Installation

INSTALLATION

COOLANT SUPPLY LINE





1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Tighten brass fitting to 41 Nm (30 ft. lbs.).
2. Position coolant supply line to mounting location.
3. Install NEW washers (2) on banjo fitting of coolant supply line. Hand start banjo bolt.
4. Hand start flared fitting of coolant supply line.
5. Tighten banjo fitting bolt to 37 Nm (27 ft. lbs.).
6. Tighten flared fitting to 31 Nm (23 ft. lbs.).
7. Lower vehicle.
8. Fill cooling system Service and Repair.

COOLANT RETURN LINE





1. Position coolant return line to mounting location.
2. Install NEW washers (2) onto banjo fitting of coolant return line. Hand start banjo bolt.
3. Install hose onto heater tube. Install hose clamp.
4. Tighten banjo fitting bolt to 37 Nm (27 ft. lbs.).
5. Install fastener securing coolant return line bracket to cylinder head cover stud.
6. Connect charge air cooler hose to throttle body.
7. Tighten hose clamp to 1.7 Nm (15 in. lbs.).
8. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose.
9. Connect Inlet Air Temperature (IAT) sensor connector.
10. Install air cleaner housing Air Cleaner Housing - Installation.
11. Fill cooling system Service and Repair.

OIL SUPPLY LINE

1. If brass fitting was removed from engine block or turbocharger, apply thread sealer to threads and install. Tighten brass fitting to 41 Nm (30 ft. lbs.).
2. Position oil supply line to mounting location.
3. Hand start flared fitting at turbocharger.
4. Raise vehicle on hoist.
5. Hand start flared fitting at engine block.
6. Tighten flared fittings to 31 Nm (23 ft. lbs.).
7. Install elbow support bracket.
8. Lower vehicle.

OIL RETURN LINE

1. Clean gasket surfaces.
2. Install new gasket.
3. Install oil return line hose over crankcase nipple.
4. Install the two fasteners securing the oil return line to the turbocharger. Tighten fasteners to 12 Nm (105 in. lbs.).
5. Install hose clamp for oil return line hose.
6. Lower vehicle.