Drain engine coolant.
Remove the engine cover.
Disconnect the battery negative terminal (A).
Remove the air cleaner assembly.
Disconnect the MAFS (Mass Air Flow Sensor) connector (B).
Remove the breather hose (C).
Remove the air hose (D).
Tightening torque :
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Remove the air cleaner assembly (E) after removing 3 bolts.
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Loosen the difference pressure sensor connector fixing bolt (A) after disconnecting the connector.
Remove the connector bracket (B) after disconnecting the exhaust gas temperature sensor (#1) connector and lambda sensor connector. (1.6L only)
Disconnect turbo charger actuator vacuum hose (C).
Remove the heat protector (D).
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
Disconnect the heater hoses (A).
Install the heater hoses as shown illustrations.
Remove the water hose (A) from the EGR cooler and the thermostat housing.
Remove the EGR cooler (A).
Tightening torque :
Bolt (B, D) : 21.6 ~ 27.5N.m (2.2 ~ 2.8kgf.m, 15.9 ~ 20.3lb-ft)
Nut (C) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
Remove the EGR valve assembly (A) and the EGR pipe (B).
Tightening torque :
Bolt (C, D) : 21.6 ~ 27.5N.m (2.2 ~ 2.8kgf.m, 15.9 ~ 20.3lb-ft)
Bolt (E) : 29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)
Remove the front muffler (A).
Tightening torque :
39.2 ~ 58.9N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lb-ft)
Remove the driveshaft. (Refer to Driveshaft in DS group)
Remove the catalytic converter brackets (A, B, C).
Tightening torque :
39.2 ~ 49.1N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)
Remove the catalytic converter (A).
Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)
Remove the intercooler pipe (A).
Tightening torque :
4.9 ~ 6.9N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)
It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
The clip wing must be located on the position mark of hose and must not run over it.
The groove of hose must be in line with the protrusion of the pipe or turbocharger.
The band must be located on the position mark of hose and must not run over it.
Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
Remove the turbocharger oil feed pipe (A) and drain pipe (B).
Tightening torque :
Bolt (C) : 13.7 ~ 18.6N.m (1.4 ~ 1.9kgf.m, 10.1 ~ 13.7lb-ft)
Bolts (F) : 9.8 ~ 14.7N.m (1.0 ~ 1.5kgf.m, 7.2 ~ 10.9lb-ft)
Nuts (E) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.9 ~ 14.5lb-ft)
Bolt (D) : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Remove the turbocharger (A).
Tightening torque :
44.1 ~ 49.1N.m (4.5 ~ 5.0kgf.m, 32.6 ~ 36.2lb-ft)
Remove the exhaust manifold (A) with the gasket (B) .
Tightening torque :
29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)
Installation is the reverse order of removal.
