Turbocharger - Installation

INSTALLATION

CAUTION: The oil supply and return lines MUST be replaced whenever the lines are loosened or removed.





1. With the manifold removed, invert the manifold and turbocharger.
2. Install a newgasket onto the manifold/turbocharger mating surface.
3. Set the manifold onto the turbocharger studs and install four new nuts (1) by hand.
4. Tighten the four nuts to 25 Nm (18 ft. lbs.).
5. After the nuts are tightened to 25 Nm (18 ft. lbs.) once, repeat the step to be sure that all nuts are at the proper torque.






NOTE: Replace any stud that loosens during removal. If a stud is to be replaced, tighten the new stud to 11 Nm (97 in. lbs.). Age of the vehicle and environment impact how many of the studs come out. Any that stay in the head also need to be checked for the 11 N-m (97 in. lbs.).

NOTE: The turbocharger has been removed for clarity.

6. Install a new manifold gasket/shield assembly.
7. Set the manifold and turbocharger assembly onto the cylinder head studs.
8. Install the nine exhaust manifold washers and new nuts (1).
9. 1) Tighten to 15 Nm (133 in. lbs.) in order from 1 to 9.
10. 2) Retighten to 15 Nm (133 in. lbs.) in order from 1 to 4 only.
11. 3) Add additional 30 degrees of rotation to all in order from 1 to 9.





12. Install thenew converter to turbo seal ring (1).





13. Install the catalytic converter assembly (3).
14. Position the exhaust manifold shield and install the two bolts and one new nut.
15. Tighten the shield bolts to 9 Nm (80 in. lbs.).

CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.

16. Install the catalytic converter v-clamp (2) at the turbocharger (1).
17. Tighten clamp to 8 Nm (71in. lb).
18. Connect the O2 sensor connector.





19. Install the lower catalytic converter support bracket (2).
20. Install and tighten the bracket bolts (3) to 56 Nm (41 ft. lbs.).
21. Install a new converter to pipe gasket.
22. Install the front exhaust pipe.
23. Install the nuts that secure the cross under pipe to the catalytic converter.
24. Tighten the front exhaust pipe nuts to 56 Nm (41 ft. lbs.).





25. Install the front exhaust pipe support bolt (2). Tighten to 56 Nm (41 ft. lbs.).
26. Install the exhaust flange nuts (1). Tighten to 69 Nm (51 ft. lbs.).






NOTE: Banjo bolts and and banjo bolt gaskets must be replaced during assembly.

NOTE: The oil supply and return lines must be replaced during assembly or ANY TIME the fittings are loosened to prevent turbine bearing failure from debris.

27. Connect the vacuum line to the actuator pump (2).
28. Connect the turbocharger pressure sensor hose (1).
29. Install the coolant return line located on the rear side of the turbocharger. Tighten to 38 Nm ( 28 ft. lbs.).
30. Install the coolant supply banjo bolt (4) Tighten to 38 Nm (28 ft. lbs.).
31. Install the oil supply line banjo bolt (3). Tighten to 30 Nm (22 ft. lbs.).
32. Install the lower oil return line (5). Tighten the bolt to 14 Nm (124 in. lbs.).
33. Connect the turbocharger surge valve connector (6).





34. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger.
35. Install the CAC hose clamp and tighten.
36. Install the catalytic converter heat shield (3).





37. Tighten the nuts and bolts to 8 Nm (71 in. lbs.).
38. Connect the upstream and downstream O2 sensor connectors.





39. Install the turbocharger bracket (2), bolts (1) and new nut (3).
40. Tighten the bolts and nut to 25 Nm (18 ft. lbs.).




41. Position the Front End Module onto the front of the vehicle.
42. Install the front cooling module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 Nm (33 ft. lbs.). Tighten the four bolts (1) to 24 Nm (18 ft. lbs.). Tighten the eight bolts (3) to 45 Nm (33 ft. lbs.).





43. Connect the throttle body inlet hose (1) and turbocharger outlet hose (2) at the lower quick disconnects located behind the cooling fan (3).





44. Engage the block heater wire harness retainer (1) at the upper core support.





45. Connect the wire harness connector (1) to the horn (2).
46. Engage the wire harness connector to the bumper reinforcement.





47. Connect the wire harness connector (2) to the right and left front impact sensors (1).





48. Press down the latch release (3) and install the hood latch cable (2) to the latch.





49. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 Nm (10 ft. lbs.).





50. Connect the cooling fan electrical connector (3).
51. Install the upper and lower radiator hoses and clamps. Tighten the clamps.
52. Recharge the AC system to specifications.





53. Connect the electrical connector to the cooling fan resistor (1).





54. Install the right and left headlamp units (2) Headlamp Unit - Installation.
55. Install the fascia assembly Front Bumper Fascia - Installation