Turbocharger Coolant Line: Service and Repair

LINES AND HOSES

REMOVAL

COOLANT SUPPLY LINE





1. Raise vehicle on hoist.
2. Drain cooling system.





3. Remove banjo bolt (2) from coolant supply line (3) at turbocharger.





4. Disconnect coolant supply line (3) flared fitting (2) from brass fitting (1) at engine block.
5. Remove coolant supply line.

COOLANT RETURN LINE





1. Drain cooling system.
2. Remove air cleaner housing.
3. Disconnect Inlet Air Temperature (IAT) sensor connector.
4. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose.
5. Loosen hose clamp at throttle body.
6. Disconnect charge air cooler hose from throttle body Reposition charge air cooler hose.
7. Remove fastener securing coolant return line bracket to cylinder head cover stud.
8. Remove hose clamp from coolant return line (2) at heater tube. Disconnect hose from heater tube.
9. Remove banjo bolt from coolant return line at turbocharger.
10. Remove coolant return line.

INSTALLATION

COOLANT SUPPLY LINE





1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Torque brass fitting to 41 Nm (30 ft. lbs.).
2. Position coolant supply line to mounting location.
3. Install NEW washers (2) on banjo fitting of coolant supply line. Hand start banjo bolt.
4. Hand start flared fitting of coolant supply line.
5. Torque banjo fitting bolt to 37 Nm (27 ft. lbs.).
6. Torque flared fitting to 31 Nm (23 ft. lbs.).
7. Lower vehicle.
8. Fill cooling system.

COOLANT RETURN LINE





1. Position coolant return line to mounting location.
2. Install NEW washers (2) Banjo fitting of coolant return line. Hand start banjo bolt.
3. Install hose onto heater tube. Install hose clamp.
4. Torque banjo fitting bolt to 37 Nm (27 ft. lbs.).
5. Install fastener securing coolant return line bracket to cylinder head cover stud.
6. Connect charge air cooler hose to throttle body.
7. Tighten hose clamp to 1.7 Nm (15 inch lbs.).
8. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose.
9. Connect Inlet Air Temperature (IAT) sensor connector.
10. Install air cleaner housing.
11. Fill cooling system.