Turbocharger Coolant Line: Service and Repair

LINES AND HOSES

REMOVAL - LINES AND HOSES





NOTE: For line and hose location refer to (Fig. 24).

COOLANT SUPPLY LINE
1. Raise vehicle on hoist.
2. Drain cooling system.





3. Remove banjo bolt from coolant supply line at turbocharger (Fig. 25).





4. Disconnect coolant supply line flared fitting from brass fitting at engine block (Fig. 26).
5. Remove coolant supply line.

COOLANT RETURN LINE
1. Drain cooling system.





2. Remove turbocharger clean air hose (Fig. 27).





3. Remove fastener securing coolant return line bracket to cylinder head cover stud (Fig. 28).
4. Remove hose clamp from coolant return line at heater tube (Fig. 28). Disconnect hose from heater tube.
5. Remove banjo bolt from coolant return line at turbocharger (Fig. 25).
6. Remove coolant return line.

OIL SUPPLY LINE
1. Raise vehicle on hoist.





2. Remove elbow support bracket (Fig. 29).





3. Disconnect oil supply line flared fitting from brass fitting at engine block (Fig. 30).
4. Lower vehicle.
5. Disconnect oil supply line banjo fitting at turbocharger (Fig. 25).
6. Remove oil supply line.

OIL RETURN LINE
1. Raise vehicle on hoist.
2. Remove the two fasteners securing the oil return line to the turbocharger.
3. Remove hose clamp from oil return line.
4. Remove oil return line from crankcase nipple (Fig. 24).

INSTALLATION - LINES AND HOSES

NOTE: For line and hose location refer to (Fig. 24).

COOLANT SUPPLY LINE
1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Torque brass fitting to 41 Nm (30 ft. lbs.).
2. Position coolant supply line to mounting location.





3. Install NEW washers on banjo fitting of coolant supply line (Fig. 31). Hand start banjo bolt.
4. Hand start flared fitting of coolant supply line.
5. Torque banjo fitting bolt to 37 Nm (27 ft. lbs.) (Fig. 25).
6. Torque flared fitting to 31 Nm (23 ft. lbs.) (Fig. 26).
7. Lower vehicle.
8. Fill cooling system.

COOLANT RETURN LINE
1. Position coolant return line to mounting location.
2. Install NEW washers on banjo fitting of coolant return line (Fig. 31). Hand start banjo bolt.
3. Install hose onto heater tube. Install hose clamp (Fig. 28).
4. Torque banjo fitting bolt to 37 Nm (27 ft. lbs.) (Fig. 25).
5. Install fastener securing coolant return line bracket to cylinder head cover stud (Fig. 28).
6. Install turbocharger clean air hose (Fig. 27).
7. Tighten hose clamps to 1.7 Nm (15 in. lbs.).
8. Fill cooling system.

OIL SUPPLY LINE
1. If brass fitting was removed from engine block, apply thread sealer to threads and install. Torque brass fitting to 41 Nm (30 ft. lbs.).
2. Position oil supply line to mounting location.
3. Install NEW washers on banjo fitting of oil supply line (Fig. 31). Hand start banjo bolt at turbocharger (Fig. 25).
4. Raise vehicle on hoist.
5. Hand start flared fitting at engine block (Fig. 30).
6. Torque flared fitting to 31 Nm (23 ft. lbs.) (Fig. 30) and (Fig. 25).
7. Install elbow support bracket (Fig. 29).
8. Lower vehicle.
9. Torque banjo fitting bolt to 37 Nm (27 ft. lbs.) (Fig. 25).

OIL RETURN LINE
1. Clean gasket surfaces.
2. Install new gasket.
3. Install oil return line hose over crankcase nipple (Fig. 24).
4. Install the two fasteners securing the oil return line to the turbocharger. Torque fasteners to 12 Nm (105 in. lbs.).
5. Install and tighten hose clamp for oil return line hose.
6. Lower vehicle.