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. A00YV6ZC01
        *a 32 mm (1.26 in.)
        *b 20 mm (0.787 in.)
        *c 10 mm (0.394 in.)

        Using an E8 "TORX" wrench, install the 3 stud bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. A00YX4RC01
        *a 43 mm (1.69 in.)
        *b 16 mm (0.630 in.)
        *c 24.5 mm (0.965 in.)
        *d 12 mm (0.472 in.)
        *e 9.0 mm (0.354 in.)

        Install the 2 stud bolts labeled A shown in the illustration.

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

      3. Using an E5 "TORX" wrench, install the 2 stud bolts labeled B shown in the illustration.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      4. A00YTZVC01
        *a 47 mm (1.85 in.)
        *b 14 mm (0.551 in.)
        *c 15 mm (0.591 in.)

        Using an E8 "TORX" wrench, install the stud bolt.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A00YVALC01
      *a 43 mm (1.69 in.)
      *b 16 mm (0.630 in.)

      For exhaust manifold:

      Install the stud bolt.

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

  2. INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY


    1. A00YS7WC01
      *1 Collar
      *2 Groove

      Temporarily install a new gasket, and the exhaust manifold and 2 collars with 2 new nuts labeled A. Tighten the nuts until the mating surface of the exhaust manifold contacts the cylinder head.

    2. Temporarily install the 6 collars with 6 new nuts.

      Tech Tips


      • When installing the collars, pay attention to the mounting orientation. The ring groove of the collar should be on the outside. Refer to the illustration.

      • Do not fully tighten the nuts as doing so may result in misalignment of the exhaust manifold.

    3. Install a new gasket and the turbocharger sub-assembly with 3 new nuts.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    4. Connect the vacuum hose.

    5. Install the 2 collars and a new turbocharger stay with 2 new nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

      Note

      Do not reuse the turbocharger stay.

    6. Tighten the 8 nuts of the exhaust manifold.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  3. INSTALL NO. 2 TURBO OIL PIPE


    1. Install the No. 2 turbo oil pipe and 2 new gaskets with the 2 union bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  4. INSTALL NO. 5 WATER BY-PASS PIPE


    1. Install the No. 5 water by-pass pipe with the 2 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  5. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose to the No. 1 water by-pass pipe, and slide the clamp to secure the hose.

  6. INSTALL NO. 1 TURBO INSULATOR


    1. Install the No. 1 turbo insulator with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  7. INSTALL TURBO OIL OUTLET PIPE


    1. Install 2 new gaskets to the turbo oil outlet pipe.

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

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

  8. INSTALL EGR COOLER WITH PIPE ASSEMBLY

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  9. PERFORM TURBOCHARGER INITIALIZATION