Disassembly and assembly

18 KENR6226-01
Disassembly and Assembly Section
5. Ensure that tube assemblies (10) and (13) are
clean and free f
rom damage. If necessary, replace
the tube assemblies.
6. If necessary,
position a new joint (11) and tube
assembly (10) onto the cylinder block. Install bolts
(9). Tighten th e bolts finger tight.
Position a new joint (7) on tube assembly (10).
Align tube assembly (10) to the bottom of the
turbocharge
r. Install bolts (8). Tighten the bolts
finger tight.
Tighten bolt
s (8) and (9) to a torque of 10 N·m
(89lbin).
7. Lubricate th
e bearings of turbocharger (4) with
clean engine oil through oil inlet port (16). Rotate
the shaft of the turbocharger in order to distribute
the lubrica
nt.
8. Install a new O-ring seal (12) to tube assembly
(13). Posit
ion tube assembly (13) against the
cylinder block. Install bolts (14). Tighten the bolts
toatorqueof10N·m(89lbin).
9. Install new washers (3) and banjo bolt (2) to tube
assembly (13). Position tube assembly (13) onto
turbochar
ger (4). Tighten the banjo bolt finger
tight.
10. If necessa
ry, install the spacer and install the
fasteners (not shown) to tube clips (6). Torque the
fasteners to 10 N·m (89 lb in).
11. Tighten banjo bolt (2) to a torque of 18 N·m
(13 lb ft).
Note: Ensure that the tube assembly does not come
into contact with any other components.
12. Clean the mating surfaces of exhaust elbow (19).
Position a new gasket (18) and exhaust elbow (19)
on turboc
harger (4). Install allen head screws (21).
Tighten the bolts to a torque of 32 N·m (24 lb ft).
13. Ensure th
at inlet hose (1) is clean and free from
defects or restrictions. Loosely install hose clamps
(5) to air inlet hose (1). Install the air inlet hose to
the conn
ection of the inlet manifold (not shown)
and to the turbocharger. Tighten the hose clamps.
i02959965
Exhaust Manifold - Remove
and Install
Removal Procedure
Start By:
a. If the engine is equipped with a turbocharger,
remove the tur
bocharger. Refer to Disassembly
and Assembly, “ Turbocharger, Remove and
Install”.
NOTICE
Keep all parts
clean from contaminants.
Contaminants may cause rapid wear and shortened
component li
fe.
Note: The two cylinder, the three cylinder and the four
cylinder engines have different exhaust manifolds.
The removal procedure is similar for all models.
g01326567
Illustration 25
Typical example
1. Loosen nuts (5) and bolts (6).
Note: In order to prevent distortion of the exhaust
manifold, loosen the outer fasteners first.
2. Remove nuts (5) and bolts (6).
Note: Identify bolts of different lengths so that the
bolts can be installed in the correct positions.
3. Remove exhaust manifold (4) from cylinder head
(1). Note the orientation of the exhaust manifold
for installation.
4. Remove gasket (3) from cylinder head (1).
This document has been printed from SPI². Not for Resale