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Turbocharger System: Turbocharger: Installation: Installation

WARNING: This page is about a different car, the 2016 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Remove/Install Turbocharger
GC0158170Courtesy of CHRYSLER GROUP, LLC
  1. Clean the oil and coolant line sealing surfaces.
  2. If removed, using a NEW  gasket (2) install the turbocharger oil return line (3). Tighten the bolts (4) to 13 N.m (10 ft. lbs.).
  3. Install a NEW  oil return line grommet into the engine block.
  4. Using care, position the turbo on to the engine block while guiding the oil return tube into the grommet.
    Fig 2: Coolant Tube & Lower Banjo Bolt
    GC0158021Courtesy of CHRYSLER GROUP, LLC
  5. Using a NEW  sealing washers, install the lower banjo bolt (1) securing coolant tube (2) to the turbocharger. Tighten the banjo bolt (1) to 35 N.m (26 ft. lbs.).
    Fig 3: Upper Banjo Bolt & Turbocharger Supply Lines
    GC0146655Courtesy of CHRYSLER GROUP, LLC
  6. Using a NEW  sealing washer, install banjo bolt (2) onto the oil supply line (3) at the engine block. Tighten the banjo bolt (2) to 35 N.m (26 ft. lbs.).
  7. Remove support and lower the vehicle.
    Fig 4: Coolant Tube & Upper Banjo Bolt
    GC0158029Courtesy of CHRYSLER GROUP, LLC
  8. Using a NEW  sealing washers (2), install the upper banjo bolt (1) securing coolant tube (3) to the turbocharger finger tight.
  9. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    Fig 5: Actuator, Turbo, Heat Shield & Bolts
    GC0146654Courtesy of CHRYSLER GROUP, LLC
  10. Install the turbocharger M10 mounting bolts to the engine block and tighten to 55 N.m (41 ft. lbs.).
  11. Install the turbocharger M8 mounting bolt to the cylinder head and tighten the M8 bolts to 25 N.m (18 ft. lbs.).
    Fig 6: Coolant Tube & Upper Banjo Bolt
    GC0158029Courtesy of CHRYSLER GROUP, LLC
  12. Tighten the upper coolant tube banjo bolt (1) to 35 N.m (26 ft. lbs.).
    Fig 7: Turbocharger Oil Supply Line & Upper Banjo Bolt
    GC0158051Courtesy of CHRYSLER GROUP, LLC
  13. Install the turbocharger oil supply line (2). Using a NEW  sealing washers, tighten the upper banjo bolt (1) to 25 N.m (18 ft. lbs.).
  14. Remove the support and lower the vehicle.
    Fig 8: Turbocharger Outlet Flange & O-Ring
    GC0158182Courtesy of CHRYSLER GROUP, LLC
  15. Install a NEW  O-ring seal (1) onto turbocharger (2).
    Fig 9: Turbocharger Outlet Elbow & Bolts
    GC0158084Courtesy of CHRYSLER GROUP, LLC
  16. Install the turbocharger outlet elbow (1). Tighten the bolts (2) to 10 N.m (89 in. lbs.).
    Fig 10: Air Outlet Temperature Sensor
    GC0157442Courtesy of CHRYSLER GROUP, LLC
  17. Connect the turbocharger outlet temperature sensor wire harness connector (1).
    Fig 11: Fuel Rail Cross-Over Line & Bolt
    GC0146745Courtesy of CHRYSLER GROUP, LLC
  18. Install the fuel cross over tube (1). Tighten the bolt (2) to 15 N.m (11 ft. lbs.).
  19. Install the right side exhaust manifold. Refer to MANIFOLD, EXHAUST, INSTALLATION .
  20. Install the left side exhaust manifold. Refer to MANIFOLD, EXHAUST, INSTALLATION .
    Fig 12: Turbocharger-To-EGR Cooler Tube Bolts
    GC0158212Courtesy of CHRYSLER GROUP, LLC
  21. Using a NEW  gasket, install the EGR cooler tube. Tighten the bolts (1) to 25 N.m (18 ft. lbs.).
  22. Raise and support the vehicle.
    Fig 13: EGR Cooler Tube & Bolts
    GC0158036Courtesy of CHRYSLER GROUP, LLC
  23. Install a NEW  gasket on the EGR cooler tube (1). Tighten the bolts (2) to 15 N.m (11 ft. lbs.).
    Fig 14: Remove/Install Diesel Particulate Filter (DPF)
    GC0158187Courtesy of CHRYSLER GROUP, LLC
  24. Using a NEW  gasket (1), install the Diesel Particulate Filter (DPF) elbow (3) onto the turbocharger. Tighten the nuts (2) to 32 N.m (24 ft. lbs.).
  25. Install the transmission. Refer to INSTALLATION .
  26. Install the left front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .
  27. Install the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .
  28. Remove the support and lower the vehicle.
  29. Install the left fuel injector silencer pad.
  30. Install the CAC to turbocharger.
  31. Install the air intake hose to turbocharger and the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 15: Removing/Installing Intake Manifold Silencer
    GC0157987Courtesy of CHRYSLER GROUP, LLC
  32. Install the right fuel injector silencer pad (1).
  33. Install the intake manifold silencer pad (2)
    Fig 16: Removing/Installing Engine Cover
    GC0158138Courtesy of CHRYSLER GROUP, LLC
  34. Install the engine cover (1).
  35. Fill the cooling system. Refer to STANDARD PROCEDURE .
  36. Connect the negative battery cable.
  37. Start the engine and check for leaks.
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