76. Turbocharger Installation

Turbocharger Installation




1. Install a new turbocharger oil return pipe gasket.
2. Install the turbocharger oil return pipe into the engine block.




3. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the PCV hose fitting bolt and tighten to 10 Nm (89 lb in).
5. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
6. Install the turbocharger oil return pipe bolts and tighten to 10 Nm (89 lb in).
7. Install a new turbocharger gasket.
8. Install the turbocharger.
9. Install the turbocharger nuts.

* Tighten the turbocharger nuts to 30 Nm (22 lb ft).
* Tighten the turbocharger nuts a second time to 35 Nm (26 lb ft).




10. Install the turbocharger brace.
11. Install the turbocharger brace nut and tighten to 50 Nm (37 lb ft).




12. Install the catalytic converter bracket.
13. Install the catalytic converter bracket bolt and nut and tighten to 50 Nm (37 lb ft).




14. Install the turbocharger coolant feed pipe.
15. Install the turbocharger coolant feed pipe gaskets.
16. Install the turbocharger coolant feed pipe bolts.

* Tighten the turbocharger coolant feed pipe bolts to 20 Nm (15 lb ft).
* Tighten the turbocharger coolant feed pipe mounting bolt to 10 Nm (89 lb in).

17. Connect the positive crankcase ventilation (PCV) and hose assembly.




18. Install the turbocharger air cooler outlet pipe.
19. Install the turbocharger air cooler outlet pipe bolts and tighten to 25 Nm (18 lb ft).




20. Install the turbocharger coolant return pipe.
21. Install the turbocharger coolant return pipe gaskets.
22. Install the turbocharger coolant return pipe bolts and tighten to 20 Nm (15 lb ft).





Caution: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

23. Install the turbocharger oil feed pipe.
24. Install the turbocharger oil feed pipe gaskets.
25. Install the turbocharger oil feed pipe bolts and tighten to 20 Nm (15 lb ft).




26. Install the catalytic converter seal.
27. Install the catalytic converter.
28. Install the catalytic converter bolts and tighten to 50 Nm (37 lb ft).
29. Install the catalytic converter nuts and tighten to 50 Nm (37 lb ft).




30. Install the turbocharger heat shield.
31. Install the turbocharger heat shield bolts and tighten to 10 Nm (89 lb in).