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. A295031C03

      *a

      27 mm (1.06 in.)

      *b

      16 mm (0.630 in.)

      *c

      9.0 mm (0.354 in.)

      *d

      40 mm (1.57 in.)

      *e

      23 mm (0.906 in.)

      *f

      15 mm (0.591 in.)

      Using an E6 "TORX" wrench, install the 3 stud bolts (A) to the turbocharger sub-assembly.

      3.0 N*m

      31 kgf*cm

      27 in.*lbf

    2. Using an E10 "TORX" wrench, install the stud bolt (B) to the turbocharger sub-assembly.

      22 N*m

      224 kgf*cm

      16 ft.*lbf

    3. A295035C01

      *a

      41.4 mm (1.63 in.)

      *b

      18 mm (0.709 in.)

      *c

      13 mm (0.512 in.)

      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 (w/o Glow Plug Controller)

    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

    2. Install the exhaust manifold to the cylinder head sub-assembly with the 8 nuts.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

  3. INSTALL EXHAUST MANIFOLD (w/ Glow Plug Controller)

    1. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.

    2. Temporarily install the No. 2 manifold support bracket to the cylinder head sub-assembly and cylinder block sub-assembly with the 2 bolts.

    3. Temporarily install the exhaust manifold to the cylinder head sub-assembly with the 8 nuts.

    4. A359371C01
      V100135

      Bolt
      V100136

      Nut

      Tighten the 2 bolts and 8 nuts in the order shown in the illustration.

      Bolt

      37 N*m

      377 kgf*cm

      27 ft.*lbf

      Nut

      43 N*m

      438 kgf*cm

      32 ft.*lbf

  4. INSTALL INLET COMPRESSOR ELBOW SUB-ASSEMBLY

    1. A295038C02

      *a

      Groove

      *b

      Protrusion

      Install a new inlet compressor gasket to the inlet compressor elbow sub-assembly as shown in the illustration.

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

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  5. TEMPORARILY INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

    1. Install a new No. 1 outlet turbo oil gasket to the cylinder block sub-assembly.

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

  6. INSTALL TURBOCHARGER SUB-ASSEMBLY

    1. A300231C01

      *a

      Turbocharger Side

      *b

      Compressor Side

      Install a new inlet turbo oil gasket to the turbocharger sub-assembly as shown in the illustration.

    2. A295039C01

      *a

      RH

      *b

      Rear

      Install a new turbo to exhaust manifold gasket to the exhaust manifold.

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

      53 N*m

      540 kgf*cm

      39 ft.*lbf

      Note:

      • When installing the turbocharger sub-assembly, do not hold it by the electric actuator rod.

      • Do not drop the gasket when connecting the turbo oil inlet pipe sub-assembly.

    4. Connect the 2 turbocharger sub-assembly connectors.

  7. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

    1. A294237E02

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

      11 N*m

      112 kgf*cm

      8 ft.*lbf

    2. Tighten the 2 nuts (B).

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  8. INSTALL MANIFOLD STAY

    1. Install the manifold stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  9. INSTALL TURBOCHARGER STAY

    1. Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder head sub-assembly with the 2 bolts and nut.

    2. A357446C02

      *A

      w/o Glow Plug Controller

      *B

      w/ Glow Plug Controller

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

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  10. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ Glow Plug Controller)

    1. Install a new water by-pass gasket to the turbocharger sub-assembly.

    2. Install the No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the 4 bolts.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

  11. CONNECT NO. 2 TURBO WATER HOSE (w/ Glow Plug Controller)

    1. Connect the No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

  12. CONNECT NO. 1 TURBO WATER HOSE (w/ Glow Plug Controller)

    1. Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

  13. CONNECT NO. 1 AIR HOSE

    1. A295030C02

      *a

      View A

      *b

      LH

      *c

      Front

      *d

      200° (Hose Clamp Bolt Area)

      *e

      Paint Mark

      *f

      Stopper

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

    2. A295676N01

      Tighten the hose 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 the distance (B) is 0 to 2 mm (0 to 0.0787 in.).

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

  14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o Glow Plug Controller)

    Click here

  15. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ Glow Plug Controller)

    Click here

  16. CLEAR DTC (P0046)

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

  17. PERFORM TURBOCHARGER INITIALIZATION