EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL EXHAUST MANIFOLD


    1. Install a new gasket and the turbocharger sub-assembly with 3 new nuts to the exhaust manifold.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

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

  2. INSTALL EXHAUST MANIFOLD


    1. Temporarily install the turbo oil pipe sub-assembly and manifold stay.

      Tech Tips

      Wash the oil pipe before installing it.

      B003QGWC01
      *1 Gasket - -
      *a Claw *b Narrow
      *c Wide - -
      B003R2S Outside - -

    2. Temporarily install a new gasket and the turbo oil pipe sub-assembly with the 2 nuts, but only loosely install the nuts.

      Note

      The notch (wide part) of the gasket must face the engine.

    3. Temporarily install a new gasket and the turbo oil pipe sub-assembly with the 2 bolts (labeled: A), but only loosely install the bolts.

      Note

      The claws of the gasket must face the turbo oil pipe sub-assembly.

    4. Temporarily install a new gasket and the turbo oil pipe sub-assembly with the union bolt (labeled: B), but only loosely install the union bolt.

    5. Temporarily install the manifold stay with the 2 bolts.

      Tech Tips

      The manifold stay's indented area must face the turbocharger sub-assembly.

    6. B003OCIE01

      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.

    7. Tighten the 2 nuts and union bolt of the turbo oil inlet pipe sub-assembly, and the 2 bolts.

      Torque:
      for nut
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    8. Tighten the 2 bolts and the manifold stay.

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

  3. INSTALL TURBINE OUTLET ELBOW


    1. Temporarily install the turbocharger stay to the turbine outlet elbow with the 2 bolts.

    2. Temporarily install a new gasket and the turbine outlet elbow (with turbocharger stay) to the turbocharger sub-assembly with the 4 new nuts.

    3. Temporarily install the turbocharger stay to the cylinder block sub-assembly with the 2 bolts.

    4. Tighten the 4 nuts of the turbocharger sub-assembly.

      Torque:
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }

    5. Tighten the 4 bolts of the turbocharger stay.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  5. INSTALL NO. 1 INTAKE PIPE

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  6. INSTALL PCV HOSE HEAT INSULATOR


    1. Install the PCV hose heat insulator with the 2 bolts.

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

  7. 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.

  8. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  9. 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. Attach the clamp and connect the intake air temperature sensor connector.

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  11. INSPECT FOR OIL LEAK

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  12. INSPECT ENGINE OIL LEVEL

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  13. INSTALL NO. 2 ENGINE UNDER COVER

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  14. INSTALL NO. 1 ENGINE UNDER COVER

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