Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - Body On
Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body OnRemoval
CAUTION: 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.
CAUTION: 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 when both turbocharger inlet pipes and the EGR-oxidation catalytic converter (OC) pipe must all be removed, and the vehicle body is not being removed. If the vehicle body is being removed, refer to Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes 6.4L Diesel, Body Off.
NOTE: This procedure is provided for use when it is necessary to remove both turbocharger inlet pipes and EGR-OC pipe. If service is only being performed on one pipe, refer to Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) or Turbocharger Inlet Pipe LH or Turbocharger Inlet Pipe - RH.
1. Remove the exhaust downpipe.
2. Disconnect the exhaust pressure (EP) sensor tube fitting.
3. Remove the EGR-OC pipe bracket-to-cylinder head bracket bolt and washer. Remove the EGR-OC pipe bracket-to-LH cylinder head bolt, washers and the bracket.
^ Discard the bolts.
4. Remove the RH turbocharger inlet pipe-to-EGR-OC pipe bolts and the EGR-OC-to-turbocharger bracket bolts.
^ Discard the bolts.
5. Remove the EGR-OC-to-EGR cooler bolts and position the EGR-OC pipe to the left side of the vehicle and aside.
^ Discard the bolts.
6. Remove the exhaust gas temperature (EGT) sensor from the RH turbocharger inlet pipe and position aside.
7. Remove the RH turbocharger inlet pipe-to-exhaust manifold nuts.
^ Discard the nuts.
8. Remove the RH turbocharger inlet pipe-to-turbocharger bolts.
^ Discard the bolts.
9. Remove the RH turbocharger inlet pipe from the vehicle.
^ Discard the gaskets.
10. Remove the LH turbocharger inlet pipe-to-turbocharger bolts and remove the EGR-OC bracket.
^ Discard the bolts.
11. 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.
12. 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 studs.
13. NOTE: To aid in removal of the EGR-OC pipe, lower the pipe down slightly, rotate the EGR-OC-to-RH turbocharger inlet pipe flange to the LH side of the vehicle and then lower the EGR-OC pipe completely out of the vehicle.
Remove the LH turbocharger inlet pipe and then remove the EGR-OC pipe from the vehicle.
^ Discard the gaskets.
14. Inspect the EGR-OC pipe for clogging.
Installation
CAUTION: 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.
CAUTION: Do not bend or twist the turbocharger inlet pipe or damage to the bellow on the turbocharger inlet pipe may occur.
1. NOTE: To aid in installation of the EGR-OC pipe, install the pipe with the EGR-OC pipe-to-RH turbocharger inlet pipe flange facing the LH side of the vehicle. Raise the EGR-OC pipe until it passes the transmission bellhousing or transmission bellhousing mating surface, then rotate the pipe back into position.
Position the EGR-OC pipe into the vehicle and to the LH side out of the way.
2. Position the LH turbocharger inlet pipe into position.
3. NOTE: To aid in installation, the upper LH turbocharge inlet pipe-to-exhaust manifold stud is replaced with a bolt.
Install the new LH turbocharger inlet pipe-to-exhaust manifold gasket and the 2 lower studs.
^ Tighten to 18 Nm (159 lb-inch).
4. Position the new LH turbocharger inlet pipe-to-turbocharger gasket and loosely install the EGR-OC bracket and new bolts.
5. Loosely install new LH turbocharger inlet pipe-to-exhaust manifold nuts.
6. NOTE: To aid in installation, the upper LH turbocharger inlet pipe-to-exhaust manifold stud is replaced with bolt part number W302649.
Loosely install a new LH turbocharger inlet pipe-to-exhaust manifold bolt.
7. Install the RH turbocharger inlet pipe-to-exhaust manifold gasket and position the RH turbocharger inlet pipe into the vehicle.
8. Position a new RH turbocharger inlet pipe-to-turbocharger gasket and install new bolts.
9. Loosely install new RH turbocharger inlet pipe-to-exhaust manifold nuts.
10. Tighten the LH turbocharger inlet pipe-to-turbocharger bolts.
^ Tighten to 25 Nm (18 lb-ft).
11. Tighten the 2 LH turbocharger inlet pipe-to-exhaust manifold nuts.
^ Tighten to 31 Nm (23 lb-ft).
12. CAUTION: 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 min (14.5 inch) or 381.0 min (15.0 inch) 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 specified 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.
Torque Chart - LH Turbocharger Inlet Pipe-to-LH Exhaust Manifold Upper Bolt:
13. Tighten the RH turbocharger inlet pipe-to-turbocharger bolts and RH turbocharger inlet pipe-to-exhaust manifold nuts.
1 Tighten the bolts to 25 Nm (18 lb-ft).
2 Tighten the nuts to 31 Nm (23 lb-ft).
14. Install the EGT sensor into the RH turbocharger inlet pipe.
^ Tighten to 44 Nm (32 lb-ft).
15. Position the EGR-OC pipe and install a new EGR-OC pipe-to-horizontal EGR cooler gasket and loosely install the new bolts.
16. CAUTION: 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.
Install a new EGR-OC pipe-to-RH turbocharger inlet pipe gasket and loosely install new bolts. Loosely install new EGR-OC-to-turbocharger bracket bolts.
17. 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.
18. Tighten the EGR-OC-to-EGR cooler bolts.
^ Tighten to 31 Nm (23 lb-ft).
19. Tighten the RH turbocharger inlet pipe-to-EGR-OC bolts.
^ Tighten to 31 Nm (23 lb-ft).
20. Tighten the EGR-OC-to-turbocharger bracket bolts.
^ Tighten to 31 Nm (23 lb-ft).
21. CAUTION: 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).
22. CAUTION: 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.
CAUTION: 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 min (14.5 inch) or 381.0 min (15.0 inch) 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.
^ An 11-mm Allen socket (to drive the Half-moon wrench).
NOTE: To obtain the specified 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.
Torque Chart - EGR-OC Pipe Bracket-to-LH Cylinder Head Bolt:
23. Install the EP sensor tube fitting into the EGR-OC pipe.
^ Tighten to 20 Nm (177 lb-inch).
24. Install the exhaust downpipe.