Removal and Installation

CAUTION:

To prevent scalding by the hot exhaust parts, wait until the engine cools down to room temperature.

NOTE:

Use fender covers to avoid damaging painted surfaces.
When handling the metal gasket, be careful not to fold or damage the surface.
To avoid damage, disconnect the wiring connectors carefully.
Replace all gaskets with new ones. Do not reuse.

Disconnect the negative battery terminal.
Remove the engine cover.
(Refer to the Engine And Transaxle Assembly - "ENGINE COVER ")
Remove the engine room under cover.
(Refer to the Engine And Transaxle Assembly - "ENGINE ROOM UNDER COVER ")
Remove the front muffler.
(Refer to the Intake And Exhaust System - "MUFFLER ")
Remove the engine wiring connectors and harness clamps around the exhaust manifold and then remove the connector brackets and wiring protector.

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Disconnect the O2 sensor connector (A) from wiring bracket.

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Remove the heat protector (A).
Tightening torque:

7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)

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Remove the lower heat protector (A).
Tightening torque:

7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)

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Remove the WCC bracket mounting nut (A) and WCC stay mounting nuts (B).
Tightening torque:

Stay mounting bolt (to Block): 39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb-ft)

Stay mounting nut (to WCC): 18.6 - 24.5 N.m (1.9 - 2.5 kgf.m, 13.7 - 18.1 lb-ft)

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Remove the V-clamp (A), and then remove the WCC (B).
Tightening torque:

13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)

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Remove the air duct and air intake hose.
(Refer to the Intake And Exhaust System - AIR CLEANER ")
Disconnect the intercooler inlet hose (A).

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NOTE:
- When separate the intercooler inlet pipe, pull out the quick connector clamp (A).
- When working with quick connector type intercooler hoses and pipes, be careful not to touch or detach the rubber seal (B) inside.
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- When installing, Align the marks of the intercooler pipes/hoses and assembling parts.
- When mounting, Install it by pushing it all the way until the nipple clicks.
Disconnect the hose (A), and then remove the air intake hose B (B).

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Disconnect the breather hose (A).

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Remove the oil feed pipe (A).
Tightening torque:

Eyebolt: 27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft)

Nut: 7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)

Bolt: 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

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Remove the oil drain pipe (A).
Tightening torque:

7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)

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Disconnect the turbo charger water feed pipe & hose (A) and turbo charger water drain pipe & hose (B).

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Remove the turbo charger & exhaust manifold (A) with the gasket (B)
Tightening torque:

49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

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NOTE:
- Do not reuse the turbo charger & exhaust manifold gasket.
- When installing, pretighten the nuts in the order shown below and then completely tighten the bolts to specified torque in the order.
Fig 1: Turbo Charger And Exhaust Manifold Gasket Nuts Tightening Sequence
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Remove the turbo charger water feed pipe & hose (A) and turbo charger water drain pipe & hose (B).
Tightening torque:

26.5 - 23.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb-ft)

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Remove the electric WGT control actuator (A) after loosening the mounting bolts.
Tightening torque:

11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)

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Install in the reverse order of removal

NOTE:

Adjust the EWGA rod.

(Refer to Engine Control/Fuel System - "ELECTRIC WASTE GATE ACTUATOR (EWGA) ")