exhaust manifold

exhaust manifold
6A – 36 ENGINE MECHANICAL
EXHAUST MANIFOLD
3
6
5
7
2
8
1
4
9
For Europe
3
6
7
2
8
4
1
9
5
025R200004
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose
(5)
(6)
(7)
(8)
(9)
REMOVAL
manifold.
6. Remove exhaust manifold fixing nuts, then remove
exhaust manifold.
1. Remove the hose from both turbocharger outlet and
intake manifold inlet side, then remove intercooler
assembly.
2. Loosen belt tensioner, remove A/C compressor
assembly.
3. Remove heat protector from turbocharger.
4. Remove water hoses and oil pipes from
turbocharger.
5. Remove turbocharger assembly from exhaust
Water Hose
Heat Protector
Oil Pipe
Oil Pipe
Gasket
ENGINE MECHANICAL 6A – 37
RINSTALLATION
1. Install gasket on the exhaust manifold and tighten
to the specified torque.
Torque : 30 N·m (3.1 kg·m/22 lb ft)
2. Install turbocharger on the exhaust manifold.
Torque : 27 N·m (2.8 kg·m/20.2 lb ft)
3. Install water hoses and oil pipes.
4. Install heat protector to turbocharger.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
5. Install A/C compressor assembly and readjust belt
tensioner.
6. Install the intercooler assembly in the normal
position.
Connect both hoses to turbocharger and intake
manifold.
6A – 38 ENGINE MECHANICAL
TURBOCHARGER
3
6
5
7
2
8
1
4
9
For Europe
3
6
7
2
8
4
1
9
5
025R200004
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose
(5)
(6)
(7)
(8)
(9)
Water Hose
Heat Protector
Oil Pipe
Oil Pipe
Gasket
ENGINE MECHANICAL 6A – 39
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Remove battery.
Drain engine coolant.
Remove air cleaner cover with air duct.
Remove intercooler assembly.
Refer to “Intercooler” in this manual.
Remove water pipe for turbocharger inlet.
Remove oil pipe for turbocharger.
1) Remove eye bolt from turbocharger.
2) Plug oil port on the turbocharger to prevent entry
of foreign materials.
Remove oil drain pipe from turbocharger.
Remove water outlet pipe.
Remove heat protector.
Remove exhaust adaptor.
Remove turbocharger assembly from exhaust
manifold.
For Europe
025R200006
6A – 40 ENGINE MECHANICAL
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque : 27 N·m (2.8 kg·m/20.2 lb ft)
6. Install oil supply pipe to turbocharger.
1) Fill with 100 cc engine oil at the turbocharger oil
supply hole before installing the oil pipe.
2) Turn the turbocharger by hand to lubricate
turbocharger shaft.
3) Install oil supply pipe with new gasket to the
turbocharger and tighten oil supply pipe bolts to
the specified torque.
Torque : 22 N·m (2.2 kg·m/15.9 lb ft) for M10
54 N·m (5.5 kg·m/39.8 lb ft) for M14
For Europe
For Europe
025R200007
2. Install exhaust adaptor.
Torque : 27 N·m (2.8 kg·m/20.2 lb ft)
3. Install heat protector.
4. Install water outlet pipe with gasket.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
5. Install turbocharger oil drain pipe.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
025R200007
7. Install water inlet pipe with new gasket, tighten to
the specified torque.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct, connect both
side hoses.
10. Fill with engine coolant.
11. Install the battery and connect battery cables.
For Europe
025R200006
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