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

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

Torque:

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

Text in Illustration

*1	Collar
	Engine Side

NOTICE:

1. Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
   
2. Tighten the nuts in the order shown in the illustration.
   

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

HINT:

It is easier to install the turbo oil inlet pipe if the 3 nuts are only loosely installed.

Temporarily install the turbo oil inlet pipe.

Text in Illustration

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

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

   NOTICE:

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

2. Install a new gasket and the oil inlet pipe with the 2 bolts, but only loosely install the bolts.
   

   NOTICE:

   The claws of the gasket must face the pipe.

3. Install a new gasket and the oil inlet pipe with the union bolt, but only loosely install the union bolt.
   

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

Tighten the 3 nuts of the turbocharger.

Torque:

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

Tighten the 2 nuts and 2 bolts of the turbo oil inlet pipe, and the union bolt.

Torque:

for bolt:

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

for nut:

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

for union bolt:

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

Tighten the 2 bolts and nut of the turbocharger stay.

Torque:

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

Install a new gasket and the turbine outlet elbow with the 4 new nuts.

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install the No. 1 exhaust manifold heat insulator with the 2 bolts.

Torque:

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

Install the air cleaner hose and air No. 3 cleaner hose with the clamp labeled A as shown in the illustration.

HINT:

Align the protrusion of the turbocharger and the protrusion of the hose.

Install the compressor inlet elbow with the clamp labeled B as shown in the illustration.

HINT:

Install the inlet elbow with the clamp labeled B as shown in the illustration.

Connect the 2 ventilation hoses to the cylinder head cover and compressor inlet elbow.

Install the ventilation pipe to the cylinder head with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 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}

Connect the connector to the mass air flow meter.

Tighten the hose clamp.

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.