EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE


  1. INSTALL EXHAUST MANIFOLD


    1. Install 2 new gaskets to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold with the 8 nuts.

    3. Tighten the 8 nuts of the exhaust manifold.

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

    4. Tighten the 8 nuts again.

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

  2. INSTALL EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

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  3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  4. CONNECT FUEL FEED PIPE SUB-ASSEMBLY

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  5. CONNECT NO. 1 AIR TUBE ASSEMBLY


    1. Connect the No. 1 air tube assembly to the manual transaxle assembly with the 2 bolts.

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

    2. Connect the outlet heater water hose to the No. 2 radiator pipe, and slide the clamp to secure the hose.

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

    4. Attach the clamp and connect the water hose sub-assembly to the compressor outlet elbow.

    5. Connect the water by-pass hose assembly to the No. 2 radiator pipe, and slide the clamp to secure the hose.

    6. Connect the radiator hose sub-assembly to the No. 1 radiator pipe, and slide the clamp to secure the hose.

  6. INSTALL NO. 4 WATER BY-PASS HOSE


    1. Install the No. 4 water by-pass hose to the No. 2 radiator pipe, and slide the clamp to secure the hose.

    2. B00425YC01
      *a Retainer

      Connect the No. 4 water by-pass hose to the EGR cooler assembly and lock the retainer as shown in the illustration.

  7. CONNECT ENGINE WIRE


    1. Connect the engine wire to the No. 1 air tube assembly with the 2 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Attach the 2 clamps to the No. 1 air tube assembly.

  8. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. B00446DE01

      Temporarily install a new gasket, the turbocharger sub-assembly and the 3 bolts (A).

    2. Temporarily install the bolt (B).

    3. Tighten the 4 bolts.

      Torque:
      for Bolt (A)
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for Bolt (B)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Connect the connector to the turbocharger sub-assembly.

  9. INSTALL NO. 1 EXHAUST MANIFOLD PIPE


    1. Temporarily install the No. 1 exhaust manifold pipe with the bolt.

    2. Temporarily install 2 new gaskets with the union bolt.

    3. Tighten the bolt and union bolt.

      Torque:
      for Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for Union Bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    4. Connect the exhaust manifold pressure sensor connector.

  10. CONNECT NO. 1 TURBO OIL PIPE


    1. Connect the No. 1 turbo oil pipe and 2 new gaskets with the union bolt.

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

  11. INSTALL TURBO OIL OUTLET PIPE


    1. Install a new O-ring to the turbo oil outlet pipe.

    2. Install a new gasket and the turbo oil outlet pipe with the 3 bolts.

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

  12. CONNECT COMPRESSOR OUTLET ELBOW


    1. B0042L7C02
      *a Retainer

      Connect the compressor outlet elbow to the turbocharger sub-assembly and lock the retainer as shown in the illustration.

  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


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

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  14. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY


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

    2. B0044CMC01
      *a Retainer

      Connect the air cleaner hose assembly to the turbocharger sub-assembly and lock the retainer as shown in the illustration.

    3. Attach the 2 clamps to install the air cleaner cap sub-assembly.

    4. Connect the ventilation hose to the cylinder head cover sub-assembly.

    5. Attach the clamp and connect the No. 2 fuel hose to the air cleaner hose assembly.

    6. Attach the clamp and connect the No. 1 fuel hose to the air cleaner hose assembly.

    7. Attach the clamp and connect the vacuum hose to the air cleaner hose assembly.

    8. Attach the clamp and connect the mass air flow meter sub-assembly connector.

  15. INSTALL BATTERY CARRIER


    1. Install the battery carrier with the 4 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Attach the 2 clamps to connect the engine wire.

  16. INSTALL BATTERY TRAY

  17. INSTALL BATTERY

  18. INSTALL BATTERY INSULATOR

  19. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Attach the hook of the battery clamp sub-assembly to the battery carrier.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Adjust the battery clamp sub-assembly position.

    4. Tighten the nut and bolt.

      Torque:
      for Bolt
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
      for Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  20. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  21. CONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  22. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  23. ADD ENGINE COOLANT

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  24. INSPECT FOR COOLANT LEAK

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