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Home >> Subaru >> 2004 >> Forester XT, Standard >> Repair and Diagnosis >> Engine Mechanical >> Exhaust >> Exhaust (H4DOTC) >> Center Exhaust Pipe >> Installation

Center Exhaust Pipe: Installation

NOTE: Replace the gaskets with new ones.
  1. Install the center exhaust pipe and temporarily tighten the bolt which holds center exhaust pipe to hanger bracket.
  2. Temporarily tighten the bolt which holds center pipe to transmission.
  3. Connect the center exhaust pipe to turbocharger.
    1. Tightening torque: 35 N.m (3.6 kgf-m, 26.0 ft-lb) 
    Fig 1: Connecting Center Exhaust Pipe To Turbocharger
    G00967197Courtesy of SUBARU OF AMERICA, INC.
  4. Install the center exhaust pipe to rear exhaust pipe.
    1. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) 
    Fig 2: Identifying Rear Exhaust Pipe
    G00967198Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the connector to rear oxygen sensor.
    Fig 3: Connecting Connector To Rear Oxygen Sensor
    G00967199Courtesy of SUBARU OF AMERICA, INC.
  6. Secure the clip on crossmember.
    Fig 4: Identifying Clip On Crossmember
    G00967200Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the bolt which holds center exhaust pipe bracket to transmission.
    1. Tightening torque: 30 N.m (3.1 kgf-m, 22.4 ft-lb) 
    Fig 5: Tightening Bolt Which Holds Center Exhaust Pipe Bracket To Transmission
    G00967201Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the bolt which holds center exhaust pipe to hanger bracket.
    1. Tightening torque: 35 N.m (3.6 kgf-m, 26.0 ft-lb) 
    Fig 6: Tightening Bolt Which Holds Center Exhaust Pipe To Hanger Bracket
    G00967202Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten the bolts which hold intercooler bracket.
    1. Tightening torque: 35 N.m (3.6 kgf-m, 26.0 ft-lb) 
  10. Lower the vehicle.
  11. Place the turbocharger lower cover, and tighten the bolts which install upper side of lower cover.
    1. Tightening torque: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) 
    Fig 7: Tightening Bolts Which Install Upper Side Of Lower Cover
    G00967203Courtesy of SUBARU OF AMERICA, INC.
  12. Place the turbocharger upper cover, and tighten the bolts which install upper side of upper cover.
    1. Tightening torque: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) 
    Fig 8: Identifying Bolts & Upper Cover
    G00967204Courtesy of SUBARU OF AMERICA, INC.
  13. Lift-up the vehicle.
  14. Tighten the bolts which install under side of turbocharger upper cover.
    1. Tightening torque: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) 
    Fig 9: Tightening Bolts Which Install Under Side Of Turbocharger Upper Cover
    G00967205Courtesy of SUBARU OF AMERICA, INC.
  15. Install the universal joint.
  16. Align the bolt hole on long yoke side of universal joint with the cutout at serrated section of shaft end, and insert the universal joint.
  17. Align the bolt hole on short yoke side of universal joint with the cutout at serrated section of gearbox assembly. Lower the universal joint completely.
  18. Temporarily tighten the bolt on short yoke side. Raise the universal joint to make sure the bolt is properly passing through the cutout at serrated section.
  19. Tighten the bolt on long yoke side, then that on the short yoke side.
    1. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) 
    CAUTION:
    • Make sure that the universal joint bolts are tightened through notches in shaft serration.
    • Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation.
    1. Standard clearance between gearbox to DOJ: Over 15 mm (0.59 in) 
    Fig 10: Tightening Bolt Of Long And Short Yoke Side
    G00967206Courtesy of SUBARU OF AMERICA, INC.
  20. Install the under cover.
  21. Lower the vehicle.
  22. Install the intercooler bracket.
    Fig 11: Identifying Intercooler Bracket
    G00967207Courtesy of SUBARU OF AMERICA, INC.
  23. Install the intercooler. < Ref. to INSTALLATION , Intercooler . >
  24. Align the center of roll connector.
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