Clean the gasket sealing surfaces on the oil drain line and the turbocharger. Clean the o-ring seating bore in the cylinder block, taking care not to drop any dirt and debris into the cylinder block. Clean the turbocharger oil drain line with solvent and dry with compressed air. Inspect the oil drain line for any… Read More »
Clean around the area where the oil drain line inserts into the cylinder block with a clean cloth. Remove the two capscrews that hold the oil drain line to the turbocharger. Pull the oil drain line out of the cylinder block.
Inspect the line for oil leaks or damage. Repair or replace as necessary.
Install the turbocharger coolant supply hose by connecting the hose to the fittings to the cylinder block and into the bottom of the turbocharger bearing housing. Do not tighten the fittings at this time. Install the turbocharger coolant return hose by connecting the hose to the fittings in the EGR cooler coolant inlet and in… Read More »
Clean the coolant hoses with solvent and dry with compressed air. Inspect the sealing a-rings for cuts or deformation. Replace as necessary. Inspect the coolant hoses for cuts, cracks, leaks, or other damage. Replace as necessary.
Disconnect the turbocharger coolant supply hose from the fitting in the cylinder block. Disconnect the turbocharger coolant supply hose from the fitting in the bottom of the turbocharger bearing housing. Remove the turbocharger coolant supply hose. NOTE: Use a second wrench to hold the coolant connection fittings at the cylinder block and the turbocharger bearing… Read More »
Install and tighten the turbocharger oil drain line. Refer to Procedure 01 0-045 in Section 10. Lubricate the bearings by pouring 59 to 89 cc [2 to 3 oz] of clean 15W-40 engine oil in the turbocharger oil supply line fitting. Rotate the turbine wheel to allow oil to enter the bearing housing. NOTE: If… Read More »
NOTE: If installing a new turbocharger, orient the compressor housing to the same position as the turbocharger that was removed. Orient the housing by loosening the v-band clamp and then positioning the housing in the correct location. Do not orient the turbine housing. Torque Value: 8 N•m [ 71 in-lb ] Apply a film of… Read More »
Clean the turbocharger and exhaust manifold gasket surfaces. Inspect the tu rbocharger and exhaust manifold gasket surfaces and mounting studs for cracks and other damage. Replace the turbocharger if any cracks or other damage is found in the mounting flange surfaces. Replace the exhaust manifold if any cracks or other damage is found in the… Read More »
Remove the four turbocharger mounting nuts. Remove the turbocharger and gasket. Cover the turbocharger exhaust inlet port with a protective cap from the Air Handling Clean Care Kit, Part Number 491 9498. Cover the opening on the exhaust manifold with heavy tape.