Turbocharger - Installation

INSTALLATION






NOTE: When installing a new turbocharger or reinstalling a used turbocharger, NEW turbocharger to exhaust manifold screws MUST be used.

1. Install the lower turbocharger to exhaust manifold mounting screws. Hand tighten.
2. Install the upper turbocharger mounting screws.
3. Tighten turbocharger mounting screws to 28 Nm (250 in. lbs.) using the sequence indicated.










4. Install the turbocharger support bracket to the cylinder block. Tighten the mounting bolts to 55 Nm (40 ft. lbs.).
5. Install catalytic converter Catalytic Converter - Installation
6. Install turbocharger oil return tube and mounting bolt. Tighten bolts to 12 Nm (106 in. lbs.).










7. If the brass fitting to the turbocharger was removed, install new fitting and tighten to 41 Nm (30 ft. lbs.).
8. Using new washers (2), install turbocharger coolant lines. Tighten banjo fitting bolts to 40 Nm (29 ft. lbs.) (1).
9. Position turbocharger heat shield (6) on turbocharger. Tighten bolts to 17 Nm (12 ft. lbs.).
10. Install the compressor to exhaust manifold support bracket. Tighten the compressor bolt to 12 Nm (106 in. lbs.) and the exhaust manifold bolt to 17 Nm (150 in. lbs.).
11. Install turbocharger oil supply tube to turbocharger. Tighten flared fitting to 31 Nm (23 ft. lbs.).
12. Install rear engine bracket.
13. Install right front and front splash shield.










14. Lower vehicle.
15. Install turbocharger inlet tubing. Tighten clamp to 1.7 Nm (15 in. lbs.).
16. Connect the vacuum hoses to wastegate solenoid, surge valve, and compressor outlet.
17. Install rear engine lifting bracket
18. Install turbocharger outlet tubing tighten clamp to 1.7 Nm ( 15 in. lbs.).





19. Tighten turbocharger heat shield bolts (1-5) to 17 Nm (12 ft. lbs.).
20. Install air cleaner housing Air Cleaner Body - Installation.
21. Fill cooling system Service and Repair.
22. Change oil and filter.
23. Connect negative battery cable.
24. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
25. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.