Turbocharger Replacement

Turbocharger Replacement

Removal Procedure

Caution:
If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.

1. Remove the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (LGH) Turbocharger Exhaust Pipe Replacement.

2. Remove the exhaust gas recirculation manifold cooling feed pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LGH) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement.

3. Remove the right side exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (LGH) Exhaust Manifold Outlet Pipe Replacement - Right Side.

4. Remove the left side exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Left Side (LGH) Exhaust Manifold Outlet Pipe Replacement - Left Side.

5. Remove the exhaust gas recirculation cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement Exhaust Gas Recirculation Valve Cooler Replacement.

6. Remove the turbocharger air inlet adapter. Refer to Turbocharger Air Inlet Adapter Replacement Turbocharger Air Inlet Adapter Replacement.




7. Remove the turbocharger upper heat shield bolts (1).

8. Remove the turbocharger upper heat shield (2).




9. Remove the eye bolt (1) and washers (2) from the turbocharger oil feed pipe.




10. Remove the turbo oil return pipe fasteners (1).




11. Remove the turbo coolant feed hose (1).

12. Disconnect electrical connector.





Caution:
Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

13. Remove the coolant return hose

14. Remove the turbocharger mounting bolts (1).

15. Remove the turbocharger cooling return pipe bolt (2).

16. Remove the turbocharger assembly (3) with the oil feed pipe, oil return pipe and cooling return pipe.




17. Remove the turbocharger lower heat shield (1).

18. Transfer parts as necessary.

19. Clean and inspect the turbocharger. Refer to Turbocharger Cleaning and Inspection Turbocharger Cleaning and Inspection.

Installation Procedure




1. Install the turbocharger lower heat shield (1).





Caution:
Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

2. Install the turbocharger assembly (2) with the oil feed pipe, oil return pipe and cooling return pipe.

Caution: Refer to Fastener Caution Fastener Caution.

3. Install the turbocharger mounting bolts (1) and tighten to 78 Nm (58 lb ft).

4. Install the turbocharger cooling return pipe bolt (3) and tighten to 25 Nm (18 lb ft).




5. Install the turbo oil return pipe fastener (1) and tighten to 25 Nm (18 lb ft).




6. Install the turbo coolant feed hose (1).





Note: Lubricate the washers with diesel fuel before installing.

7. Install the turbocharger oil feed pipe eye bolt (1) and washers (2). Tighten the eye bolt to 35 Nm (26 lb ft).




8. Install the turbocharger heat shield (2).

9. Install the turbocharger upper heat shield bolts (1) and tighten to 10 Nm (89 lb in).

10. Reconnect the electrical connector.

11. Install the exhaust gas recirculation cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement Exhaust Gas Recirculation Valve Cooler Replacement.

12. Install the left side exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Left Side (LGH) Exhaust Manifold Outlet Pipe Replacement - Left Side.

13. Install the right side exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (LGH) Exhaust Manifold Outlet Pipe Replacement - Right Side.

14. Install the exhaust gas recirculation manifold cooling feed pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LGH) Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement.

15. Install the turbocharger air inlet adapter. Refer to Turbocharger Air Inlet Adapter Replacement Turbocharger Air Inlet Adapter Replacement.

16. Install the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (LGH) Turbocharger Exhaust Pipe Replacement.

17. Install NEW engine oil and a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement Service and Repair.