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Turbocharger Installation (LDK, LHU)

Turbocharger Installation (LDK, LHU)



1. Install a new turbocharger oil return pipe gasket (1).


2. Install the turbocharger oil return pipe (2) on the turbocharger.

3. Refer to Fastener Caution .

Install the turbocharger oil return hose bolts (3) and tighten to 10 Nm (89 lb in) .

4. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.


5. Install the PCV hose fitting bolt and tighten to 10 Nm (89 lb in) .

6. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.

7. Install a new turbocharger gasket (3).

8. Install the turbocharger (2) with the oil return pipe.

9. Install the turbocharger nuts (1).

9.1. Tighten the turbocharger nuts to 30 Nm (22 lb ft) .

9.2. Tighten the turbocharger nuts a second time to 35 Nm (26 lb ft) .

10. Install the turbocharger brace (1).


11. Install the turbocharger stay nuts and tighten to 50 Nm (37 lb ft) .

12. Install the catalytic converter bracket (1).


13. Install the catalytic converter bolts and tighten to 50 Nm (37 lb ft) .

14. Install the turbocharger coolant feed pipe (1).


15. Install the turbocharger coolant feed pipe gaskets.

16. Install the turbocharger coolant feed pipe bolts.

16.1. Tighten the bolts of the turbocharger coolant delivery pipe to 35 Nm (26 lb ft) .

16.2. Tighten the turbocharger coolant feed pipe mounting bolt to 10 Nm (89 lb in) .

17. Connect the positive crankcase ventilation (PCV) and hose assembly.

18. Install the turbocharger air cooler outlet pipe (1).


19. Install the turbocharger air-cooler outlet pipe bolts and tighten to 25 Nm (18 lb ft) .

20.
Warning

Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.


Note

The engine block end of the oil feed pipe fitting has an anti-rotation feature. Ensure that the fitting is fully seated against the block when installing the bolt.


Install the turbocharger oil feed pipe (1) on the engine block side.


21. Install the turbocharger oil feed pipe gasket on the engine block side.

22. Install the bolt and tighten to 40 Nm (30 lb ft) .

23. Install the turbocharger coolant return pipe (1).


24. Install the turbocharger coolant return pipe gaskets.

25. Install the turbocharger coolant return pipe bolts and tighten to 35 Nm (26 lb ft) .

26.
Warning

Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.


Install the turbocharger oil feed pipe (1) onto the turbocharger.


27. Install the turbocharger oil feed pipe gasket for the turbocharger side.

28. Install the turbocharger oil feed pipe bolt and tighten to 40 Nm (30 lb ft) .

29. Install the catalytic converter L-bracket (2) onto the catalytic converter (1).


30. Install the catalytic converter L-bracket nuts and tighten to 50 Nm (37 lb ft) .

31. Install the catalytic converter seal (2).


32. Install the catalytic converter (1).

33. Install the catalytic converter nuts and tighten to 50 Nm (37 lb ft) .

34. Install the catalytic converter bolts and tighten to 50 Nm (37 lb ft) .

35. Install the turbocharger heat shield (1).


36. Install the turbocharger heat shield bolts and tighten to 10 Nm (89 lb in) .