Removal & Installation: Turbocharger: Installation

NOTE: Studs should always be secured with strong Thread Sealant (1161076-5) when installed.

Install new studs (if any are missing). Tighten to specification. See ENGINE SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER article. Install turbocharger. Install hoses according to marking. See Figure.
Install both upper exhaust manifold nuts, and tighten them slightly. See Figure. Raise the car. Install exhaust manifold lower nuts. See Figure. Tighten upper exhaust manifold bolts. Tighten exhaust manifold to turbocharger. Tighten all nuts. Ensure that the surfaces are parallel.
Install lower oil pipe. See Figure. Install oil pipe. Ensure to lubricate "O" ring. Install exhaust pipe bracket bolt. Lower the car.
Install the following components;
- Oil inlet pipe.
- Inlet and outlet coolant pipes (remove lock grip pliers). See Figure.
- Fresh air intake hose.
- Inner heat deflector plate.
- Upper charge air pipe.
- Outer heat deflector plate.
Install new copper washers for the coolant pipe and for the upper oil pipe.
Raise the car. Install clamp between pipes. Remove lock grip pliers from coolant return hose. Lower the car.
Test drive the engine. Check the boost pressure. See appropriate SYSTEM & COMPONENT TESTING article in ENGINE PERFORMANCE.
Check the oil and coolant levels.