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.

Tighten the PCV hose fitting bolt 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.

Tighten the turbocharger oil return pipe bolts to 10 Nm (89 lb in).

7. Install a new turbocharger gasket.
8. Install the turbocharger.
9. Install the turbocharger nuts.

Tighten
* 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 bracket.
11. Install the turbocharger brace bracket bolt.

Tighten the turbocharger brace bolt to 58 Nm (43 lb ft).

12. Install the turbocharger brace.
13. Install the turbocharger brace nuts.

Tighten the turbocharger brace nuts to 50 Nm (37 lb ft).

14. Install the turbocharger brace bolt.

Tighten the turbocharger brace bolt to 50 Nm (37 lb ft).

15. Install the turbocharger brace bracket and bolt to the turbocharger brace if necessary.

Tighten the turbocharger brace bracket bolt to 22 Nm (16 lb ft).




16. Install the turbocharger coolant feed pipe.
17. Install the turbocharger coolant feed pipe gaskets.
18. 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).

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




20. Install the turbocharger air cooler outlet pipe.
21. Install the turbocharger air cooler outlet pipe bolts.

Tighten the turbocharger air cooler outlet pipe bolts to 25 Nm (18 lb ft).




22. Install the turbocharger coolant return pipe.
23. Install the turbocharger coolant return pipe gaskets.
24. Install the turbocharger coolant return pipe bolts.

Tighten the turbocharger coolant return pipe bolts 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.

25. Install the turbocharger oil feed pipe.
26. Install the turbocharger oil feed pipe gaskets.
27. Install the turbocharger oil feed pipe bolts.

Tighten the turbocharger oil feed pipe bolts to 20 Nm (15 lb ft).




28. Install the turbocharger exhaust pipe seal.
29. Install the turbocharger exhaust pipe.
30. Install the turbocharger exhaust pipe bolt.

Tighten the turbocharger exhaust pipe bolt to 22 Nm (16 lb ft).

31. Install the turbocharger exhaust pipe nuts.

Tighten the turbocharger exhaust pipe nuts to 50 Nm (37 lb ft).




32. Install the turbocharger exhaust pipe heat shield.
33. Install the turbocharger exhaust pipe heat shield bolts.

Tighten the turbocharger exhaust pipe heat shield bolts to 10 Nm (89 lb in).




34. Install the turbocharger heat shield.
35. Install the turbocharger heat shield bolts.

Tighten the turbocharger heat shield bolts to 10 Nm (89 lb in).