Turbocharger Installation

Install the 2 stud bolts (turbo oil outlet pipe side).

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the 3 stud bolts (exhaust manifold side).

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the 3 stud bolts (exhaust manifold convertor side).

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install a new gasket and the turbo oil outlet pipe with the 2 nuts.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Temporarily install 2 new gaskets, No. 1 turbo water pipe sub-assembly and No. 2 turbo water pipe sub-assembly with the 2 union bolts and bolt.

Tighten the 2 union bolts (^*2).

Torque:

38 N*m{388 kgf*cm, 28 ft.*lbf}

Tighten the bolt (^*1).

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Install the No. 1 turbo water hose to the turbocharger sub-assembly.

HINT:

Install the clip an line up the paint marks as shown in the illustration.

Install the No. 1 turbo water hose to the No. 1 turbo water pipe.

Install a new gasket and turbocharger sub-assembly with the 3 nuts.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

Temporarily install 2 new gaskets and No. 2 turbo oil pipe with the 2 union bolts and bolt.

Tighten the 2 union bolts (^*1).

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

Tighten the bolt (^*2).

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Using pliers, slide the clip to install the turbo oil outlet hose.

Connect the No. 3 water by-pass hose.

Install the insulator with the 2 bolts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Install the turbocharger stay with the 3 bolts.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Temporarily install the No. 1 manifold stay.

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the 2 bolts and nut.

Tighten the 3 nuts (Pushing the manifold converter against the No. 1 manifold stay).

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Tighten the 2 bolts and nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Tighten the 2 bolts (Pushing the No. 2 exhaust manifold stay against the manual transmission).

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Tighten the nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Using pliers, slide the clip to install the No. 1 and No. 2 vacuum transmitting hose assembly.

HINT:

Make sure that the paint marks on the No. 1 and No. 2 vacuum transmitting hose assemblies and No. 1 and No. 2 vacuum pipes are aligned.

Using vernier calipers, measure the free length of the compression springs.

Minimum length:

38.5 mm (1.516 in.)

Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly by hand.

NOTICE:

1. Be careful with the installation direction of the gasket.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.
   

   HINT:

   Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

Install the front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold converter and front exhaust pipe assembly.

Install the No. 2 air hose to the intercooler and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

Align the matchmarks, install the No. 1 air tube to the intercooler and secure it with the 2 clips.

HINT:

Make sure that the claws on the 2 clips are positioned as shown in the illustration.

Install the air cleaner cap with air cleaner hose.

1. Connect the No. 2 ventilation hose (^*1).
   

2. Connect the hose band (^*2).
   

3. Connect the mass air flow meter connector (^*3).
   

4. Connect the 3 clamps (^*4).
   

Install the side cover with the 2 clips.

Install the intake duct seal with the 11 clips.

Install the No. 1 engine cover.