XC90 2.5T AWD L5-2.5L Turbo VIN 59 B5254T2 (2003)
new gaskets. Lift and install the manifold and turbocharger (TC)
the nuts and washers holding the manifold to the cylinder head
the upper and lower turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose
the pipe screws for the coolant pipes. Use new seal washers. Tighten
the oil pressure pipe
the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten!
Lubricate the studs on the turbocharger (TC). Use paste 116 1408.
Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten! Install the heat deflector plate over the manifold.
Installing the rear camshaft seal
To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.
Note! For cleaning, work around the shaft journal - not in and out. It is essential that any residue from the emery cloth and any other
contaminants are completely removed before the new seal ring is installed.
Use drift 999 5450 PUNCH See: Tools and Equipment/999 5450 Punch.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.
Note! If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.
Install camshaft adjustment tool 999 5452 CAMSHAFT ADJUSTMENT TOOL See: Tools and Equipment/999 5452 Camshaft Adjustment Tool at the
rear of the camshafts.
Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing the front camshaft seals