Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - Body Off

Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off

Removal

NOTICE: Do not bend or twist the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe or damage to the bellow on the EGR-OC pipe may occur.

NOTICE: Do not bend or twist the turbocharger inlet pipe or damage to the bellow on the turbocharger inlet pipe may occur.

NOTE: This procedure is provided for use with other procedures that require the removal of the vehicle body. If the vehicle body is not being removed, refer to Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body On Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - Body On.

1. Remove the vehicle body.

2. Loosen the exhaust downpipe-to-turbocharger clamp.

3. Remove the exhaust downpipe-to-Oxidation Catalytic Converter (OC) bolts and remove the exhaust downpipe from the vehicle.
- Discard the clamp and gasket.

4. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector.





5. Disconnect the Exhaust Pressure (EP) sensor tube fitting.





6. Remove the EGR-OC pipe bracket-to-cylinder head bracket bolt and washer. Remove the cylinder head bracket-to-cylinder head bolt, washers and the bracket.
- Discard the bolts.





7. Remove the RH turbocharger inlet pipe-to-EGR-OC pipe bolts.
- Discard the bolts.





8. Remove the EGR-OC-to-turbocharger bracket bolts.
- Discard the bolts.





9. Remove the EGR-OC-to-EGR cooler bolts.
- Discard the bolts.





10. Remove EGR-OC pipe from the vehicle.
- Discard the gaskets.

11. Remove the RH turbocharger inlet pipe-to-turbocharger bolts.
- Discard the bolts.

12. Remove the RH turbocharger inlet pipe-to-exhaust manifold nuts.
- Discard the nuts.

13. Remove the RH turbocharger inlet pipe from the vehicle.
- Discard the gaskets.

14. Remove the LH turbocharger inlet pipe-to-turbocharger bolts and remove the EGR-OC bracket.
- Discard the bolts.

15. NOTE: On vehicles that have had previous service to the LH turbocharger inlet pipe, a service bolt will be in place of the upper exhaust manifold nut and stud.

Remove the LH turbocharger inlet pipe-to-exhaust manifold nuts and, if equipped, service bolt.

- Discard the nuts and, if equipped, service bolt.

16. Remove the LH turbocharger inlet pipe from the vehicle.
- Discard the gaskets.

17. Inspect the EGR-OC pipe for damage, obstructions or plugging of the filter. If the filter cannot be cleaned or the obstruction removed, install a new EGR-OC pipe.

Installation

NOTICE: Do not bend or twist the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe or damage to the bellow on the EGR-OC pipe may occur.

NOTICE: Do not bend or twist the turbocharger inlet pipe or damage to the bellow on the turbocharger inlet pipe may occur.

1. Install new gaskets on the exhaust manifolds-to-turbocharger inlet pipe joints.

2. Position the turbocharger inlet pipes, new turbocharger inlet pipe-to-turbocharger gaskets and the EGR- OC bracket, and loosely install new turbocharger inlet pipe-to-turbocharger bolts.





3. NOTE: LH side shown, RH side similar.

NOTE: A new service bolt may be installed at the upper location at the LH exhaust manifold.

Loosely install the new turbocharger inlet pipe-to-exhaust manifold nuts.





4. Tighten the LH turbocharger inlet pipe-to-turbocharger bolts and LH turbocharger inlet pipe-to-exhaust manifold nuts (and service bolt).

1. Tighten the bolts to 24 Nm (18 lb-ft).

2. Tighten the nuts (and service bolt) to 31 Nm (23 lb-ft).





5. Tighten the RH turbocharger inlet pipe-to-turbocharger bolts and RH turbocharger inlet pipe-to-exhaust manifold nuts.

1. Tighten the bolts to 24 Nm (18 lb-ft).

2. Tighten the nuts to 31 Nm (23 lb-ft).





6. NOTICE: Make sure the correct bolts are installed in the bracket or damage to the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe may occur.

NOTE: EGR-OC pipe-to-RH turbocharger inlet pipe joint shown, EGR-OC pipe-to-horizontal EGR cooler joint similar.

Position the EGR-OC pipe and loosely install new EGR-OC-to-bracket bolts.

Install new gaskets and loosely install the new RH inlet pipe-to-EGR-OC pipe bolts and the new EGR-OC-to-horizontal EGR cooler bolts.





7. Position the cylinder head bracket and install the EGR- OC bracket-to-cylinder head bracket washer and a new bolt. Loosely install the cylinder head bracket-to-cylinder head washers and a new bolt. Finger-tighten both bolts.





8. Tighten the EGR-OC-to-EGR cooler bolts.
- Tighten to 31 Nm (23 lb-ft).





9. Tighten the RH turbocharger inlet pipe-to-EGR-OC bolts.
- Tighten to 31 Nm (23 lb-ft).





10. Tighten the EGR-OC-to-turbocharger bracket bolts.
- Tighten to 31 Nm (23 lb-ft).





11. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe bracket bolt will result in damage to the horizontal EGR cooler and possible engine damage.

Tighten the EGR-OC bracket-to-cylinder head bracket bolt.

- Tighten to 31 Nm (23 lb-ft).





12. NOTICE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe bracket bolt will result in damage to the horizontal EGR cooler and possible engine damage.

Tighten the cylinder head bracket-to-cylinder head bolt.

- Tighten to 62 Nm (46 lb-ft).





13. Install the EP sensor tube fitting.
- Tighten to 20 Nm (177 lb-in).





14. Connect the EGRT sensor electrical connector.





15. NOTE: Do not install the exhaust downpipe until both turbocharger inlet pipes and the EGR-OC pipe are installed and all fasteners are tightened.

Position the exhaust downpipe into the vehicle and loosely install exhaust downpipe-to-OC bolts.

16. Install a new exhaust downpipe-to-turbocharger gasket.

17. Position the exhaust downpipe to the turbocharger and install and pre-tighten a new exhaust downpipe-to-turbocharger clamp.
- Make sure the exhaust downpipe clip is over the lip on the turbocharger.
- Align the new exhaust downpipe-to-turbocharger clamp so that the exhaust downpipe clip and the opening in the exhaust downpipe-to-turbocharger clamp are aligned and tightened to maintain position.

- Align the downpipe so that the area just above the flat in the pipe is approximately 20 mm (0.787 in) from the frame.

- Pre-tighten to 10 Nm (89 lb-in) to stiffen the joint.

18. Tighten the exhaust downpipe-to-OC bolts.
- Tighten to 40 Nm (30 lb-ft).

19. Tighten the exhaust downpipe-to-turbocharger clamp.
- Tighten to 15 Nm (133 lb-in).

20. Install the vehicle body.