Part 1

TURBOCHARGER - BODY ON

Special Tool(s):

Special Tool(s)







Removal

CAUTION: 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 version of the procedure.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the degas bottle.
3. Remove the air cleaner assembly and air cleaner outlet pipe.







4. Remove the auxiliary air intake hose.







5. CAUTION: 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 turbocharger oil supply tube banjo bolts and copper sealing washers.
- Discard the copper sealing washers.







6. Remove the bolt and the turbocharger oil supply tube.
- Remove and discard the O-ring seal.
- Plug or cap the openings as needed.







7. NOTE: Roll the heat shield towards the cowl, then lift up in the front and remove forward.

Remove the bolts and the turbocharger heat shield.







8. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Remove the banjo bolts and the sealing washers at the fuel cooler.
- Discard the sealing washers.







9. Remove the 3 bolts for the fuel cooling system expansion tank.







10. Remove the bolts for the fuel cooler.







11. Remove the stud bolts for the fuel cooler.







12. Remove the 2 nuts for the fuel cooler.







13. Remove the 3 bolts for the turbocharger actuator cooler. Position the fuel cooler, fuel cooling system expansion tank and turbocharger actuator cooler aside.







14. Remove the fuel cooler bracket.







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







16. NOTE: Engine removed from art for clarity.

Remove the RH turbocharger inlet pipe-to-EGR-oxidation catalytic converter (OC) pipe bolts and the EGR-OC-to-turbocharger bracket bolts.
- Discard the bolts.

17. Remove the RH splash shield.







18. Remove the exhaust gas recirculation temperature (EGRT) sensor from the RH turbocharger inlet pipe.







19. NOTE: Index-mark the drive shaft prior to disconnecting from the axle.

If equipped, remove the 4 bolts, straps and position aside the front drive shaft aside.







20. Disconnect the exhaust pressure (EP) sensor tube from the EGR-OC pipe.







21. Remove the EP sensor tube fitting from the EGR-OC pipe.







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







23. Remove the EGR-OC-to-EGR cooler bolts.
- Discard the bolts and gasket.







24. Loosen the exhaust downpipe-to-OC pipe bolts.







25. NOTE: LH shown, RH similar.

Remove and discard the 6 LH and RH turbocharger inlet pipes-to-exhaust manifold nuts.







26. Remove and discard the exhaust downpipe clamp. Position aside the exhaust downpipe.
- Remove and discard the exhaust downpipe gasket.







27. Remove the 6 turbocharger inlet pipe bolts and EGR-OC-to-turbocharger bracket.
- Discard the bolts and gaskets.







28. Remove the 3 LH turbocharger inlet pipes-to-exhaust manifold studs and gasket. Remove the LH turbocharger inlet pipe.
- Discard the studs and gasket.







29. Remove the 2 outer RH turbocharger inlet pipes-to-exhaust manifold studs.
- Discard the studs.







30. Loosen the clamps and remove the charge air cooler (CAC) tube flex coupling.







31. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install fuel system caps to any open orifices or tubes.

Remove the fuel filter module cover, fuel filter and, using a suitable suction device, remove the fuel from the fuel filter module.
- Cover the fuel filter housing with a covering to prevent foreign material from entering the fuel system.







32. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Remove the banjo bolt, copper sealing washer and fuel cooler to fuel filter module tube.
- Discard the copper sealing washer.







33. Remove the nut and position the oil level indicator and tube aside.







34. Remove the bolts for the turbocharger crossover tube.
- Remove the front fuel cooler bracket.







35. Remove the bolt for the engine wiring harness.







36. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: Use a commercially available disconnect tool and a screwdriver to release the fuel tube.

Disconnect the fuel injection pump supply tube at the fuel filter module.







37. Remove and discard the oil filter element and O-ring seal.







38. Remove the 4 Torx bolts and the oil filter housing.







39. Remove the screw and the oil filter return tube assembly.







40. Remove and discard the oil filter base gasket and seal.
- Cover the oil cooler to prevent foreign material from entering.







41. Disconnect the EGR valve electrical connector.
42. Remove the bolts and the hold downs for the turbocharger.







43. Install the special tool.
- Tighten to 20 Nm (177 lb-in).

44. CAUTION:
- 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.
- 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.

With the help of an assistant, using the heavy duty lifting crane, remove the turbocharger assembly.
- Remove and discard the RH turbocharger inlet pipe gasket at the RH exhaust manifold.

45. 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.