EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION


  1. INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY


    1. Install a new gasket to the exhaust manifold.

    2. A00OR76E02
      Text in Illustration
      *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.

    3. 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.

    4. A00OT4BE01

      Using an E8 "TORX" wrench, install a new stud bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    5. Install a new gasket and the turbocharger with 3 new nuts.

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

    6. Connect the vacuum hose.

    7. 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.

    8. Tighten the 8 nuts of the exhaust manifold.

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

  2. 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 }

  3. 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 }

  4. CONNECT NO. 3 WATER BY-PASS HOSE

  5. 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 }

  6. 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 }

  7. INSTALL EGR COOLER WITH PIPE ASSEMBLY

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