    1. Install a new gasket and the front water by-pass joint to the No. 2 turbocharger sub-assembly.

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

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


    1. B0019GJE02

      Temporarily install a new gasket and the No. 3 turbo water pipe sub-assembly to the No. 2 exhaust manifold and No. 2 turbocharger sub-assembly 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 }

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


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

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

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


    1. Install the No. 2 turbo water hose to the No. 3 turbo water pipe sub-assembly and water outlet pipe, and slide the 2 clamps to secure the hose.

  14. INSTALL BREATHER PLUG LH (for Bank 2)


    1. w/ DPF:


      1. Install the breather plug LH.

    2. w/o DPF:


      1. Attach the clamp and install the breather plug LH.

    3. Connect the vacuum hose to the No. 2 ventilation tube sub-assembly.

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


    1. Install the No. 3 ventilation hose to the No. 2 ventilation tube sub-assembly and cylinder head cover sub-assembly LH, and slide the 2 clamps to secure the hose.

  16. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY (for Bank 1)


    1. B001864E02

      Temporarily install a new gasket and the turbo oil inlet pipe sub-assembly to the turbocharger sub-assembly with the union bolt and bolt.

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

      Torque:
      for union bolt
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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


    1. Install a new gasket and the No. 1 turbo oil pipe to the turbocharger sub-assembly with the 2 bolts.

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

  18. INSTALL COMPRESSOR INLET ELBOW (for Bank 1)


    1. Install a new gasket and the compressor inlet elbow to the turbocharger sub-assembly with the 2 bolts.

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

      Tech Tips

      Install the compressor inlet elbow with the "R" mark facing toward the outside of the vehicle.

  19. INSTALL TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD (for Bank 1)


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

    2. Install the exhaust manifold to the turbocharger sub-assembly 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. Temporarily install the No. 1 exhaust manifold pipe to the exhaust manifold with the 4 bolts.

        Tech Tips

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

        B001B3V

      3. Tighten the 4 bolts.

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

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

    5. Install the turbocharger sub-assembly with exhaust manifold to the cylinder head sub-assembly with the 10 collars and 10 new nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      B001AOME03
      Text in Illustration
      *A w/ DPF *B w/o DPF

      Tech Tips

      Install the collars with the colored side facing the nuts.

    6. Install a new gasket and the turbo oil inlet pipe sub-assembly to the cylinder block sub-assembly 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 sub-assembly bolt hole.

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

  20. INSTALL VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)


    1. B00190XE02

      Temporarily install a new gasket and the ventilation tube sub-assembly to the No. 1 turbo oil pipe and exhaust manifold 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 No. 3 vacuum transmitting hose assembly to the turbocharger sub-assembly.

  21. INSTALL TURBOCHARGER STAY (for Bank 1)


    1. Temporarily install the No. 1 turbocharger stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts.

    2. Tighten the 2 bolts.

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

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


    1. Install a new gasket and the No. 1 turbo water pipe sub-assembly to the exhaust manifold and turbocharger sub-assembly with 2 new nuts and the 3 bolts.

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

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

  23. CONNECT TURBO OIL OUTLET HOSE (for Bank 1)


    1. Connect the turbo oil outlet hose to the oil pan sub-assembly, and slide the clamp to secure the hose.

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


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

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

  25. INSTALL BREATHER PLUG RH (for Bank 1)


    1. Install the breather plug RH to the starter hose bracket sub-assembly and attach the clamp.

    2. Connect the vacuum hose to the ventilation tube sub-assembly.

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


    1. Install the No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and water by-pass outlet sub-assembly, and slide the 2 clamps to secure the hose.

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


    1. Install the No. 2 ventilation hose to the ventilation tube sub-assembly and cylinder head cover sub-assembly, and slide the 2 clamps to secure the hose.

  28. INSTALL INTAKE AIR CONNECTOR PIPE (for Bank 1)


    1. Install the intake air connector pipe to the turbocharger sub-assembly and intake air connector bracket with the bolt.

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

    2. Tighten the hose clamp.

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

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

  29. INSTALL 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 engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide to the cylinder head sub-assembly and oil pan sub-assembly with the 2 bolts.

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

  30. INSTALL ENGINE 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.


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

  32. INSPECT FOR OIL LEAK

    Click here

  33. INSPECT FOR COOLANT LEAK

    Click here

  34. INSPECT ENGINE OIL LEVEL

    Click here

  35. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  36. PERFORM TURBOCHARGER INITIALIZATION