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EXHAUST SYSTEM AND TURBOCHARGER

11 - 1

EXHAUST SYSTEM AND TURBOCHARGER

TABLE OF CONTENTS

page

DESCRIPTION AND OPERATION

EXHAUST SYSTEM........................1

EXHAUST HEAT SHIELDS ..................1

REMOVAL AND INSTALLATION

EXHAUST PIPE ...........................1

MUFFLER AND EXHAUST TAILPIPE...........2

EXHAUST MANIFOLD AND TURBOCHARGER

(LHD..................................2

EXHAUST MANIFOLD AND TURBOCHARGER

(RHD..................................5

INTAKE MANIFOLD.......................10

SPECIFICATIONS

TORQUE SPECIFICATIONS .................10

DESCRIPTION AND OPERATION

may result in excessive temperatures in the exhaust

system and on the floor pan.

EXHAUST SYSTEM

The basic exhaust system consists of an engine

exhaust manifold, turbocharger,exhaust down pipe,

exhaust

pipe,

exhaust

heat

shield(s),

muffler

and

exhaust tailpipe

The exhaust system uses a single muffler.

The exhaust system must be properly aligned to

prevent stress, leakage and body contact. If the sys-

tem contacts any body panel, it will transfer objec-

tionable noises originating from the engine to the

body.

When inspecting an exhaust system, critically

inspect for cracked or loose joints, stripped screw or

bolt threads, corrosion damage and worn, cracked or

broken

hangers.

Replace

all

components

that

are

badly

corroded

damaged.

NOT

attempt

Fig. 1 Heat Shields

1 – EXHAUST MANIFOLD HEAT SHIELD

2 – DOWN PIPE HEAT SHIELD

repair.

When replacement is required, use original equip-

ment parts (or equivalent). This will assure proper

alignment and provide acceptable exhaust noise lev-

els.

REMOVAL AND INSTALLATION

CAUTION: Avoid application of rust prevention

compounds or undercoating materials to exhaust

system floor pan exhaust heat shields. Light over-

spray near the edges is permitted. Application of

coating will result in excessive floor pan tempera-

tures and objectionable fumes.

EXHAUST PIPE

WARNING: IF TORCHES ARE USED WHEN WORK-

ING ON THE EXHAUST SYSTEM, DO NOT ALLOW

THE FLAME NEAR THE FUEL LINES.

REMOVAL

(1) Raise and support the vehicle.

(2) Saturate the bolts and nuts at turbo down pipe

to exhaust pipe with heat valve lubricant. Allow 5

minutes for penetration..

(3) Disconnect bolts from exhaust pipe to turbo

down pipe (Fig. 2).

EXHAUST HEAT SHIELDS

Exhaust heat shields are needed to protect both

the vehicle and the environment from the high tem-

peratures (Fig. 1).

DO NOT allow the engine to operate at fast idle for

extended

periods

(over

minutes).

This

condition

11 - 2

EXHAUST SYSTEM AND TURBOCHARGER

REMOVAL AND INSTALLATION (Continued)

(3) Use a new clamp and tighten the nuts to 43

N·m torque.

(4) Lower the vehicle.

(5) Start the engine and inspect for exhaust leaks

and exhaust system contact with the body panels.

Adjust the alignment, if needed.

MUFFLER AND EXHAUST TAILPIPE

All original equipment exhaust systems are manu-

factured with the exhaust tailpipe welded to the muf-

fler.

Service

replacement

mufflers

and

exhaust

tailpipes

are

either

clamped

together

welded

together.

WARNING: IF TORCHES ARE USED WHEN WORK-

ING ON THE EXHAUST SYSTEM, DO NOT ALLOW

THE FLAME NEAR THE FUEL LINES.

REMOVAL

(1) Raise and support the vehicle.

(2) Remove

Fig. 2 Exhaust Down Pipe to Exhaust Pipe

1 – EXHAUST INLET PIPE RETAINING BOLTS

2 – EXHAUST SYSTEM SUPPORT CLAMP

the

front

muffler

clamp

from

the

exhaust pipe and muffler connection.

(3) Remove the rear exhaust tailpipe hanger clamp

and

(4) Remove the clamp nuts at muffler (Fig. 3). To

remove the exhaust pipe from the muffler, apply heat

until the metal becomes cherry red. Disconnect the

exhaust pipe from the muffler. Remove the exhaust

pipe.

remove

the

exhaust

tailpipe

from

the

front

exhaust tailpipe hanger.

(4) Remove the exhaust tailpipe assembly from the

muffler.

INSTALLATION

(1) Install the muffler onto the exhaust pipe.

Install the clamp and tighten the nuts finger tight.

(2) Install the exhaust tailpipe into the rear of the

muffler.

(3) Install the exhaust tailpipe/muffler assembly

on the rear exhaust tailpipe hanger. Make sure that

the exhaust tailpipe has sufficient clearance from the

floor pan.

(4) Install

the

remaining

clamps

and

the

front

exhaust tailpipe hanger.

(5) Tighten the nuts on the muffler-to-exhaust pipe

clamp to 43 N·m torque.

(6) Lower the vehicle.

(7) Start the engine and inspect for exhaust leaks

and exhaust system contact with the body panels.

Adjust the alignment, if needed.

Fig. 3 Front Pipe to Muffler

EXHAUST MANIFOLD AND TURBOCHARGER

(LHD)

1 – BRACKET

2 – FRONT PIPE

3 – RUBBER ISOLATOR

4 – MUFFLER

REMOVAL

(1) Disconnect the negative battery cable

(2) Disconnect the breather hose from air cleaner

outlet hose (Fig. 4).

INSTALLATION

(1) Assemble exhaust pipe to muffler, loosely to

permit proper alignment of all parts.

(2) Connect the exhaust pipe to the turbo down

pipe manifold. Tighten the bolts to 22.5 N·m torque.

EXHAUST SYSTEM AND TURBOCHARGER

11 - 3

REMOVAL AND INSTALLATION (Continued)

Fig. 5 Exhaust System Inlet Pipe Connection

1 – EXHAUST INLET PIPE RETAINING BOLTS

2 – EXHAUST SYSTEM SUPPORT CLAMP

Fig. 4 Engine Compartment

1 – INTAKE MANIFOLD ELBOW

2 – BREATHER HOSE

3 – INNERCOOLER OUTLET HOSE

4 – AIR FILTER COVER

5 – AIR FILTER OUTLET (FRESH AIR) HOSE

6 – INNERCOOLER INLET HOSE

7 – HEATER CORE COOLANT SUPPLY HOSES

(3) Remove the air filter cover and hose from tur-

bocharger, remove the assembly (Fig. 4).

(4) Remove the EGR vacuum supply hose from the

EGR valve.

(5) Remove the innercooler inlet and outlet hoses

from the engine (Fig. 4).

(6) Remove the (2) bolts holding the EGR tube to

the EGR valve.

(7) Remove the intake manifold elbow and EGR

valve as an assembly.

(8) Raise the vehicle on a hoist.

(9) Drain the cooling system. Refer to Group 7,

Cooling System for procedure.

(10) Remove

the

exhaust

system

support

clamp

(Fig. 5).

(11) Disconnect the exhaust system at the (3) bolt

flange (Fig. 5).

Fig. 6 Exhaust Downpipe Heatshield

1 – EXHAUST MANIFOLD DOWNPIPE HEATSHIELD RETAINING

STRAPS

CAUTION: Heatshield is very sharp. Wear gloves to

prevent injury.

(16) Remove the (2) exhaust manifold heatshield

retaining bolts and remove the heatshield.

(17) Remove the heater supply and return hoses

from the vehicle.

(18) Remove

(12) Unstrap

the

exhaust

downpipe

heatshield

(Fig. 6).

(13) Disconnect the turbocharger oil return hose

from the engine block (Fig. 7).

(14) Lower the vehicle from the hoist.

(15) Remove the EGR tube from exhaust manifold.

the

oil

pressure

supply

line

bango

bolt from the turbocharger.

11 - 4

EXHAUST SYSTEM AND TURBOCHARGER

REMOVAL AND INSTALLATION (Continued)

Fig. 7 Turbocharger Oil Return Hose

1 – VEHICLE UNDERBODY

2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT

3 – TURBOCHARGER OIL RETURN HOSE

4 – EXHAUST MANIFOLD DOWNPIPE

5 – TURBOCHARGER

Fig. 8 Turbocharger / Exhaust Manifold Assembly

1 – OIL RETURN LINE

2 – WASTEGATE VACUUM SUPPLY HOSE

3 – TURBO TO EXHAUST MANIFOLD RETAINING NUTS

4 – BENCH VISE

5 – TURBOCHARGER ASSEMBLY (REMOVED FROM VEHICLE)

6 – WASTEGATE VACUUM ACTUATOR

CAUTION: Heatshield is very sharp. Wear gloves to

prevent injury.

(3) Install the exhaust manifold and turbocharger

assembly in the vehicle

(4) Install the (8) exhaust manifold retaining nuts.

Torque nuts to 32 N·m (23 ft. lbs.).

(5) Install the exhaust manifold downpipe. Torque

bolts to 32 N·m (23 ft. lbs.).

(19) Remove the exhaust downpipe heatshield by

pulling straight up.

(20) Remove the (5) bolts attaching the exhaust

downpipe to the turbocharger and remove pipe.

(21) Remove the (8) exhaust manifold retaining

bolts, it is necessary to access the bolt behind the

manifold outlet from the underneath of the vehicle.

(22) Remove

CAUTION: Heatshield is very sharp. Wear gloves to

prevent injury.

the

exhaust

manifold

and

turbo-

charger assembly from the vehicle

(23) Place assembly in a vice to remove the (3)

exhaust manifold to turbocharger retaining nuts (Fig.

8).

(6) Slide the exhaust downpipe heatshield down

over pipe. Do not attempt to strap heatshield in posi-

tion at this time, wait until vehicle is raised on hoist.

(7) Install the oil supply line on turbocharger.

Torque bango bolt fitting to 27 N·m (20 ft. lbs.).

(8) Connect the heater hoses.

(9) Position and install the exhaust manifold heat-

shield. Torque bolts to 11 N·m (97 in. lbs.).

(10) Raise the vehicle on a hoist.

(11) Connect the turbocharger oil return line to the

engine block (Fig. 9).

(12) Strap the exhaust downpipe heatshield in its

original position.

(13) Install

Cleaning

Always use new gaskets during assembly. All gas-

ket mating surfaces must be cleaned of old gasket

material to produce a smooth and dirt free sealing

surface for the new gasket.

INSTALLATION

(1) Transfer the oil return line to the new turbo-

charger (Fig. 8).

(2) Install the turbo on the exhaust manifold (Fig.

8). Torque the nuts to 32 N·m (23 ft. lbs.).

the

exhaust

system

support

clamp

(Fig. 10). Torque nuts to 23 N·m (17 ft. lbs.).

EXHAUST SYSTEM AND TURBOCHARGER

11 - 5

REMOVAL AND INSTALLATION (Continued)

(16) Install the intake manifold elbow and EGR

valve as an assembly. Torque bolts to 27 N·m (20 ft.

lbs.).

(17) Install the (2) bolts holding the EGR tube to

the EGR valve. Torque bolts to 27 N·m (20 ft. lbs.).

(18) Install the innercooler inlet and outlet hoses

on the engine (Fig. 11).

Fig. 9 Turbocharger Oil Return Hose

1 – VEHICLE UNDERBODY

2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT

3 – TURBOCHARGER OIL RETURN HOSE

4 – EXHAUST MANIFOLD DOWNPIPE

5 – TURBOCHARGER

(14) Connect the exhaust system at the (3) bolt

flange (Fig. 10). Torque the bolts to 23 N·m (17 ft.

lbs.).

Fig. 11 Engine Compartment

1 – INTAKE MANIFOLD ELBOW

2 – BREATHER HOSE

3 – INNERCOOLER OUTLET HOSE

4 – AIR FILTER COVER

5 – AIR FILTER OUTLET (FRESH AIR) HOSE

6 – INNERCOOLER INLET HOSE

7 – HEATER CORE COOLANT SUPPLY HOSES

(19) Install the EGR vacuum supply hose on the

EGR valve.

(20) Install the air filter cover and outlet hose on

turbocharger (Fig. 11).

(21) Connect the breather hose on the air cleaner

outlet hose (Fig. 11).

(22) Fill

the

cooling

system.

Refer

Group

Cooling System for procedure.

(23) Connect the negative battery cable

(24) Start the engine and check for leaks.

EXHAUST MANIFOLD AND TURBOCHARGER

(RHD)

Fig. 10 Exhaust System Inlet Pipe Connection

1 – EXHAUST INLET PIPE RETAINING BOLTS

2 – EXHAUST SYSTEM SUPPORT CLAMP

REMOVAL

(1) Disconnect the negative battery cable

(2) Disconnect

the

breather

hose

from

the

air

cleaner outlet hose.

(15) Lower the vehicle from the hoist.

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