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	27 mm (1.06 in.)
         *b	16 mm (0.629 in.)
         *c	9.0 mm (0.354 in.)
         *d	40 mm (1.574 in.)
         *e	23 mm (0.905 in.)
         *f	15 mm (0.590 in.)

         Using an E6 "TORX" wrench, install the 3 stud bolts (A).

         3.0 N*m

         31 kgf*cm

         27 in.*lbf

      2. Using an E10 "TORX" wrench, install the stud bolt (B).

         22 N*m

         224 kgf*cm

         16 ft.*lbf

   2. 

      *a	41.4 mm (1.63 in.)
      *b	18 mm (0.708 in.)
      *c	13 mm (0.511 in.)

      For exhaust manifold:

      1. Using an E10 "TORX" wrench, install the stud bolt to the exhaust manifold.

         22 N*m

         224 kgf*cm

         16 ft.*lbf

2. INSTALL EXHAUST MANIFOLD

   1. Install a new gasket onto the cylinder head sub-assembly.

   2. Install the exhaust manifold with the 8 nuts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

3. INSTALL INLET COMPRESSOR ELBOW SUB-ASSEMBLY

   1. 

      *a	Groove
      *b	Protrusion

      Install a new gasket onto the inlet compressor elbow sub-assembly.

   2. Install the inlet compressor elbow sub-assembly onto the turbocharger sub-assembly with the 3 nuts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

4. TEMPORARILY INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

   1. Install a new gasket onto the cylinder block.

   2. Temporarily install the inlet turbo oil pipe sub-assembly onto the cylinder block with the 2 nuts.

5. INSTALL TURBOCHARGER SUB-ASSEMBLY

   1. 

      *a	Turbocharger Side
      *b	Compressor Side

      Install a new gasket onto the turbocharger sub-assembly.

   2. 

      *a	RH Side
      *b	Rear Side

      Install a new gasket onto the exhaust manifold.

   3. Install the turbocharger sub-assembly onto the exhaust manifold with the 3 nuts.

      53 N*m

      540 kgf*cm

      39 ft.*lbf

      Note:

      When connecting the inlet turbo oil pipe sub-assembly simultaneously, ensure that the gasket does not fall off.

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

6. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

   1. 

      Install the inlet turbo oil pipe sub-assembly onto the turbocharger sub-assembly with the 2 nuts (A).

      11 N*m

      112 kgf*cm

      8 ft.*lbf

   2. Tighten the 2 nuts (B).

      10 N*m

      102 kgf*cm

      7 ft.*lbf

7. INSTALL MANIFOLD STAY

   1. Install the manifold stay with the 2 bolts.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

8. INSTALL TURBOCHARGER STAY

   1. 

      Temporarily install the turbocharger stay with the 2 bolts and nut.

   2. Tighten the 2 bolts and nut in the order shown in the illustration.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

9. CONNECT NO. 1 AIR HOSE

   1. 

      *a	View A
      *b	LH Side
      *c	Front Side
      *d	200° (Hose Clamp Area)
      *e	Paint Mark
      *f	Stopper

      Connect the No. 1 air hose to the turbocharger sub-assembly as shown in the illustration.

   2. 

      Tighten the clamp of the No. 1 air hose on the turbocharger sub-assembly side.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

      Tip:

      • Push in the No. 1 air hose so that distance B is 0 to 2 mm (0 to 0.0787in.).

      • Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).

10. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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11. CLEAR DTC (P0046)

    1. When a new turbocharger is installed, DTC P0046 is likely to be stored. It should be cleared by the special method.

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12. PERFORM TURBOCHARGER INITIALIZATION

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