EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. For turbocharger sub-assembly:


      1. A012J85C03
        *a 27 mm (1.06 in.)
        *b 16 mm (0.629 in.)
        *c 9.0 mm (0.354 in.)
        *d 40 mm (1.574 in.)
        *e 23 mm (0.905 in.)
        *f 15 mm (0.590 in.)

        Using an E6 "TORX" wrench, install the 3 stud bolts (A).

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

      2. Using an E10 "TORX" wrench, install the stud bolt (B).

        Torque:
        22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A012HBEC01
      *a 41.4 mm (1.63 in.)
      *b 18 mm (0.708 in.)
      *c 13 mm (0.511 in.)

      For exhaust manifold:


      1. Using an E10 "TORX" wrench, install the stud bolt to the exhaust manifold.

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

  2. INSTALL EXHAUST MANIFOLD


    1. Install a new gasket onto the cylinder head sub-assembly.

    2. Install the exhaust manifold with the 8 nuts.

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

  3. INSTALL INLET COMPRESSOR ELBOW SUB-ASSEMBLY


    1. A012LXQC01
      *a Groove
      *b Protrusion

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

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

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

  4. TEMPORARILY INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. Install a new gasket onto the cylinder block.

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

  5. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. A012MHTC01
      *a Turbocharger Side
      *b Compressor Side

      Install a new gasket onto the turbocharger sub-assembly.

    2. A012FKRC01
      *a RH Side
      *b Rear Side

      Install a new gasket onto the exhaust manifold.

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

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

      Note

      When connecting the inlet turbo oil pipe sub-assembly simultaneously, ensure that the gasket does not fall off.

    4. Connect the 2 connectors to the turbocharger sub-assembly.

  6. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. A012LDBE02

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

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

    2. Tighten the 2 nuts (B).

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

  7. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

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

  8. INSTALL TURBOCHARGER STAY


    1. A012H7UE01

      Temporarily install the turbocharger stay with the 2 bolts and nut.

    2. Tighten the 2 bolts and nut in the order shown in the illustration.

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

  9. CONNECT NO. 1 AIR HOSE


    1. A012NC1C01
      *a View A
      *b LH Side
      *c Front Side
      *d 200° (Hose Clamp Area)
      *e Paint Mark
      *f Stopper

      Connect the No. 1 air hose to the turbocharger sub-assembly as shown in the illustration.

    2. A012FT5N01

      Tighten the clamp of the No. 1 air hose on the turbocharger sub-assembly side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tech Tips


      • Push in the No. 1 air hose so that distance B is 0 to 2 mm (0 to 0.0787in.).

      • Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).

  10. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  11. CLEAR DTC (P0046)


    1. When a new turbocharger is installed, DTC P0046 is likely to be stored. It should be cleared by the special method.

      Click here

  12. PERFORM TURBOCHARGER INITIALIZATION

    Click here