EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

   Tip:

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

   1. For turbocharger sub-assembly:

      1. 

         *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 to the turbocharger sub-assembly.

         8.0 N*m

         82 kgf*cm

         71 in.*lbf

      2. 

         *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 to the turbocharger sub-assembly.

         10 N*m

         102 kgf*cm

         7 ft.*lbf

      3. 

         *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 (A).

         20 N*m

         204 kgf*cm

         15 ft.*lbf

      4. Using an E5 "TORX" wrench, install the 2 stud bolts (B).

         5.0 N*m

         51 kgf*cm

         44 in.*lbf

   2. 

      *a	43 mm (1.69 in.)
      *b	16 mm (0.630 in.)

      For exhaust manifold:

      Install the stud bolt to the exhaust manifold.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

2. INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY

   1. 

      *1	Collar
      *2	Groove

      Temporarily install a new gasket, the exhaust manifold, and 2 collars with 2 new nuts (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.

      Tip:

      • 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 with 3 new nuts.

      60 N*m

      612 kgf*cm

      44 ft.*lbf

   4. 

      *1	New Turbocharger Stay
      *2	Collar

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

      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 (A) first.

   5. Tighten the 8 nuts of the exhaust manifold.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

3. INSTALL TURBO OIL OUTLET PIPE

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

      11 N*m

      112 kgf*cm

      8 ft.*lbf

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

      35 N*m

      357 kgf*cm

      26 ft.*lbf

4. INSTALL NO. 3 WATER BY-PASS HOSE

   1. Install the No. 3 water by-pass hose and slide the 2 clips to secure it.

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

   1. Install the No. 2 vacuum transmitting pipe with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

   2. Connect the 2 vacuum transmitting hoses.

6. INSTALL TURBOCHARGER WIRE

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

   2. Connect the 2 connectors.

7. INSTALL NO. 2 TURBO OIL OUTLET PIPE

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

      11 N*m

      112 kgf*cm

      8 ft.*lbf

8. INSTALL TURBO OIL OUTLET HOSE

   1. Install the turbo oil outlet hose and slide the 2 clips to secure it.

9. INSTALL NO. 1 TURBO INSULATOR

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

      20.5 N*m

      209 kgf*cm

      15 ft.*lbf

10. INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY

    Click here

11. PERFORM TURBOCHARGER INITIALIZATION

    Click here