Installation
Turbocharger - Body On
Removal
NOTICE: Position a suitable material in front of the Charge Air Cooler (CAC) or damage to the CAC may occur.
NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to the Turbocharger - Body Off Turbocharger - Body Off version of the procedure.
Installation
1. NOTE: Lubricate the low-pressure turbocharger oil drain tube with clean engine oil prior to installing.
NOTE: Install the low-pressure turbocharger drain tube with the taper side down.
Install the new low-pressure turbocharger drain tube in the turbocharger.
2. NOTE: Install 2 new O-rings seals and lubricate with clean engine oil prior to installing.
Install the turbocharger high-pressure oil drain tube.
3. 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 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: Make sure the turbocharger is positioned under the high-pressure fuel pump heat shield on the right side.
NOTE: Install a new gasket for the RH turbocharger inlet pipe at the RH exhaust manifold prior to installing the turbocharger assembly.
With the help of an assistant, using the Heavy Duty Floor Crane, install the turbocharger assembly.
4. 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.
5. Install the 2 turbocharger hold downs and bolts.
- Tighten to 201 Nm (148 lb-ft).
6. Connect the EGR valve electrical connector.
7. Install the new oil filter base gasket and O-ring seal.
- Apply clean engine oil to the oil filter base gasket and O-ring seal.
8. Install the oil filter return tube assembly and screw.
- On new oil return tubes, tighten to 7 Nm (62 lb-in).
- On used oil return tubes, tighten to 5 Nm (44 lb-in).
9. Install the oil filter housing and 4 Torx bolts.
- Tighten to 22 Nm (16 lb-ft).
10. NOTE: Install a new O-ring seal on the oil filter cap and apply clean engine oil.
Install a new oil filter element and the oil filter cap.
- Tighten to 25 Nm (18 lb-ft).
11. Connect the fuel injection pump supply tube at the fuel filter module.
12. Install the bolt for the engine wiring harness.
- Tighten to 8 Nm (71 lb-in).
13. NOTE: Rear bolts shown, front bolts similar.
Position the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
- Tighten to 31 Nm (23 lb-ft).
14. Position back the oil level indicator and tube and install the nut.
- Tighten to 31 Nm (23 lb-ft).
15. NOTICE: Use only 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 fuel system.
Install fuel cooler-to-fuel filter module tube, new sealing washers and the banjo bolt.
- For Viton(R) sealing washers, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, tighten to 38 Nm (28 lb-ft).
16. Install the fuel filter element and cover.
- Tighten to 27 Nm (20 lb-ft).
17. Install the CAC tube flex coupling and clamps.
- Tighten the engine clamp to 12 Nm (106 lb-in).
- Tighten the tube clamp to 8 Nm (71 lb-in).
18. Install the 2 new studs for the RH turbocharger inlet pipe.
- Tighten to 18 Nm (159 lb-in).
19. NOTICE: Do not bend or twist the turbocharger inlet pipe or damage to the turbocharger inlet pipe may occur.
NOTE: To aid in installation, replace the top stud with bolt part number W302649.
NOTE: It will be necessary to position the EGR-OC pipe as needed.
Position the LH turbocharger inlet pipe in the vehicle. Install the new gasket and 2 new studs for the LH turbocharger inlet pipe. Loosely install the bolt.
- Tighten the studs to 18 Nm (159 lb-in).
20. Install the new turbocharger inlet pipe gaskets, bracket and loosely install the 6 new bolts.
- Tighten the top 4 bolts to 25 Nm (18 lb-ft).
21. NOTICE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE: To complete this step, it will be necessary to use the following tools:
- A 3/8-in drive torque wrench that is 241.3 mm (9.5 in) or 368.3 mm (14.5 in) from center of the handle to the center of the square drive.
- One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
- A 12-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the required torque value of 25 Nm (18 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
Tighten the turbocharger inlet pipes-to-turbocharger bottom 2 bolts.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
22. NOTE: LH shown, RH similar.
Install the 5 new lower turbocharger inlet pipe nuts.
- Tighten to 31 Nm (23 lb-ft).
23. NOTICE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE: To complete this step, it will be necessary to use the following tools:
- A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
- One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
- A 12-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the required torque value of 31 Nm (23 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
Tighten the LH turbocharger inlet pipe-to-LH exhaust manifold bolt.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
24. Install the new gasket and clamp for the exhaust downpipe.
- Tighten to 15 Nm (133 lb-in).
25. NOTICE: Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.
Position the EGR-OC pipe and loosely install the 2 new bracket bolts. Install a new gasket and loosely install the 2 new bolts.
26. Tighten the 2 bolts for the exhaust downpipe at the OC.
- Tighten to 40 Nm (30 lb-ft).
27. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolts will result in damage to the horizontal EGR cooler and possible engine damage.
Install the bracket, washers and loosely install the 2 new bolts for the EGR-OC pipe bracket.
28. Install the new gasket and the 2 new bolts for the EGR-OC pipe at the EGR cooler.
- Tighten to 31 Nm (23 lb-ft).
29. Tighten the 2 EGR-OC pipe bolts at the RH turbocharger inlet pipe.
- Tighten to 31 Nm (23 lb-ft).
30. Tighten the 2 bolts for the EGR-OC pipe bracket at the turbocharger.
- Tighten to 31 Nm (23 lb-ft).
31. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
Tighten the bolt for the EGR-OC pipe bracket.
- Tighten to 31 Nm (23 lb-ft).
32. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
NOTICE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
NOTE: To complete this step, it will be necessary to use the following tools:
- A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
- One of the 11-mm/13-mm Half-moon wrenches listed in the following chart.
- A 11-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the required torque value of 63 Nm (46 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
Tighten the EGR-OC pipe bracket-to-LH cylinder head bolt.
- Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
33. Install the EP sensor tube fitting into the EGR-OC pipe.
- Tighten to 27 Nm (20 lb-ft).
34. Connect the EP sensor tube to the EGR-OC pipe.
- Tighten to 20 Nm (177 lb-in).
35. If equipped, position back the front driveshaft and install the 2 straps and 4 bolts.
- Tighten to 35 Nm (26 lb-ft).
36. Install the EGRT sensor into the RH turbocharger inlet pipe.
- Tighten to 44 Nm (32 lb-ft).
37. Install the RH splash shield.
38. Connect the turbocharger actuator electrical connector and pin-type retainer.
39. Position the fuel cooler bracket.
40. Position back the fuel cooler, fuel cooling system expansion tank and turbocharger actuator cooler. Install the 3 bolts for the turbocharger actuator cooler. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Finger-tighten the bolts.
- Stage 2: Tighten to 7 Nm (62 lb-in).
41. Install the 2 nuts for the fuel cooler.
- Tighten to 19 Nm (168 lb-in).
42. NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.
Install the 2 stud bolts for the fuel cooler.
- Tighten to 25 Nm (18 lb-ft).
43. Install the 2 bolts for the fuel cooler.
- Tighten to 9 Nm (80 lb-in).
44. Install the 3 bolts for the fuel cooling system expansion tank.
- Tighten to 9 Nm (80 lb-in).
45. NOTICE: Use only 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 fuel system.
NOTICE: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.
Install the new sealing washers and 2 banjo bolts at the fuel cooler.
- Tighten to 25 Nm (18 lb-ft).
46. Position the turbocharger heat shield and install the 5 bolts.
- Tighten to 11 Nm (97 lb-in).
47. 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).
48. Prelubricate the oil inlet holes of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearings with oil.
49. NOTICE: Use only 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.
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.
NOTE: The back banjo bolt will require a torque adapter to be tightened properly.
Install new sealing washers and the 2 turbocharger oil supply tube banjo bolts.
- Calculate the correct torque wrench setting for the following torque.
- For Viton(R) sealing washers, using a torque adapter, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, using a torque adapter, tighten to 38 Nm (28 lb-ft).
- Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
50. Position the auxiliary air intake hose in the vehicle.
51. Install the ACL assembly and ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
52. Install the degas bottle. For additional information, refer to Cooling System &/or Engine Block Heater.
53. Bleed the low pressure fuel system. For additional information, refer to Fuel Delivery and Air Induction.