EXHAUST MANIFOLD W/ TURBOCHARGER > INSTALLATION

for Preparation Click here

1. Install a new gasket.
   

2. Install the turbocharger with the 3 nuts.
   

   Torque:

   53 N*m{ 540 kgf*cm , 39 ft.*lbf }

1. Install a new gasket to the turbocharger.
   

   *1	Compressor Side

2. Install the inlet turbo oil pipe with the 2 nuts.
   

   Torque:

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

1. Install 2 new gaskets to the cylinder head and cylinder block.
   

2. Install the turbocharger with exhaust manifold with the 11 nut.
   

   NOTICE:

   Fully tighten the nuts to the exhaust manifold side before tightening the nuts to the turbo oil inlet pipe.

   Torque:

   Nut A:

   43 N*m{ 438 kgf*cm , 32 ft.*lbf }

   Nut B:

   9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

3. Connect the 2 turbocharger connectors.
   

1. Install the manifold stay with the 2 bolts.
   

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Temporarily tighten the No. 2 turbocharger stay with the bolt and nut.
   

2. Fully tighten the nut on the turbocharger side before tightening the bolt on the cylinder head side.
   

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Temporarily tighten the turbocharger stay with the 2 bolts and nut.
   

2. Fully tighten the nut on the turbocharger side before tightening the bolts on the cylinder head side.
   

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Install No. 1 turbo insulator with the 2 bolts.
   

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

1. Install a new gasket onto the turbocharger.
   

2. Install the exhaust manifold converter with 3 new nuts.
   

   Torque:

   26 N*m{ 265 kgf*cm , 19 ft.*lbf }

3. Engage the harness clamp and connect the connector.
   

1. Install a new gasket onto the turbocharger.
   

2. Install the exhaust manifold converter with 3 new nuts.
   

   Torque:

   26 N*m{ 265 kgf*cm , 19 ft.*lbf }

1. Install the No. 1 air hose with the 2 hose clamps.
   

   HINT:

   1. Align the paint mark of the intercooler air hose with the location mark of the turbocharger.
      
   2. Align the paint mark of the intercooler air hose with the location mark of No. 1 air tube.
      
   3. Make sure that the hose clamp is at the correct angle when installing.
      

1. Temporarily tighten the manifold support bracket with the 2 bolts and nut.
   

2. Fully tighten the 2 bolts and nut, as shown in the illustration.
   

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Install the No. 2 manifold support bracket with the bolt and nut.
   

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Install the tail exhaust pipe assembly (Click here).
   

1. Install the tie rod end onto the steering knuckle with a new castle nut.
   

   Torque:

   59 N*m{ 600 kgf*cm , 43 ft.*lbf }

   NOTICE:

   If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

2. Install a new clip.
   

1. Install the O-ring to the oil level dipstick guide.
   

2. Install the oil level dipstick guide with the 2 bolts.
   

   Torque:

   9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

3. Engage the harness clamp and install the oil level dipstick guide and wire harness with the bolt.
   

   Torque:

   9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install the No. 2 turbo insulator with the bolt and nut.
   

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 ft.*lbf }

1. Using SST, install the air fuel ratio sensor.
   

   SST

   09224-00010  
   

   Text in Illustration 

   *1	Fulcrum length

   Torque:

   without SST:

   44 N*m{ 449 kgf*cm , 32 ft.*lbf }

   with SST:

   40 N*m{ 408 kgf*cm , 30 ft.*lbf }

   NOTICE:

   1. The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) (Click here).
      
   2. This torque value is effective when SST is parallel to the torque wrench.
      

2. Engage the 3 wire harness clamps and install the air fuel ratio sensor wire harness.
   

3. Connect the air fuel ratio sensor connector.
   

1. Engage the 3 claws and install the engine cover.
   

1. Install the air cleaner hose.
   

   NOTICE:

   Position the clip so that the claws are centered over the paint mark on the hose.

1. Install the air cleaner case with the 3 bolts.
   

   Torque:

   7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

1. Install the air cleaner filter element.
   

   NOTICE:

   Engage the air cleaner filter element protrusion with the air cleaner case groove.

1. Engage the 2 claws and 2 clamps and install the air cleaner cap.
   

2. Connect the connector and 2 wire harness clamps.
   

   Text in Illustration 

   *1	Wire harness clamp
   *2	Clamp

3. Connect the air cleaner hose to the air cleaner cap.
   

   HINT:

   1. The clamp should contact the air cleaner hose stopper.
      
   2. Make sure that the air cleaner hose recession is securely engaged with the air cleaner cap protrusion.
      

1. Install the front wiper motor and link (Click here).
   

1. Install the exhaust pipe (Click here).