Installing Turbocharger

Information 

You will need a second mechanic to help you with this step.

1. Install turbocharger.

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   Turbocharger

   1. 1.1  Position the turbocharger.
   2. 1.2  Secure coolant supply line -2-  to the turbocharger.
      1. 1.2.1  Replace O-rings.
      2. 1.2.2  Push on coolant supply line -2-  .
      3. 1.2.3  Screw in and tighten screw for coolant supply line -1-  .
         • Tightening torque 9 Nm (6.5 ftlb.) 
2. Secure turbocharger -1-  .

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   Turbocharger

   1. 2.1  Replace exhaust flange seal.
   2. 2.2  Fit exhaust flange.
   3. 2.3  Replace nuts on exhaust flange -4-  .
   4. 2.4  Screw on and tighten new  nuts on exhaust flange -4-  .
      • Tightening torque 25 Nm (19 ftlb.) 
   5. 2.5  Fit heat shield for turbocharger -3-  .
   6. 2.6  Screw in and tighten screws for heat shield on turbocharger -2-  .
      • Tightening torque 9 Nm (6.5 ftlb.) 
3. Secure coolant return line and oil supply line -1 and 2-  .

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   Coolant return line and oil supply line

   1. 3.1  Replace O-rings.
   2. 3.2  Connect line connections from coolant return line and oil supply line -1 and 2-  .
   3. 3.3  Screw in and tighten screw for coolant return line -3-  .
      • Tightening torque 9 Nm (6.5 ftlb.) 
   4. 3.4  Screw in and tighten screw for oil supply line -4-  .
      • Tightening torque 9 Nm (6.5 ftlb.) 
4. Push on and lock electric plug connections for recirculating air valve -1-  and electronic adjuster -2-  .

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   Electric plug connections

5. Install oil return line -1-  .

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   Oil return line

   1. 5.1  Replace O-rings.
   2. 5.2  Insert oil return line -1-  .
   3. 5.3  Screw in and tighten screw securing oil return line -2-  to turbocharger.
      • Tightening torque 9 Nm (6.5 ftlb.) 
   4. 5.4  Screw in and tighten screw securing oil return line -2-  to engine.
      • Tightening torque 25 Nm (19 ftlb.) 
6. Install turbocharger support -1-  .

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   Turbocharger support

   1. 6.1  Position turbocharger support -1-  .
   2. 6.2  Screw in screws on turbocharger support -2-  .
   3. 6.3  Tighten screw securing turbocharger support -2-  to turbocharger.
      • Tightening torque 9 Nm (6.5 ftlb.) 
   4. 6.4  Tighten screw securing turbocharger support -2-  to engine.
      • Tightening torque 30 Nm (22 ftlb.) 
7. Secure pressure hose -1-  to the turbocharger.

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   Pressure hose on turbocharger

   1. 7.1  Connect pressure hose -1-  .
   2. 7.2  Tighten screw-type hose clamp -2-  .
      • Tightening torque 5.5 Nm (4 ftlb.)