EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Note

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


    1. B003R03

      Using an E10 "TORX" socket wrench, install the 3 stud bolts at the positions shown in the illustration.

      Torque:
      14.7 N*m  { 150 kgf*cm, 11 ft.*lbf }
    2. B003K9K

      Using an E8 "TORX" socket wrench, install the 4 stud bolts at the positions shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B003KHE

      Using an E5 "TORX" socket wrench, install the 4 stud bolts at the positions shown in the illustration.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  2. INSTALL COMPRESSOR OUTLET ELBOW


    1. Install the hose clamp with the bolt.

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

    2. Install a new gasket.

    3. Install a new gasket and the compressor outlet elbow with the 2 nuts.

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

  3. INSTALL COMPRESSOR INLET ELBOW


    1. Using an E8 "TORX" socket wrench, install a new gasket and the compressor inlet elbow with the stud bolt.

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

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

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

    3. Install the compressor inlet elbow stay with the 2 bolts.

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

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


    1. Install a new gasket.

    2. Temporarily install the turbo water pipe sub-assembly with the bolt and 2 nuts.

    3. Tighten the bolt and 2 nuts.

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

    4. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the 2 hose clips to secure the hoses.

  5. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. B003QTGC01
      *a NG
      *b OK

      Install a new gasket as shown in the illustration.

      Note

      Do not install the gasket upside down.

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

  6. TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. Install 2 new gaskets to the exhaust manifold and turbocharger sub-assembly.

    2. Temporarily install the exhaust manifold to turbocharger sub-assembly with 3 new nuts.

    3. B003S9GC01
      *A w/ DPF
      *B w/o DPF
      *1 Collar
      B003LF2 Engine Side

      Temporarily install the exhaust manifold with turbocharger sub-assembly, 8 collars and the 8 plate washers to the cylinder head sub-assembly with 8 new nuts.

      Note

      Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

    4. Install a new gasket on the union bolt side to turbo oil inlet pipe sub-assembly.

    5. Temporarily install the union bolt.

  7. INSTALL TURBO OIL OUTLET PIPE


    1. Install a new gasket to the turbo oil outlet pipe.

      Note

      The claws of the gasket must face the turbo oil outlet pipe.

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

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the turbo oil outlet hose to the turbo oil outlet pipe, turbo oil inlet pipe and slide the 2 hose clips to secure the hoses.

  8. TEMPORARILY INSTALL TURBOCHARGER STAY


    1. Temporarily install the turbocharger stay to the turbocharger sub-assembly, with 3 bolts and nut.

  9. TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. B003OKLC01
      *A w/ DPF
      *B w/o DPF

      Tighten the exhaust manifold with turbocharger sub-assembly, to the cylinder head sub-assembly with 8 nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      Tighten the nuts in the order shown in the illustration.

    2. Tighten the turbocharger sub-assembly, to the exhaust manifold with the 3 nuts.

      Torque:
      73 N*m  { 744 kgf*cm, 54 ft.*lbf }

    3. Tighten the 2 nuts and then union bolt of the turbo oil inlet pipe sub-assembly.

      Torque:
      for nut
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

      Note

      If the connecting part of the union bolt gasket is cracked, remove the connecting part.

  10. TIGHTEN TURBOCHARGER STAY


    1. B003NALE01

      Tighten the 3 bolts and nut of the turbocharger stay in the order shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  11. INSTALL WIRE HARNESS CLAMP BRACKET (for Manual Transmission)


    1. Connect the wire harness clamp and install the bolt.

      Torque:
      18.6 N*m  { 190 kgf*cm, 14 ft.*lbf }

  12. INSTALL OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET (for Automatic Transmission)


    1. Attach the 2 wire harness clamps and connect the wire harness.

    2. Connect the oil cooler tube bracket with the bolt.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  13. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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  14. CONNECT TURBO WATER HOSE


    1. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the water outlet sub-assembly, engine water pump assembly and slide the 2 hose clips to secure the hoses.

      Note

      The turbocharger sub-assembly may be damaged if the No. 1 turbo water hose and No. 2 turbo water hose are connected to the wrong locations.

  15. INSTALL NO. 1 WATER BY-PASS PIPE

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  16. INSTALL PCV HOSE


    1. Attach the clamp and install the PCV hose.

    2. Slide the 2 hose clips to secure the hoses.

  17. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Connect the 2 water hoses to the oil cooler assembly and No. 2 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

    2. Install the No. 3 water by-pass pipe with the bolt.

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

  18. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


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

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

    2. Connect the 3 wire harness clamps.

  19. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

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


    1. Attach the 4 clips to install the air cleaner cap sub-assembly with air cleaner hose.

    2. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Connect the mass air flow meter connector and attach the 2 wire harness clamps.

  21. INSTALL FAN SHROUD

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  22. INSTALL RADIATOR RESERVOIR

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  23. INSTALL NO. 1 OIL RESERVOIR BRACKET

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  24. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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  25. INSTALL NO. 1 RADIATOR HOSE

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  26. INSTALL NO. 2 AIR TUBE

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  27. INSTALL NO. 4 AIR HOSE

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  28. INSTALL NO. 1 AIR HOSE

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  29. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


  30. ADD ENGINE OIL

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  31. ADD ENGINE COOLANT

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  32. INSPECT FOR COOLANT LEAK

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  33. INSPECT FOR OIL LEAK

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  34. INSPECT ENGINE OIL LEVEL

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  35. INSPECT FOR EXHAUST GAS LEAK

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  36. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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  37. PERFORM INITIALIZATION