Turbocharger

Turbocharger





Removal

NOTICE: The engine oil must be changed any time the turbocharger is removed from the engine. The passages in the block underneath the turbocharger are direct passages to the lubrication system. Debris and or coolant may enter lubrication system and engine damage may occur.

1. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

2. Drain the primary engine cooling system. For additional information, refer to Engine Cooling - Diesel Engine Cooling System Draining, Filling and Bleeding.

3. Remove the lower intake manifold. For additional information, refer to Engine - 6.7L Diesel Service and Repair.

4. Disconnect the heater core inlet hose from the heater inlet tube.

5. Remove 2 bolts and the heater core inlet tube.
- Inspect O-ring seal for damage, replace if necessary.

6. Disconnect the turbocharger actuator electrical connector.

7. If equipped, disconnect the turbocharger wastegate actuator vacuum hose.

8. NOTE: Mark the position of the exhaust upper downpipe clamp for installation.

Loosen the exhaust upper downpipe clamp.





9. Remove the RH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

10. Remove the exhaust upper downpipe bracket bolt.





11. Remove the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts and remove the downpipe assembly.
- Discard the exhaust upper downpipe clamp.





12. Loosen the RH turbocharger inlet pipe clamp and slide the clamp off the turbocharger.
- Discard the clamp after turbocharger is removed.

13. Loosen the LH turbocharger inlet pipe clamp and slide the clamp off the turbocharger.
- Discard the clamp after turbocharger is removed.

14. NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant outlet tube.

NOTE: If necessary, remove the turbocharger heat shield and discard the bolts.

Disconnect the turbocharger coolant outlet tube from the turbocharger.





15. NOTE: Lift the turbocharger off locating dowels before positioning forward for removal.

NOTE: The turbocharger is a tight fit between cowl and injection pump fuel lines but comes out without removing fuel lines.

Remove the 4 bolts and the turbocharger.

- Discard the turbocharger gasket and bolts.

16. NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant outlet tube.

If servicing or replacing the turbocharger, disconnect the turbocharger oil supply tube from the turbocharger oil supply fittings.

- Discard the oil supply tube.

17. Inspect the turbocharger coolant outlet tube fitting at the center housing of the turbocharger and replace, as necessary.

Installation

1. If removed, install the coolant outlet tube fitting at the center housing of the turbocharger.
- Tighten to 22 Nm (16 lb-ft).

2. If removed, install the turbocharger oil supply tube, first to the top of the turbocharger oil supply tube fitting and then to the front of the fitting.

3. If removed, install the turbocharger heat shield.
- Tighten to 10 Nm (89 lb-in).

4. Position the new LH and RH turbocharger inlet pipe clamps on the inlet pipes.

5. Wipe turbocharger valley clean of all oil and debris.

6. NOTE: Make sure the spring clip for the coolant outlet tube is on the turbocharger before installing the turbocharger on the engine.

NOTE: The turbocharger is a tight fit between cowl and injection pump fuel lines but can be installed without removing fuel lines.

NOTE: Position the turbocharger on locating dowels when installing.

Using a new gasket, install the turbocharger and the 4 new bolts finger tight.

7. Position the LH turbocharger inlet pipe and clamp to the turbocharger.
- Do not tighten at this time.

8. Position the RH turbocharger inlet pipe and clamp to the turbocharger.
- Do not tighten at this time.

9. Tighten the turbocharger bolts to 55 Nm (41 lb-ft) in sequence shown.





10. NOTE: The LH turbocharger inlet pipe clamp nut should be in vertical position.

Tighten the LH turbocharger inlet pipe and clamp to 15 Nm (133 lb-in).

11. NOTE: The RH turbocharger inlet pipe clamp nut should be in vertical position.

Tighten the RH turbocharger inlet pipe and clamp to 15 Nm (133 lb-in).

12. Disengage the new exhaust upper downpipe clamp T-bolt and loosely install the clamp on the turbocharger.

13. Position the exhaust downpipe assembly in the vehicle and hand tighten the exhaust upper downpipe bracket bolt.
- Do not tighten the exhaust upper downpipe bracket bolt at this time.





14. Install the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts and hand tighten.
- Do not tighten the exhaust lower downpipe-to-catalyst and particulate filter assembly bolts at this time.





15. Tighten the exhaust upper downpipe bracket bolt to 25 Nm (18 lb-ft).





16. Engage the new exhaust upper downpipe clamp T-bolt and position the clamp as marked during removal.
- Tighten to 15 Nm (133 lb-in).





17. Tighten the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts to 40 Nm (30 lb-ft).





18. Install the RH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

19. Position the coolant outlet tube and install it into the turbocharger spring clip fitting.

20. If equipped, connect the turbocharger wastegate actuator vacuum hose.

21. Connect the turbocharger actuator electrical connector.

22. NOTE: Lubricate the O-ring seal with engine coolant.

Install the heater core inlet tube and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).

23. Connect the heater core inlet hose to the heater inlet tube.

24. Inspect the Charge Air Cooler (CAC) and CAC tubes for metal particles. Carry out the Charge Air Cooler (CAC) Cleaning. For additional information, refer to Intake Air Distribution and Filtering Procedures.

25. Install the lower intake manifold. For additional information, refer to Engine - 6.7L Diesel Service and Repair.

26. Remove and discard the engine oil filter.

27. Drain the engine oil by turning the oil pan drain plug one quarter turn Counterclockwise (CCW).
- Install the engine oil pan drain plug and tighten one quarter turn Clockwise (CW).

28. NOTE: Lubricate the engine oil filter seal with clean engine oil.

Install a new engine oil filter.

- Tighten to 5 Nm (44 lb-in) then an additional 180 degrees.

29. Fill the engine with the correct motor oil for the climate. For additional information, refer to Description and Operation in Engine - 6.7L Diesel Engine.

30. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

31. Evaluate the primary cooling system. For additional information, refer to Cooling System Condition Evaluation in Engine Cooling - Diesel Engine Cooling System Condition Evaluation.

32. Perform the cooling system pressure test. For additional information, refer to Engine Cooling - Diesel Engine Engine Cooling.