Turbocharger - Body Off

Turbocharger - Body Off









Turbocharger Oil, Air and Electrical Connections









Turbocharger Crossover Tube and Heat Shield









Turbocharger Assembly









Removal

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to the Turbocharger - Body On Turbocharger - Body On version of the procedure.

1. Remove the body.

2. Remove the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off procedure. For additional information, refer to Exhaust System &/or Catalytic Converter.

3. Remove the clamp and disconnect the Air Cleaner (ACL) outlet tube-to-crankcase vent oil separator hose at the vent oil separator.

4. Loosen the clamp and remove the ACL outlet tube.

5. NOTICE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.

NOTE: Use a back-up wrench to prevent the fittings from turning.

Remove the 2 turbocharger oil supply tube banjo bolts and sealing washers.

- Discard the sealing washers.

6. Remove the bolt and the turbocharger oil supply tube.
- Remove and discard the O-ring seal.

7. Disconnect the turbocharger actuator electrical connector and pin-type retainer.

8. Remove the 4 bolts for the turbocharger crossover tube and the front fuel cooler bracket.

9. Remove the 5 bolts and the turbocharger heat shield.

10. Remove the 2 bolts and hold downs for the turbocharger.

11. Install the Turbocharger Lifting Bracket and 2 bolts.
- Tighten to 20 Nm (177 lb-in).





12. NOTICE: Failure to use the Turbocharger Lifting Bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure.

NOTICE: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.

NOTE: Use care when removing the turbocharger. The crossover tube should not be removed. The seals in the crossover tube are one-time-use seals and must be installed new.

Using the Heavy Duty Floor Crane, remove the turbocharger assembly.

13. Remove the turbocharger oil drain tubes.
- Remove and discard the low-pressure drain tube.

- Remove the high-pressure oil drain tube.

- Remove and discard the 2 O-ring seals.

Installation

1. If removed, install the Turbocharger Lifting Bracket and 2 bolts.
- Tighten to 20 Nm (177 lb-in).





2. NOTE: Lubricate the low-pressure oil drain tube with clean engine oil prior to installing.

NOTE: Install the low-pressure drain tube with the taper side down.

Install the new low-pressure turbocharger oil drain tube in the turbocharger.

3. NOTE: Install 2 new O-ring seals and lubricate with clean engine oil prior to installing the tube.

Install the turbocharger high-pressure oil drain tube.

4. NOTICE: Failure to use the Turbocharger Lifting Bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure.

NOTICE: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.

Using the Heavy Duty Floor Crane, install the turbocharger assembly.

5. NOTE: After removing the Turbocharger Lifting Bracket, the 2 bolt holes remain open on the turbocharger.

Remove the 2 bolts and the Turbocharger Lifting Bracket.

6. Install the 2 turbocharger hold downs and the bolts.
- Tighten to 201 Nm (148 lb-ft).

7. Position the turbocharger heat shield and install the 5 bolts.
- Tighten to 11 Nm (97 lb-in).

8. Position the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
- Tighten to 31 Nm (23 lb-ft).

9. Connect the turbocharger actuator electrical connector and pin-type retainer.

10. NOTE: Install a new O-ring seal and apply clean engine oil.

Position the turbocharger oil supply tube and install the bolt.

- Tighten to 13 Nm (115 lb-in).

11. Prelubricate the oil inlet holes of the turbocharger assembly with clean oil and spin the compressor wheel several times to coat the bearings with oil.

12. NOTICE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.

NOTE: Use a back-up wrench to prevent the fittings from turning.

Install new sealing washers and the 2 oil supply tube banjo bolts on the turbocharger oil supply fittings.

- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).

- For copper sealing washer, tighten to 38 Nm (28 lb-ft).

- Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.

13. Install the ACL outlet tube and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).

14. NOTE: Install a new clamp prior to connecting the hose.

Connect the ACL outlet tube-to-crankcase vent oil separator hose to the vent oil separator and tighten the clamp.

15. Install the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off procedure. For additional information, refer to Exhaust System &/or Catalytic Converter.

16. Install the body.