Installation Procedure (Side Mounted Turbochargers)
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
Test the wastegate actuator (19) for correct operation. If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced.
Clean the mating surfaces of the exhaust manifold (12). If necessary, install the four studs (13) to the exhaust manifold. Tighten the studs to a torque of 18 N�m (13 lb ft). Install a new joint (14) to the exhaust manifold (12).
Position the turbocharger (6) on the exhaust manifold. Ensure that the turbocharger is correctly oriented.
Install the four nuts (15). Tighten the nuts to a torque of 44 N�m (32 lb ft).
If a new turbocharger is installed, the bearing housing (18) and the compressor housing (20) must be oriented to the correct positions.
Loosen the two band clamps (21) sufficiently in order to allow the housings to rotate. If the band clamps are damaged, replace the band clamps.
Carefully turn the bearing housing (18) until the port for the oil feed (17) is upward. Rotate the compressor housing (20) until the compressor outlet is in the correct position. Ensure that the band clamps (21) are correctly oriented.
Tighten the band clamps finger tight.
Ensure that the tube assemblies (3) and (10) are clean and free from damage. Replace any damaged components. Position a new joint (7) and the two setscrews (8) onto the tube assembly (10).
Install the tube assembly (10) to the turbocharger (6). Tighten the setscrews (8) finger tight.
Position a new joint (9) between the flange of the tube assembly (10) and the cylinder block. Install the two setscrews (11) finger tight.
If a new turbocharger has been installed, check that the orientation of the bearing housing (18) is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until the tube assembly (10) fits correctly. Tighten the two band clamps (21) to a torque of 13 N�m (9.6 lb ft).
Tighten the setscrews (8) and (11) to a torque of 22 N�m (16 lb ft).
Remove the plug from the oil inlet port (17). 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.
Use Tooling in order to lubricate a new O-ring seal (4). Install the O-ring seal (4) to the tube assembly (3).
Install the banjo bolt (1) and two new sealing washers (2) to the tube assembly (3).
Install the tube assembly (3) to the cylinder block and to the turbocharger (6). Tighten the banjo bolt (1) finger tight.
Install the setscrew (5) finger tight. Ensure that the tube assembly (3) fits correctly. Tighten the banjo bolt (1) to a torque of 20 N�m (14 lb ft). Tighten the setscrew (5) and (11) to a torque of 22 N�m (16 lb ft).
If the turbocharger has an exhaust elbow, install the exhaust elbow.
Connect the exhaust pipe. If the turbocharger has a remote wastegate solenoid, connect the hose for the solenoid to the turbocharger.
Connect the air inlet hose and connect the air outlet hose to the turbocharger.
Installation Procedure (Top Mounted Turbochargers)
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the wastegate actuator (19) for correct operation. If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced.
Clean the mating surfaces of the exhaust manifold (1). If necessary, install the four studs (16) to the exhaust manifold. Tighten the studs to a torque of 18 N�m (13 lb ft). Support the exhaust manifold during installation of the turbocharger. Install a new joint (15) to the exhaust manifold (1).
Position the turbocharger (12) on the exhaust manifold (1).
Install the four nuts (11). Tighten the nuts to a torque of 44 N�m (32 lb ft).
If a new turbocharger is installed, the bearing housing (18) and the compressor housing (20) must be oriented to the correct positions.
Loosen the two band clamps (21) sufficiently in order to allow the housings to rotate. If the band clamps are damaged, replace the band clamps.
Carefully turn the bearing housing (18) until the port for the oil feed (17) is upward.
Rotate the compressor housing (20) until the compressor outlet is in the correct position.
Ensure that the band clamps (21) are correctly oriented. Tighten the band clamps finger tight.
Ensure that the tube assemblies (4) and (7) are clean and free from damage. Replace any damaged components. Position a new joint (13) and the two setscrews (14) onto the tube assembly (4).
Install the tube assembly (4) to the turbocharger (12). Tighten the setscrews (14) finger tight. Remove the plug from the oil inlet port (17). 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 the banjo bolt (9) and two new sealing washers (10) to the tube assembly (7). Use Tooling in order to lubricate a new O-ring seal (6). Install the O-ring seal (6) to the tube assembly (7). Install the tube assembly (7) to the turbocharger (12). Tighten the banjo bolt (9) finger tight.
Install the exhaust manifold (1) and the assembly of the turbocharger to the cylinder head.
Install the setscrew (8) finger tight. Ensure that the tube assembly (7) fits correctly.
Position a new joint (3) between the flange of the tube assembly (4) and the cylinder block. Install the two setscrews (5) finger tight.
If a new turbocharger has been installed, check that the orientation of the bearing housing (18) is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until the tube assemblies (4) and (7) fit correctly. Tighten the two band clamps (21) to a torque of 13 N�m (9.6 lb ft).
Tighten the banjo bolt (9) to a torque of 20 N�m (14 lb ft). Tighten the setscrew (5) and (8) to a torque of 22 N�m (16 lb ft).
Install the fasteners for the tube clips (2) to the cylinder block.
If the turbocharger has an exhaust elbow, install the exhaust elbow.
Connect the exhaust pipe.
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