Exhaust Manifold: Service and Repair

EXHAUST MANIFOLD AND TURBOCHARGER [2.0L ENGINE Turbo]

REMOVAL AND INSTALLATION
















Required Special Tools:
- MB991614: Angle Gauge

REMOVAL SERVICE POINT

[[A]] TURBOCHARGER OIL FEED TUBE REMOVAL

CAUTION: Take care not to allow foreign objects to get into the oil passage hole of the turbocharger assembly after the turbocharger oil feed tube is removed.

INSTALLATION SERVICE POINTS

]]A[[ TURBOCHARGER INSTALLATION

1. Clean the fitting between turbocharger oil tube and turbocharger water pipe, the inside of eye bolts, the inside of tube and the inside of pipe for clogs.

CAUTION: Take care not to allow foreign objects to get into the turbocharger.

2. Clean or use compressed air to remove any carbon particles stuck to the oil passage of the turbocharger.
3. Refill new engine oil at the turbocharger oil feed tube fitting hole of the turbocharger.

]]B[[ TURBOCHARGER BRACKET/TURBOCHARGER BRACKET AND TURBOCHARGER ASSEMBLY COUPLING BOLT INSTALLATION







1. Check that the turbocharger bracket is in close contact with the turbocharger assembly and with the cylinder block. Then, temporarily tighten the turbocharger bracket mounting bolts, the turbocharger bracket and the turbocharger assembly coupling bolts.
2. Tighten the turbocharger bracket mounting bolts to the specified torque.

Tightening torque: 51 ± 7 N.m (38 ± 5 ft-lb)

3. Tighten the turbocharger bracket and turbocharger assembly coupling bolt to the specified torque.

Tightening torque: 64 ± 5 N.m (48 ± 3 ft-lb)

]]C[[ EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY COUPLING BOLT AND NUT INSTALLATION

1. Tighten the bolts and nuts according to the procedure below.







1. Install two washers with their identification holes facing outside as shown in the figure.
2. Tighten the bolts and nuts to the specified torque.

Tightening torque: 29 ± 2 N.m (22 ± 1 ft-lb)

CAUTION:
- When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
- When the tightening angle is larger than the specified tightening angle, remove the bolt and nut to start from the beginning again according to the procedure.







3. Use special tool MB991614 to tighten bolts and nuts 65 ± 5 degrees angle.

]]D[[ TURBOCHARGER OIL RETURN TUBE GASKET INSTALLATION







Install the gasket as its protrusion is in the direction shown.Install the gasket so that its protrusion faces in the direction shown in the illustration.

]]E[[ TURBOCHARGER EXHAUST OUTLET FITTING BRACKET INSTALLATION







1. Check that the turbocharger exhaust outlet fitting bracket is in close contact with the turbocharger exhaust outlet fitting and with the cylinder block, and then temporarily tighten the turbocharger exhaust outlet fitting bracket mounting bolts.
2. Tighten the bolt of the cylinder block side to the specified torque.

Tightening torque: 51 ± 7 N.m (38 ± 5 ft-lb)

3. Tighten the bolt of the turbocharger exhaust outlet fitting bracket side to the specified torque.

Tightening torque: 64 ± 5 N.m (48 ± 3 ft-lb)