LINES AND HOSES
REMOVAL - LINES AND HOSES
COOLANT SUPPLY LINE
1. Raise vehicle on hoist.
2. Drain cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
3. Remove banjo bolt from coolant supply line at turbocharger.
4. Disconnect coolant supply line flared fitting from brass fitting at engine block.
5. Remove coolant supply line.
COOLANT RETURN LINE
1. Drain cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
2. Remove air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL).
3. Disconnect Inlet Air Temperature (IAT) sensor connector.
4. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose.
5. Loosen hose clamp at throttle body.
6. Disconnect charge air cooler hose from throttle body. Reposition charge air cooler hose.
7. Remove fastener securing coolant return line bracket to cylinder head cover stud.
8. Remove hose clamp from coolant return line at heater tube. Disconnect hose from heater tube.
9. Remove banjo bolt from coolant return line at turbocharger.
10. Remove coolant return line.
OIL SUPPLY LINE
1. Raise vehicle on hoist.
2. Remove elbow support bracket.
3. Disconnect oil supply line flared fitting from brass fitting at engine block.
4. Lower vehicle.
5. Disconnect oil supply line flared fitting from brass fitting at turbocharger.
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.
INSTALLATION - LINES AND HOSES
COOLANT SUPPLY LINE
1. If brass fitting was removed from engine block, apply thread sealer to threads and install in engine block. Tighten brass fitting to 41 N·m (30 ft. lbs.).
2. Position coolant supply line to mounting location.
3. Install NEW washers (2) on banjo fitting of coolant supply line. Hand start banjo bolt.
4. Hand start flared fitting of coolant supply line.
5. Tighten banjo fitting bolt to 37 N·m (27 ft. lbs.).
6. Tighten flared fitting to 31 N·m (23 ft. lbs.).
7. Lower vehicle.
8. Fill cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
COOLANT RETURN LINE
1. Position coolant return line to mounting location.
2. Install NEW washers (2) onto banjo fitting of coolant return line. Hand start banjo bolt.
3. Install hose onto heater tube. Install hose clamp.
4. Tighten banjo fitting bolt to 37 N·m (27 ft. lbs.).
5. Install fastener securing coolant return line bracket to cylinder head cover stud.
6. Connect charge air cooler hose to throttle body.
7. Tighten hose clamp to 1.7 N·m (15 in. lbs.).
8. Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose.
9. Connect Inlet Air Temperature (IAT) sensor connector.
10. Install air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION).
11. Fill cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
OIL SUPPLY LINE
1. If brass fitting was removed from engine block or turbocharger, apply thread sealer to threads and install. Tighten brass fitting to 41 N·m (30 ft. lbs.).
2. Position oil supply line to mounting location.
3. Hand start flared fitting at turbocharger.
4. Raise vehicle on hoist.
5. Hand start flared fitting at engine block.
6. Tighten flared fittings to 31 N·m (23 ft. lbs.).
7. Install elbow support bracket.
8. Lower vehicle.
OIL RETURN LINE
1. Clean gasket surfaces.
2. Install new gasket.
3. Install oil return line hose over crankcase nipple.
4. Install the two fasteners securing the oil return line to the turbocharger. Tighten fasteners to 12 N·m (105 in. lbs.).
5. Install hose clamp for oil return line hose.
6. Lower vehicle.