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. A206341C01

        *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.

        10 N*m

        102 kgf*cm

        7 ft.*lbf

      2. A291341C01

        *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 labeled A shown in the illustration.

        20 N*m

        204 kgf*cm

        15 ft.*lbf

      3. Using an E5 "TORX" wrench, install the 2 stud bolts labeled B shown in the illustration.

        5.0 N*m

        51 kgf*cm

        44 in.*lbf

      4. A206342C01

        *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.

        8.0 N*m

        82 kgf*cm

        71 in.*lbf

    2. A291348C01

      *a

      43 mm (1.69 in.)

      *b

      16 mm (0.630 in.)

      For exhaust manifold:

      Install the stud bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  2. INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY

    1. A273051C01

      *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.

    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 sub-assembly with 3 new nuts.

      60 N*m

      612 kgf*cm

      44 ft.*lbf

    4. Connect the vacuum hose.

    5. 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.

    6. Tighten the 8 nuts of the exhaust manifold.

      47 N*m

      479 kgf*cm

      35 ft.*lbf

  3. INSTALL NO. 2 TURBO OIL PIPE

    1. Install the No. 2 turbo oil pipe and 2 new gaskets with the 2 union bolts.

      35 N*m

      357 kgf*cm

      26 ft.*lbf

  4. INSTALL NO. 5 WATER BY-PASS PIPE

    1. Install the No. 5 water by-pass pipe with the 2 bolts.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

  5. CONNECT NO. 3 WATER BY-PASS HOSE

    1. Connect the No. 3 water by-pass hose to the No. 1 water by-pass pipe, and slide the clamp to secure the hose.

  6. INSTALL NO. 1 TURBO INSULATOR

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

      21 N*m

      209 kgf*cm

      15 ft.*lbf

  7. 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.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

  8. INSTALL EGR COOLER WITH PIPE ASSEMBLY

    Click here

  9. PERFORM TURBOCHARGER INITIALIZATION