Turbocharger, Remove and Install
 Remove, Disconnect Remove radiator fan shroud with fan motor and radiator - see operation "Radiator, Remove and Install". Detach hose clamps from intake pipe. Unbolt bracket for intake pipe from cylinder head. Remove intake pipe (see illus. I). Detach hose clamp from charge air pipe on turbocharger. Unbolt charge air pipe from intake manifold and remove (see illus. II). Unbolt heat shield from turbocharger and remove (see illus. III). Unbolt front exhaust pipe from turbocharger connection (see illus. IV). | 
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Remove, Disconnect Unscrew oil pressure line connector from cylinder block. Collect escaping engine oil! Detach oil return hose clamps and remove hose completely (see illus. I). Unbolt turbocharger support from cylinder block (see illus. II). Unbolt heat shield from turbocharger and remove (see illus. III). Unbolt coolant line bracket from cylinder head. Detach hose clamp and remove hose from thermostat housing (see illus. IV). | 
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Remove, Disconnect Unbolt lower coolant hose connection from cylinder block and press off from water pipe (see illus. I). Unbolt exhaust manifold from cylinder head and remove complete with turbocharger and coolant pipes (see illus. II). Remove old exhaust manifold gasket. Remove coolant pipes (see illus. III). Unbolt turbocharger from exhaust manifold (see illus. IV). | 
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 Clean Clean sealing surfaces on turbocharger, exhaust manifold, lower coolant hose connection and cylinder head.
 Install, Connect Bolt turbocharger to exhaust manifold.
 Tighten (Torque) Turbocharger to exhaust manifold - 22-31 Nm / 16-23 lbf. ft.
Install, Connect | 
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Bolt oil return line connection with new gasket to turbocharger. Screw oil pressure line with new seal rings into turbocharger and cylinder block. Bolt line to oil return hose connection. Bolt on coolant pipes with new seal rings. | 
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Install, Connect Place new gaskets for exhaust manifold and lower coolant hose connection. Bolt exhaust manifold with turbocharger and coolant pipes to cylinder head.
Tighten (Torque) | 
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Exhaust manifold to cylinder head - 30 Nm / 22 lbf. ft.
Install, Connect Use new seal ring for coolant pipe. Press lower coolant hose connection onto coolant pipe and bolt to cylinder block. Fasten turbocharger support to cylinder block (see illus.). | 
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Install, Connect Bolt oil pressure line to turbocharger and to cylinder block and install oil return hose (see illus. I). Use new seal rings. Bolt coolant line bracket to cylinder head (1). Attach hose to thermostat housing and fasten hose clamp (2). Bolt heat shield to exhaust manifold (3).
Tighten (Torque) Heat shield to exhaust manifold - 10 Nm / 7 lbf. ft. | 
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Install, Connect Bolt front exhaust pipe to turbocharger connection.
Tighten (Torque) Exhaust pipe to turbocharger connection - 70 Nm / 52 lbf. ft. | 
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Install, Connect Install heat shield at turbocharger - 10 Nm / 7 lbf. ft. Install charge air pipe and air intake hose. Install radiator and radiator fan shroud with fan motor - see operation "Radiator, Remove and Install".
 Inspect Check engine oil level, top up if necessary. Check charge pressure - see operation "Charge Pressure, Check". | 
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