Turbocharger (G2778635): Installation

NOTE: If a new cylinder head is installed only 303-1449-02 must be used.

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- Install the special tools.
  Special Tool(s): 303-1449-01 , 303-1449-02
- Install the exhaust manifold gasket.
  Renew Part: Exhaust manifold gasket Quantity: 1 .
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- Install the turbocharger.
- Install 2 new bolts, spacers and washers in the illustrated positions.
  Renew Part: Exhaust manifold bolts Quantity: 2 .
- Use the special tool to tighten the 2 bolts, spacers and washers.
  Special Tool(s): JLR-303-1683
  
  Torque : 5 Nm
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Remove the special tools.

Special Tool(s): 303-1449-01 , 303-1449-02
Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC
- Install 11 new bolts, spacers and washers in the illustrated positions.
  Renew Part: Exhaust manifold bolts Quantity: 11 .
- Use the special tool to tighten the 11 bolts, spacers and washers.
  Special Tool(s): JLR-303-1683
  
  Torque : 720°
CAUTION: Allow 4 hours for the thread locking compound to cure.

Fig 1: Turbocharger Tightening Sequence
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Use the special tool to tighten the 13 bolts in the illustrated sequence.

Special Tool(s): JLR-303-1683

Torque

Stage 1: 8 Nm

Stage 2: 12 Nm

Stage 3: 15 Nm

Stage 4: 135°

Stage 5: 24 Nm
- Install 2 new O-ring seals.
  Renew Part: Oil return pipe O-ring seal Quantity: 2 .
- Install the oil return pipe.
- Install and tighten the bolt.
  Torque : 10 Nm
- Install the 2 new oil supply pipe sealing washers.
- Install a new banjo bolt.
- Reposition the oil supply pipe in the correct location.
- Tighten the bolt.
  Torque : 18 Nm
- Install the turbocharger inner heatshield to the clip.
- Install and tighten the bolt.
  Torque : 9 Nm
- Install the turbocharger rear heatshield to the clip.
- Install and tighten the 2 bolts.
  Torque : 9 Nm
- Install the turbocharger front heatshield to the 2 clips.
- Install the turbocharger upper heatshield to the 2 clips.
- Install and tighten the 2 bolts.
  Torque : 6.5 Nm
- Install and tighten the 3 bolts.
  Torque : 9 Nm
- Install 2 new O-ring seals.
  Renew Part: Turbocharger coolant pipe O-ring seal Quantity: 2 .
- Connect the 2 coolant pipes to the turbocharger.
- Install and tighten the bolt.
  Torque : 11 Nm
- Secure the coolant pipe to the clip.
- Install and connect the coolant pipe.
- Secure the clip.
Connect the turbocharger actuator electrical connector.
Install and tighten the turbocharger mounting bolt.
Torque : 26 Nm
Install the catalytic converter.
Refer to: CATALYTIC CONVERTER
Install the electric supercharger.
Refer to: ELECTRIC SUPERCHARGER
Install the charge air cooler inlet pipe.
Refer to: CHARGE AIR COOLER INLET PIPE