Exhaust Manifold W/ Turbocharger (W/O Egr Cooler) Installation

Install a new gasket, exhaust manifold and 8 plate washers to the cylinder head with 8 new nuts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

NOTICE:

Tighten the nuts in the order shown in the illustration.

Temporarily install a new gasket and the turbocharger with 3 new nuts.

HINT:

When installing the turbo oil pipe, loosely install the 3 nuts so that the turbocharger and cylinder head can be aligned easily.

Temporarily install the turbo oil pipe and manifold stay.

Text in Illustration

*1	New Gasket	*2	Claw
*3	Narrow	*4	Wide
	Outside	-	-

HINT:

Wash the oil pipe before installing it.

1. Temporarily install a new gasket and the turbo oil pipe with the 2 nuts, but only loosely install the nuts.
   

   NOTICE:

   The notch (wide part) of the gasket must face the engine.

2. Temporarily install a new gasket and the turbo oil pipe with the 2 bolts (labeled: A), but only loosely install the bolts.
   

   NOTICE:

   The claws of the gasket must face the turbo oil pipe.

3. Temporarily install a new gasket and the turbo oil pipe with the union bolt (labeled: B), but only loosely install the union bolt.
   

4. Temporarily install the manifold stay with the 2 bolts.
   

   HINT:

   The manifold stay's indented area must face the turbocharger.

Tighten the bolts and nuts.

1. Tighten the 3 nuts of the turbocharger.
   

   Torque:

   52 N*m{530 kgf*cm, 38 ft.*lbf}

2. Tighten the 2 nuts of the turbo oil pipe.
   

   Torque:

   13 N*m{133 kgf*cm, 10 ft.*lbf}

3. Tighten the 2 bolts of the turbo oil pipe.
   

   Torque:

   12 N*m{122 kgf*cm, 9 ft.*lbf}

4. Tighten the union bolt.
   

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

5. Tighten the 2 bolts of the manifold stay.
   

   Torque:

   19 N*m{194 kgf*cm, 14 ft.*lbf}

Temporarily install a new gasket and the turbine outlet elbow (with turbocharger stay) to the turbocharger with the 4 new nuts.

Temporarily install the turbocharger stay with the 4 bolts.

Tighten the 4 nuts of the turbocharger.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Tighten the 4 bolts of the turbocharger stay.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Connect the No. 2 air cleaner pipe with the 2 air hoses and install the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Tighten the 2 clamps.

Connect the vacuum hose to the gas filter.

Connect the manifold absolute pressure sensor connector.

Install the ventilation hose heat insulator with the 2 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Connect the No. 1 air cleaner hose.

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Tighten the hose clamp.

w/ Mass Air Flow Meter:
Connect the connector to the mass air flow meter.

w/o Mass Air Flow Meter:
Attach the clamp and connect the intake air temperature sensor connector.

Attach the 4 claws to the pins of the cover bracket and install the No. 1 engine cover.

Using a vernier caliper, measure the free length of the compression spring.

Minimum length:

40 mm (1.57 in.)

Install the front exhaust pipe to the exhaust pipe support.

Install a new gasket to the turbine outlet elbow.

NOTICE:

1. Be careful with the installation direction of the gasket.
   

1. Do not reuse the gasket.
   

1. To ensure a proper seal, do not use the front exhaust pipe to force the gasket onto the turbine outlet elbow.
   

HINT:

Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and turbine outlet elbow are properly fit.

Install the front exhaust pipe and 2 compression springs with the 2 bolts. Alternately tighten the bolts in several passes.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

Install the front fender apron seal upper with the 5 clips.

Install the front fender seal with the 5 clips.