Turbocharger Installation

Turbocharger Installation





Note: The exhaust pipe studs do not come installed on new turbochargers. If the turbocharger is being replaced, new studs will need to be installed.

1. Install the turbocharger oil feed pipe (2) and NEW washers (3) onto the turbocharger.

Caution: Refer to Fastener Caution Fastener Caution.

2. Install the turbocharger oil feed pipe bolt (1) and tighten to 35 Nm (26 lb ft).

3. Install a NEW turbocharger oil return pipe gasket (4).

4. Install the turbocharger oil return pipe (5) onto the turbocharger.

5. Install the turbocharger oil return pipe bolts (6) and tighten to 10 Nm (89 lb in).




6. Install a NEW turbocharger gasket (3) on the turbocharger.

7. Install NEW turbocharger oil feed and oil return pipe gaskets (4, 5).

8. Install the turbocharger (1).

Caution: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

9. Install NEW turbocharger nuts (2) finger tight.

10. Install the turbocharger oil feed and return pipe bolts (6) at the engine block. tighten the bolts to 10 Nm (89 lb in).





Note: The PCV hose and fitting assembly connection is permanent. Reinstall these components as an assembly unless new components are being used.

11. Install the PCV hose and fitting assembly (1) to the turbocharger. Install the PCV hose fitting assembly bolt (2) and tighten to 8 Nm (71 lb in).




12. Tighten the turbocharger nuts in sequence to 30 Nm (22 lb ft) plus 90 degrees.




13. Install the turbocharger bypass valve solenoid (2).

14. Install the turbocharger bypass valve solenoid bolts (1) and tighten to 8 Nm (71 lb in).




15. Install the turbocharger wastegate regulator solenoid valve (1).

16. Install the turbocharger wastegate regulator solenoid valve bracket bolt (2) and tighten to 8 Nm (71 lb in).

17. Connect the turbocharger wastegate regulator solenoid valve hoses to the turbocharger.




18. Install the turbocharger coolant feed pipe (5) and NEW washers (2) on the turbocharger.

19. Install the turbocharger coolant feed pipe bolt (1) and tighten to 35 Nm (26 lb ft).

20. Install a NEW turbocharger coolant feed pipe gasket (4).

21. Install the turbocharger coolant feed pipe bolts (3) and tighten to 10 Nm (89 lb in).

22. Connect the turbocharger coolant feed pipe hose to the engine oil cooler.




23. Install the turbocharger coolant return pipe (2) and NEW washers (4, 5) on the turbocharger.

24. Install the turbocharger coolant return pipe bolt (3) and tighten to 35 Nm (26 lb ft).

25. Connect the turbocharger coolant return pipe to the air bleed hose.

26. Install the camshaft cover heat shield bolt (1) that retains the turbocharger coolant return pipe (2) at the camshaft cover. Tighten the bolt to 10 Nm (89 lb in).




27. Install the turbocharger wastegate actuator (2) and actuator bolts (1) and tighten to 8 Nm (71 lb in).

28. Install the turbocharger wastegate actuator arm retainer (3).




29. Install the turbocharger heat shield (2).

30. Install the turbocharger heat shield bolts (1, 3) and tighten to 14 Nm (124 lb in).