0321221 JOHNSON SEAL,Pressure release valve

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 1 g03790859
If necessary, follow Step 3.a through Step 3.j in order to install boost pressure chamber cover (38).
Position a new gasket (37) (not shown) onto boost pressure chamber cover (38).
Position boost pressure chamber cover (38) onto the engine oil cooler. Install bolts (36). Tighten the bolts to a torque of 10 N m (89 lb in)
Install a new sealing washer (35) to banjo bolt (34). Install the banjo bolt assembly to hose assembly (7) and install the remaining new sealing washer (35). Install hose assembly (7) to boost pressure chamber cover (38) finger tight.
Install hose assembly (7) to the correct clip (32).
Install a new sealing washer (39) to banjo bolt (40). Install the banjo bolt assembly to hose assembly (28) and install the remaining new sealing washer (39). Install hose assembly (28) to boost pressure chamber cover (38) finger tight.
Install hose assembly (28) to the correct clip (32).
Install hose assembly (28) to wastegate solenoid (30). Tighten hose clamp (29).
Install clip (27) and clip (33) to hose assembly (7) and hose assembly (28). Ensure that the hose assemblies are correct installed and correctly routed.
Tighten banjo bolt (34) and banjo bolt (39) to a torque of 12 N m (106 lb in). Ensure that the hose assemblies are not strained or come into contact with other components as the banjo bolts are tightened.
Install alternator (31) and the mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure.
Illustration 2 g03790858
Illustration 3 g03790857
Illustration 4 g03790856
Clean the gasket surface of exhaust manifold (23). If necessary, install the studs (26) to turbocharger (10) and exhaust manifold (23). Tighten the studs to a torque of 15 N m (133 lb in).
Clean the gasket surface of turbocharger (10).
Install a new gasket (24) (not shown) to exhaust manifold (23). Ensure that the gasket is correctly orientated.
Install turbocharger (10) to exhaust manifold (23). Note: Do not use the actuator rod to lift the turbocharger.
If necessary, follow Step 8.a through Step 8.f in order to install tube assembly (15) to the cylinder block.
Install new O-ring seals (21) (not shown) to tube assembly (15). Install the tube assembly to the cylinder block. Ensure that the tube assembly is not damaged as the tube assembly is installed to the cylinder block.
Position bracket (19) onto oil cooler (22). Install bolt (18) to the bracket. Tighten the bolt to a torque of 25 N m (221 lb in). Ensure that the bracket is not strained as the bolt is tightened.
Install a new O-ring seal (17) (not shown) to tube assembly (20).
Install tube assembly (20) onto oil cooler (22). Ensure that the tube assembly is correctly orientated.
Install bolts (16) to tube assembly (20). Tighten the bolts to a torque of 25 N m (221 lb in).
Fill the coolant from the coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Install a new gasket (11) (not shown) between turbocharger (10) and tube assembly (15).
Install bolts (12) to tube assembly (15). Tighten the bolts to a torque of 10 N m (89 lb in).
Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.
Install tube assembly (13) to turbocharger (10) and the cylinder block. Connect tube nut (14) hand tight.
Position a new sealing washer (2) (not shown) onto banjo bolt (1). Install banjo bolt (1) onto tube assembly (13) and install remaining new sealing washer (2) to banjo bolt (1).
Tighten banjo bolt (1) to a torque of 35 N m (26 lb ft). Tighten tube nut (14) to a torque of 25 N m (221 lb in).Note: Ensure that the tube assembly is not strained and does not come into contact with any other engine component.
Connect hose assembly (5) to turbocharger (10). Tighten hose clamp (4) for the hose assembly. Ensure that hose clamp is correctly positioned on the hose assembly.
Connect hose assembly (5) to wastegate actuator (9). Tighten hose clamp (8) for the hose assembly. Ensure that hose clamp is correctly positioned on the hose assembly.
Connect the hose assemblies to turbocharger inlet (6) and to turbocharger outlet (3). Tighten the hose clamps securely. End By:
Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.