75. 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.

Notice: Refer to Fastener Notice (Fastener Notice) .

4. Install the PCV hose fitting bolt.

Tighten the PCV hose fitting bolt to 10 N.m (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 N.m (89 lb in).

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

Tighten the turbocharger nuts to 30 N.m (22 lb ft).


Tighten the turbocharger nuts a second time to 35 N.m (26 lb ft).





10. Install the turbocharger brace.
11. Install the turbocharger brace nut.

Tighten the turbocharger brace upper nut to 50 N.m (37 lb ft).





12. Install the catalytic converter bracket.
13. Install the catalytic converter bracket bolt and nut.

Tighten the catalytic converter bracket bolt and nut to 50 N.m (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 N.m (15 lb ft).
* Tighten the turbocharger coolant feed pipe mounting bolt to 10 N.m (89 lb in).


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




18. Install the turbocharger outlet adapter.
19. Install the turbocharger outlet adapter bolts.

Tighten the turbocharger outlet adapter bolts to 25 N.m (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.

Tighten the turbocharger coolant return pipe bolts to 20 N.m (15 lb ft).






Notice: 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.

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





26. Install the catalytic converter seal .
27. Install the catalytic converter.
28. Install the catalytic converter bolts.

Tighten the catalytic converter bolts to 50 N.m (37 lb ft).

29. Install the catalytic converter nuts.

Tighten the catalytic converter nuts to 50 N.m (37 lb ft).





30. Install the turbocharger heat shield.
31. Install the turbocharger heat shield bolts.

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