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. B0042DIC03
      *a 27 mm (1.06 in.)
      *b 16 mm (0.630 in.)
      *c 9.0 mm (0.354 in.)
      *d 40 mm (1.57 in.)
      *e 23 mm (0.906 in.)
      *f 15 mm (0.591 in.)

      Using an E6 "TORX" wrench, install the 3 stud bolts (A) to the turbocharger sub-assembly.

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

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

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    3. B0042Z2C01
      *a 41.4 mm (1.63 in.)
      *b 18 mm (0.709 in.)
      *c 13 mm (0.512 in.)

      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 exhaust manifold to head gasket to the cylinder head sub-assembly.

    2. Temporarily install the No. 2 manifold support bracket to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

    3. Temporarily install the exhaust manifold to the cylinder head sub-assembly with the 8 nuts.

    4. B00446XC01
      B0042CO Bolt
      B0043VS Nut

      Tighten the 2 bolts and 8 nuts in the order shown in the illustration.

      Torque:
      Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Nut
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  3. INSTALL INLET COMPRESSOR ELBOW SUB-ASSEMBLY


    1. B0044XIC02
      *a Groove
      *b Protrusion

      Install a new inlet compressor gasket to the inlet compressor elbow sub-assembly as shown in the illustration.

    2. Install the inlet compressor elbow sub-assembly to 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 No. 1 outlet turbo oil gasket to the cylinder block sub-assembly.

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

  5. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. B0044JXC01
      *a Turbocharger Side
      *b Compressor Side

      Install a new inlet turbo oil gasket to the turbocharger sub-assembly as shown in the illustration.

    2. B0041Z6C01
      *a RH
      *b Rear

      Install a new turbo to exhaust manifold gasket to the exhaust manifold.

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

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

      Note


      • When installing the turbocharger sub-assembly, do not hold it by the electric actuator rod.

      • Do not drop the gasket when connecting the turbo oil inlet pipe sub-assembly.

    4. Connect the 2 turbocharger sub-assembly connectors.

  6. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY


    1. B0043U6E02

      Install the inlet turbo oil pipe sub-assembly to 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:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  7. INSTALL MANIFOLD STAY


    1. Install the manifold stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts.

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

  8. INSTALL TURBOCHARGER STAY


    1. Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder head sub-assembly with the 2 bolts and nut.

    2. B00442LN01

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

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

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


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

    2. Install the No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the 4 bolts.

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

  10. CONNECT NO. 2 TURBO WATER HOSE


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

  11. CONNECT NO. 1 TURBO WATER HOSE


    1. Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

  12. CONNECT NO. 1 AIR HOSE


    1. B0041WTC02
      *a View A
      *b LH
      *c Front
      *d 200° (Hose Clamp Bolt Area)
      *e Paint Mark
      *f Stopper

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

    2. B004465N01

      Tighten the hose 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 the distance (B) is 0 to 2 mm (0 to 0.0787 in.).

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

  13. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  14. CLEAR DTC (P0046)


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

      Click here

  15. PERFORM TURBOCHARGER INITIALIZATION

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