EXHAUST MANIFOLD W/ TURBOCHARGER (for DPF) INSTALLATION


  1. INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY


    1. A01INXCE02
      Text in Illustration
      *1 Collar
      *2 Groove

      Temporarily install a new gasket, the exhaust manifold, and the 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. A01IUMFE02
      Text in Illustration
      *1 New Turbocharger Stay
      *2 Collar

      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.

      • When installing the turbocharger stay, be sure to tighten the nut labeled A first.

    5. Tighten the 8 nuts of the exhaust manifold.

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

  2. INSTALL TURBO OIL OUTLET PIPE


    1. Install a new gasket and the turbo oil outlet pipe with the 3 nuts.

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

    2. Connect the turbo oil outlet pipe and a new gasket with the union bolt.

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

  3. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Install the No. 3 water by-pass hose to the No. 1 water by-pass pipe and turbo oil outlet pipe, and slide the 2 clamps to secure it.

  4. INSTALL NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 2 vacuum transmitting pipe sub-assembly with the bolt.

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

    2. Connect the 2 vacuum transmitting hoses.

  5. INSTALL TURBOCHARGER WIRE


    1. Install the turbocharger wire and attach the 3 wire harness clamps.

    2. Connect the 2 connectors to the turbocharger sub-assembly.

  6. INSTALL NO. 2 TURBO OIL OUTLET PIPE


    1. Install a new gasket and the No. 2 turbo oil outlet pipe with the 2 bolts.

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

  7. INSTALL TURBO OIL OUTLET HOSE


    1. Install the turbo oil outlet hose to the turbo oil outlet pipe and No. 2 turbo outlet pipe, and slide the 2 clamps to secure it.

  8. 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 }

  9. INSTALL EGR COOLER WITH PIPE ASSEMBLY

    Click here

  10. PERFORM TURBOCHARGER INITIALIZATION

    Click here