Turbocharger.

Turbocharger Replacement

Removal Procedure
1. Disconnect the negative battery cable.




2. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).





3. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
4. Loosen the exhaust pipe clamp. Slide the clamp onto the exhaust pipe.





5. If equipped with an automatic transmission, remove the fill tube to bellhousing nuts.
6. Position the fill tube to the right side of the vehicle. The tube does not require removal from the transmission.





7. Remove the left exhaust heat shield nuts (2) and shield (3) at the front of the lower dash panel.





8. Remove the left exhaust pipe heat shield bolts.
9. Position the left exhaust pipe heat shield in order to access the left exhaust pipe to exhaust manifold bolts. Do not remove the heat shield from the vehicle at this time.





Important: Do not bend the exhaust pipe at the expansion area.

10. Remove the left exhaust pipe to exhaust manifold bolts (2).
11. Remove and discard the gasket.





Important: Do not bend the exhaust pipe at the expansion area.

12. Remove the right exhaust pipe to exhaust manifold bolts (1).
13. Remove and discard the gasket.





14. Remove the lower bolt (2) for the exhaust outlet shield.
15. Lower the vehicle.





16. Loosen the outlet duct clamp at the upper intake manifold cover.
17. Remove the upper intake manifold cover from the outlet duct.
18. Remove the upper intake manifold cover.
19. Drain the cooling system.





Important: After removing the turbocharger ducts, cover the turbocharger openings with tape to prevent entry of objects.

20. Loosen the outlet duct clamps at the turbocharger and the Mass Air Flow/Intake Air Temperature (MAF/IAT) sensor.
21. Remove the outlet duct from the turbocharger.





22. Loosen the charged air cooler outlet duct to intake hose clamp (1).

Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.

23. Remove the charged air cooler outlet duct from the intake.





24. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.

25. Remove the charged air cooler inlet duct from the turbocharger.





26. Disconnect the Air Conditioning (A/C) compressor clutch electrical connector.
27. Disconnect the A/C cut out switch electrical connector.
28. Remove the drive belt.
29. Remove the A/C compressor bolts.
30. Move the A/C compressor with the hoses attached to the right side of the engine compartment.





31. Remove the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.





32. Remove the turbocharger outlet coolant hose from the turbocharger.





33. Remove the Positive Crankcase Ventilation (PCV) hose from the left valve rocker arm cover.
34. Position the hose out of the way.
35. Remove the wire connector from the intake heater.
36. If equipped, remove the intake air heater relay.





37. Remove the turbocharger heat shield bolts.
38. Remove the turbocharger heat shield.





39. Remove the remaining exhaust outlet heat shield bolts (1, 3).
40. Remove the exhaust outlet heat shield.





41. Remove the exhaust outlet bolts and nuts.

Important: The exhaust outlet does not require removal in order to remove the turbocharger.

42. Move the exhaust outlet to one side in order to access the right exhaust pipe to turbocharger bolts.
43. Remove and discard the exhaust outlet gasket.





44. Remove the right exhaust pipe to turbocharger bolts (2).
45. Remove the right exhaust pipe.
46. Remove and discard the gasket.





47. Move the exhaust outlet to one side in order to access the left exhaust pipe.
48. Remove the left exhaust pipe heat shield from the vehicle.
49. Remove the left exhaust pipe to turbocharger bolts (1).
50. Remove the left exhaust pipe.
51. Remove and discard the gasket.





52. Remove the turbocharger oil feed pipe bolt and washers.
53. Move the oil feed pipe out of the way.





54. Remove the turbocharger oil return pipe nuts at the flywheel housing.





55. Remove the turbocharger bolts.
56. Remove the turbocharger with oil return pipe.





57. If required, remove the turbocharger lower heat shield.
58. If required, remove the oil feed pipe bolt, washers, and pipe.





59. If replacing the turbocharger, remove the following items:
^ The oil return pipe
^ The coolant return hose

60. Clean the following gasket surfaces:
^ The oil return pipe to turbocharger
^ The oil return pipe to flywheel housing
^ The air intake tube
^ Both exhaust pipe flanges
^ Both exhaust manifold flanges
^ The exhaust outlet
^ Turbocharger, exhaust outlet
^ Turbocharger, both exhaust pipes

Installation Procedure
1. Install the oil return pipe and a NEW gasket to the turbocharger.





Notice: Refer to Fastener Notice in Service and Precautions.

2. Install the turbocharger oil return pipe bolts.
Tighten the bolts to 21 Nm (16 ft. lbs.).
3. Install the coolant return hose to the turbocharger.





Important: Lubricate the washers with diesel fuel before installing.

4. If required, install the oil feed pipe, bolt, and washers.
Tighten the bolt to 34 Nm (25 ft. lbs.).
5. If required, install the turbocharger lower heat shield.





6. Install the turbocharger.
7. Install the turbocharger bolts.
Tighten the bolts to 108 Nm (80 ft. lbs.).





8. Install a NEW gasket for the oil return pipe.
9. Install the turbocharger oil return pipe nuts
Tighten the nuts to 21 Nm (15 ft. lbs.).





10. If installing a NEW turbocharger, pour about 120 - 150 cc (4 -5 ounces) of clean engine oil in the turbocharger oil feed pipe opening while rotating the impeller.
11. Using NEW sealing washers, install the oil feed pipe and bolt to the turbocharger.
Tighten the bolt to 34 Nm (25 ft. lbs.).





12. Position the left exhaust pipe. The pipe flanges are different. Ensure the proper pipe flange is towards the turbocharger.
13. Install the left exhaust pipe to the turbocharger with a NEW gasket. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.
Tighten the bolts (1) to 53 Nm (39 ft. lbs.).
14. Position the left exhaust pipe heat shield, but do not install the bolts.





15. Install the right exhaust pipe with a NEW gasket to the turbocharger. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the; turbocharger temporarily install one of the pipe to manifold bolts.
16. Install the right exhaust pipe to turbocharger bolts (2).
Tighten the bolts to 53 Nm (39 ft. lbs.).





17. Install the exhaust outlet with a NEW gasket to the turbocharger.
18. Install the exhaust outlet bolts and nuts.
Tighten the bolts/nuts to 53 Nm (39 ft. lbs.).





19. Install the exhaust outlet heat shield.
20. Install the upper 2 exhaust outlet heat shield bolts (1, 3).
Tighten the bolts to 8 Nm (71 inch lbs.).





21. Install the turbocharger heat shield.
22. Install the turbocharger heat shield bolts.
Tighten the bolts to 9 Nm (80 inch lbs.).





23. Install the PCV hose to the upper left valve rocker arm cover.





24. Install the turbocharger outlet coolant hose to the turbocharger.





25. Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
26. Install the inlet air heater relay.

Notice: Refer to Fastener Notice in Service and Precautions.

27. Connect the wire terminal and the nut to intake air heater.
Tighten the nut to 4 Nm (35 inch lbs.).





28. Position the A/C compressor.
29. Install the A/C compressor bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).
30. Install the drive belt.
31. Connect the A/C cut out switch electrical connector.
32. Connect the A/C clutch electrical connector.





33. Remove the tape from the turbocharger Openings. if necessary.
34. Install the charged air cooler snip duct if: tire turbocharger.
35. Align the mark on the duct (2y with the mark on the turbocharger.
36. Position the clamp (1) as shown for proper clearance.
Tighten the clamp to 6 Nm (53 inch lbs.).





37. Install the charged air cooler outlet duct is the intake.
38. Align the mark on the duct (3) with the mark on the intake.
39. Position the clamp (1) as shown for proper clearance.
Tighten the clamp to 6 Nm (53 inch lbs.).





40. Install the outlet duct to turbocharger.
41. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).





Important: The outlet duct must be fully seated against the MAT/IAT sensor with the edge of the seal in the vertical position.

42. Install the outlet duct to the MAT/IAT sensor.
43. Tighten the outlet duct clamps at the turbocharger and the MAT/IAT sensor.
Tighten the clamps to 6 Nm (53 inch lbs.).





44. Raise the vehicle.
45. Install the lower exhaust outlet heat shield bolt (2).
Tighten the bolt to 8 Nm (71 inch lbs.).





46. Install the right exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
47. Install the right exhaust pipe bolts (2).
Tighten the bolts to 53 Nm (39 ft. lbs.).





48. install the left exhaust pipe with a NEW gasket to
exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
49. Install the left exhaust pipe bolts (1).
Tighten the bolts to 53 Nm (39 ft. lbs.).





50. Position the left exhaust pipe heat shield.
51. Install the left exhaust pipe heat shield bolts.
Tighten the bolts to 8 Nm (71 ft. lbs.).





52. Install the exhaust heat shield (3) to left Font of the dash panel.
53. install the shield nuts (2).
Tighten the nuts to 9 Nm (80 ft. lbs.)





54. If equipped, position the fill tube.
55. Install the fill tube nuts.
Tighten the nuts to 18 Nm (13 ft. lbs.).





56. Install the exhaust pipe clamp. To assist in positioning the clamp on the flanges use a suitable screw jack to hold the exhaust pipe in position.
Tighten the clamp to 40 Nm (30 ft. lbs.).
57. Lower the vehicle.
58. Fill the cooling system.





59. Install the upper intake manifold cover.
60. Install the upper intake manifold cover to the outlet duct.
61. Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten the clamp to 6 Nm (53 inch lbs.).





62. Position the hood in the normal operating position by moving the hood hinge bolts from the service position (2) to the normal operating position (1).
Tighten the bolts to 25 Nm (18 ft. lbs.).
63. Connect the negative battery cables.
64. Road test the vehicle for normal operation
65. Inspect for coolant, oil, or exhaust leaks.