Turbocharger - Install - First Stage Turbocharger
Installation Procedure Without Alignment Tools
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Required Tools | |||
Tool | Part Number | Part Description | Qty |
B | 4C-5597 | Anti-Seize Compound | 1 |
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NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Ensure that turbocharger (3) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
- Test wastegate actuator (22) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.
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Illustration 2 g01974333 - Clean the gasket surface of exhaust manifold (18). If necessary, install studs (21) to turbocharger (3). Tighten the studs to a torque of
18 N·m (160 lb in) . - Install a new gasket (20) to studs (21).
- Position turbocharger (3) onto the exhaust manifold and loosely install nuts (19).
Note: Ensure that the turbocharger is correctly oriented.
Show/hide tableIllustration 3 g02352967 Show/hide tableIllustration 4 g02386497 Turbocharger tightening sequence viewed from the exhaust manifold. - Apply sufficient pressure in position (A) to ensure that the studs (21) are in the lowest position on manifold (18) and horizontal. Do not release the pressure from the turbocharger in Position (A) until nuts (19) have been tightened securely.
- Tighten nuts (19) in the sequence shown in Illustration 4 to a torque of
44 N·m (32 lb ft) .Show/hide tableIllustration 5 g01974558 Show/hide tableIllustration 6 g01973256 - Remove plugs and caps from tube assemblies. Ensure that tube assembly (13) and tube assembly (17) are clean and free from damage. Replace any damaged components.
- Position a new gasket (15) (not shown). Install bolts (8) to tube assembly (17). Tighten bolt (8) to a torque of
22 N·m (195 lb in) . - Remove the plug from oil inlet port (23). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
- Install a new sealing washer (14) to banjo bolt (12). Install the banjo bolt to tube assembly (13). Install the remaining new sealing washer (14) to banjo bolt (12).
- Position tube assembly (13) onto turbocharger (3). Tighten banjo bolt (13) to a torque of
20 N·m (177 lb in) .Show/hide tableIllustration 7 g01973253 - Use Tooling (B) to lubricate the bolt for V-band clamp (6). Position V-band clamp (6) onto elbow (7).
- Position hose assembly (11) and elbow (7) onto the outlet of turbocharger (10) and turbocharger (3). Tighten the V-band clamp to a torque of
12 N·m (106 lb in) . - Tighten hose clamps (11) securely.
- Ensure that elbow (1) is free from wear and damage. If necessary, replace the elbow that is worn or damaged.
- Use Tooling (B) to lubricate the bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
- Use Tooling (B) to lubricate the bolt for V-band clamp (9). Position V-band clamp (9) onto turbocharger (10).
- Position elbow (1) onto turbocharger (3) and turbocharger (10).
- Tighten V-band clamp (2) and V-band clamp (7) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
- Tighten V-band clamp (2) and V-band clamp (9) to a torque of
12 N·m (106 lb in) . - Connect hose assembly (4) to the wastegate actuator.
- Connect hose assembly to air outlet (5) to turbocharger (3). Tighten the hose clamps securely.
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Illustration 1 | g01974473 |
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