Late Build (After September 29, 2003)

Turbocharger Inlet Y-Pipe - Late Build







NOTE: The names turbocharger inlet Y-pipe and turbocharger adapter pipe refer to the same component







Removal


1. With the vehicle in NEUTRAL position it on a hoist.


2. Remove the turbocharger.


3. Remove the fuel injector control module (FICM).







4. Remove the retaining nuts and the rear FICM bracket from the LH valve cover.







5. NOTE: There is a metal gasket between the exhaust inlet pipe and the exhaust gas recirculation (EGR) cooler.


Remove the turbocharger inlet Y-pipe to EGR cooler clamp by opening up the clamp pushing the clampdown positioning the bottom ofthe clamp toward the EGR cooler and then positioning the top of the clamp toward the EGR cooler.







6. Remove the LH turbocharger inlet Y-pipe to exhaust manifold nuts.







7. Remove the RH turbocharger inlet Y-pipe to exhaust manifold nuts.

8. Remove the turbocharger inlet Y-pipe.


Installation


NOTE: When installing the turbocharger inlet Y-pipe into the vehicle do not bend or twist the flex bellows.


NOTE: Only tighten the turbocharger inlet Y-pipe fasteners with hand tools.








1. NOTE: Do not tighten the nuts at this time.


NOTE: Apply anti-seize lubricant to the turbocharger inlet Y-pipe bolts.


If the turbocharger inlet Y-pipe was separated install the gasket and loosely install the bolts and nuts.

2. Position the turbocharger inlet Y-pipe in the vehicle.








3. NOTE; Do not tighten the clamp at this time.


Install the metal gasket on the EGR cooler and align the turbocharger inlet Y-pipe to the EGR cooler. Position the clamp.







4. NOTE: Do not tighten the nuts at this time.

NOTE: LH shown RH similar.


Apply anti-seize lubricant to the turbocharger inlet Y-pipe bolts then install the bolts and nuts.

5. Install the turbocharger.







6. If loosened tighten the turbocharger inlet Y-pipe nuts at the RH to LH joint.

- Tighten to 27 Nm (20 lb-ft).







7. Install the rear FICM bracket and nuts to the LH valve cover.

- Tighten to 8 Nm (71 lb-in).

8. Install the FICM.


9. Check the system for leaks.