Turbocharger Coolant Return Pipe Replacement

Turbocharger Coolant Return Pipe Replacement

Removal Procedure




1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill LE5, L61) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Static Fill LNF) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716 Fill) (Cooling System Draining and Filling (GE 47716 Fill)).
2. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LNF) (Service and Repair)Catalytic Converter Replacement (LAP) (Service and Repair).
3. Remove the O2 sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Heated Oxygen Sensor Replacement - Sensor 1).
4. Remove the charge air cooler. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement).
5. Remove the AC EVAP hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement (Air Conditioning Evaporator Hose Assembly Replacement).
6. Remove the rear condenser tube. Refer to Condenser Tube Replacement (LNF) (Condenser Tube Replacement).
7. Disconnect the brake booster vacuum hose and reposition.
8. Disconnect the shifter bracket from the transmission and reposition. Leave the cables attached.
9. Remove the turbo exhaust pipe heat shield bolts (1) and shield (2).




10. Remove the turbo heat shield bolts (1) and the turbo heat shield (2).




11. Remove the turbo brace bolts (1) the turbo brace nut (2) and the turbo brace (3),




12. Remove the turbo exhaust pipe nuts (1) and elbow (2).




13. Remove the banjo bolts (1) and the turbocharger coolant return pipe (2).

Installation Procedure




1. Install NEW gaskets to the banjo fittings (1) on the turbocharger coolant return pipe (2).

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the turbocharger coolant return pipe banjo bolts (1) and tighten to 35 Nm (26 lb ft).




3. Install a NEW turbo exhaust pipe gasket (3).
4. Install the turbo exhaust pipe elbow (2) and nuts (1) and tighten to 50 Nm (37 lb ft).




5. Install the turbo brace (3) the turbo brace bolts (1) and the turbo brace nut (2) and tighten to 58 Nm (43 lb ft).




6. Install the turbo heat shield (2) and the turbo heat shield bolts (1) and tighten to 9 Nm (80 lb in).




7. Install the turbo exhaust pipe heat shield (2) and the heat shield bolts (1).
8. Connect the shifter bracket to the transmission and reposition. Leave the cables attached.
9. Connect the brake booster vacuum hose.
10. Install the rear condenser tube. Refer to Condenser Tube Replacement (LNF) (Condenser Tube Replacement).
11. Install the AC EVAP hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement (Air Conditioning Evaporator Hose Assembly Replacement).
12. Install the charge air cooler. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement).
13. Install the O2 sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Heated Oxygen Sensor Replacement - Sensor 1).
14. Install the catalytic converter. Refer to Catalytic Converter Replacement (LNF) (Service and Repair)Catalytic Converter Replacement (LAP) (Service and Repair).
15. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill LE5, L61) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Static Fill LNF) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716 Fill) (Cooling System Draining and Filling (GE 47716 Fill)).