Turbocharger - Installation
6.7L DIESEL
CAUTION: Insure that turbocharger and charge air cooler are free of excess oil and debris. Do not allow any water or solvents to enter the turbocharger inlet or outlet If necessary, clean turbocharger Turbocharger - Cleaning or charge air cooler Charge Air Cooler and Hoses - Cleaning.
1. Clean turbocharger mounting surface and exhaust manifold flange surface.
2. Using a new gasket, position turbocharger on exhaust manifold studs.
NOTE: If old gasket appeared to be leaking, check the turbocharger/exhaust manifold mounting flanges for warping. Using a straight edge and feeler gauge measure along the two longest sides of the flanges for warpage. Spec is 0.1 mm (0.0039 inch) for the turbocharger flange and 0.05 mm(0.002 inch) maximum.
3. Install turbocharger mounting nuts (2). Using Turbocharger Tool 9866, using across pattern, tighten nuts to 43 Nm (32 ft. lbs.)
4. Install turbocharger speed sensor. Tighten bolt to 8 Nm (70 in. lbs.).
5. Install coolant supply and return lines. Tighten banjo fittings 24 Nm (18 ft. lbs.).
6. Inspect oil drain tube O-rings for nicks or cuts. Replace if necessary. Oil O-rings with new oil.
7. Position turbocharger drain tube into engine block.
8. Using a new gasket, install turbocharger drain tube mounting bolts. Tighten to 11 Nm (8 ft. lbs.).
9. Install RH engine mount Engine Mount Insulator - Installation.
10. Using a new V-clamp, connect exhaust pipe to turbocharge exhaust outlet (1). Tighten clamp to 11 Nm (8 ft. lbs.).
11. Lower vehicle.
12. Install charge air tube to turbocharger inlet (4). Tighten clamp to 11 Nm (8 ft. lbs.).
13. Install oil return line. Tighten fitting to 36 Nm (27 ft. lbs.).
14. Pre-lube turbocharger with 29.9 - 59.14 ml (1 - 2 oz) clean engine oil.
15. Install turbocharger oil pressure line (3). Tighten fitting to 36 Nm (27 ft. lbs.).
16. Connect turbocharger actuator electrical connector (6).
17. Connect valve cover breather tube.
18. Install air filter housing Air Cleaner Body - Installation.
19. Connect negative battery cable.
20. Fill cooling system Service and Repair
21. Check for leaks and proper operation.