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Home >> Mercury >> 1992 >> Capri Base, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.3L 4-CYL - VIN [H] & 1.6L 4-CYL - VINS [Z,6] >> Removal & Installation >> Exhaust Manifold >> Installation (1.6L Turbo)

Installation (1.6L Turbo)

  1. Position new gasket on exhaust manifold, and install turbocharger onto studs. Install 4 retaining nuts and tighten to specification. See TORQUE SPECIFICATIONS  table at end of article.
    NOTE: Turbocharger-to-exhaust manifold mounting nuts are of special quality. Ensure correct nuts are used.
  2. Remove oil supply line from turbocharger. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first. Carefully position turbocharger assembly in engine compartment and slide exhaust manifold on studs. Position heater tube bracket onto exhaust stud. Install 11 retaining nuts onto exhaust manifold and tighten to specification. See TORQUE SPECIFICATIONS  table at end of article. Tighten heater tube clamp bolt securely.
  3. Raise vehicle. Position new gasket and install 2 retaining bolts on heater tube outlet. Install 2 retaining bolts into turbocharger support bracket and tighten bolts to specification.
  4. Connect coolant return hose. Connect oil return hose and secure with clamp. Position exhaust pipe onto turbocharger, and start nuts and washers. Install 2 retaining bolts on exhaust hanger at engine. Slide on 2 rubber exhaust hangers at catalytic converter. Tighten exhaust pipe retaining nuts to specification. Lower vehicle.
  5. Install retaining bolt and brass washers on oil supply line, carefully position oil line into vehicle and hand-start bolt into engine block. Connect and finger tighten oil line to turbocharger. Tighten oil line bolt and oil supply line on turbocharger to specification.
    NOTE: Ensure one brass washer is positioned on each side of oil line fitting.
  6. Connect coolant supply hose. Position air cleaner duct tube on turbocharger and tighten clamp. Install 2 screws retaining air cleaner duct tube. Position power steering pump bracket on engine, and install 2 retaining bolts and one retaining nut. Tighten to specification. Position power steering pump on mounting bracket, and install though bolt and adjuster. Connect lower radiator hose. Install power steering belt. Position upper heat shield and install 2 retaining bolts finger tight.
    NOTE: Feed O2 sensor wire through upper heat shield. Install wire retainer under LH bolt.
  7. Position lower heat shield and install three retaining bolts finger tight. Tighten all heat shield bolts to specification. Connect O2 sensor and install connector into its retaining clip. See TORQUE SPECIFICATIONS  table at end of article. Position intercooler hose on turbocharger and secure with clamp. Install throttle body air intake tube. Connect negative battery cable. Refill cooling system.
NOTE: If turbocharger was replaced: Disconnect ignition coil, crank engine for 20 seconds, connect ignition coil, start engine and run at idle for 30 seconds and check for leaks.
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