Compressor Air Intake Turbocharger Replacement

Single Use Fasteners and Components Catalytic Converter Clamp Catalytic Converter Gasket Exhaust Gas Recirculation Outlet Pipe Gasket Exhaust Gas Recirculation Valve Cooler Gasket Turbocharger Coolant Feed and Return Pipe Gasket Turbocharger Gasket Turbocharger Oil Feed Pipe Gasket Turbocharger Nut [3x] Removal Procedure

1. Drain the cooling system. Cooling System Draining and Filling
2. Oil Filler Cap » Remove

Compressor Air Intake Turbocharger Replacement — figure 1

3. Intake Manifold Cover Bolt (1) » Remove
4. Intake Manifold Cover (2) » Remove
5. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
6. Plenum Front Panel Outer Reinforcement » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

Compressor Air Intake Turbocharger Replacement — figure 2

7. Charge Air Cooler Inlet Air Hose Clamp (1) » Loosen until disengaged [2x]
8. Charge Air Cooler Inlet Air Hose (2) » Remove

Compressor Air Intake Turbocharger Replacement — figure 3

9. Release the retainer spring (1).
10. Intake Manifold Resonator (2) » Remove

Compressor Air Intake Turbocharger Replacement — figure 4

11. Remove the Exhaust Gas Recirculation Cooler Temperature Sensor (2) @ the compressor air intake turbocharger and position aside.

Compressor Air Intake Turbocharger Replacement — figure 5

12. Turbocharger Heat Shield Bolt (1) » Remove [2x]
13. Turbocharger Heat Shield Nut (2) » Remove

Compressor Air Intake Turbocharger Replacement — figure 6

14. Turbocharger Heat Shield (1) » Remove

Compressor Air Intake Turbocharger Replacement — figure 7

15. Exhaust Pipe Clamp (1) » Remove and DISCARD
16. Front Wheelhouse Liner - Right Side » Remove — Front Wheelhouse Liner Replacement

Compressor Air Intake Turbocharger Replacement — figure 8

17. Catalytic Converter Brace Bracket Nut (1) » Remove
18. Remove the ground strap (2) from the lower stud and position aside.
19. Catalytic Converter Brace Bracket Nut (3) » Remove

Compressor Air Intake Turbocharger Replacement — figure 9

20. Catalytic Converter Brace Bracket Nut (1) » Loosen [2x]

Compressor Air Intake Turbocharger Replacement — figure 10

21. Catalytic Converter Brace Bracket Nut (1) » Loosen [2x]
22. Lower the vehicle.
23. Reposition the catalytic convertor enough to remove the compressor air intake turbocharger.

Compressor Air Intake Turbocharger Replacement — figure 11

24. Air Cleaner Outlet Duct Clamp (1) » Loosen [2x]
25. Air Cleaner Outlet Front Duct (2) » Remove

Compressor Air Intake Turbocharger Replacement — figure 12

26. Air Cleaner Outlet Duct Clamp (1) » Loosen
27. Air Cleaner Outlet Duct (2) » Remove

Compressor Air Intake Turbocharger Replacement — figure 13

28. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
29. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe » Remove
30. Turbocharger Coolant Feed and Return Pipe Bolt (3) » Remove

Compressor Air Intake Turbocharger Replacement — figure 14

31. Positive Crankcase Ventilation Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
32. Positive Crankcase Ventilation Hose (2) @ Turbocharger » Remove

Compressor Air Intake Turbocharger Replacement — figure 15

33. Turbocharger Bracket Bolt (1) » Remove
34. Turbocharger Bracket Nut (2) » Remove [2x]
35. Turbocharger Bracket Brace (3) » Remove

Compressor Air Intake Turbocharger Replacement — figure 16

36. Engine Wiring Harness Bracket Nut (2) » Remove [3x]
37. Disconnect electrical connectors and detach retainers as needed.
38. Engine Wiring Harness (3) » Reposition

Compressor Air Intake Turbocharger Replacement — figure 17

39. Retainer (1) » Remove
40. Exhaust Gas Temperature Sensor (2) » Reposition

Compressor Air Intake Turbocharger Replacement — figure 18

41. Exhaust Pressure Differential Sensor Bracket Stud (1) » Remove [2x]
42. Exhaust Pressure Differential Sensor Bracket (2) » Reposition

Compressor Air Intake Turbocharger Replacement — figure 19

43. Turbocharger Coolant Feed Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
44. Turbocharger Coolant Feed Hose (2) @ Water Outlet » Remove

Compressor Air Intake Turbocharger Replacement — figure 20

45. Detach wiring harness retainers from the heater inlet hose bracket (2) and position harness aside.
46. Remove the exhaust gas recirculation valve bracket nut (1).
47. Remove the heater inlet hose bracket (2).

Compressor Air Intake Turbocharger Replacement — figure 21

48. Exhaust Pressure Sensor Hose Clamp (1) @ Exhaust Pressure Differential Sensor Pipe » Disengage — Hose Clamp Replacement Guidelines - Spring Type
49. Remove the exhaust pressure differential sensor hose from the exhaust gas recirculation pipe.

Compressor Air Intake Turbocharger Replacement — figure 22

50. Exhaust Gas Recirculation Pipe Nut (1) » Remove

Compressor Air Intake Turbocharger Replacement — figure 23

51. Exhaust Gas Recirculation Pipe Nut (1) » Remove

Compressor Air Intake Turbocharger Replacement — figure 24

52. Exhaust Gas Recirculation Pipe (1) » Reposition
53. Exhaust Gas Recirculation Outlet Pipe Gasket (2) » Remove and DISCARD

Compressor Air Intake Turbocharger Replacement — figure 25

54. Disconnect the electrical connector (1).
55. Exhaust Gas Recirculation Pipe Bolt (2) » Remove [2x]

Compressor Air Intake Turbocharger Replacement — figure 26

56. Exhaust Gas Recirculation Pipe Bolt (1) » Remove [2x]

Compressor Air Intake Turbocharger Replacement — figure 27

57. Exhaust Gas Recirculation Valve (1) » Remove
58. Exhaust Gas Recirculation Valve Cooler Gasket (2) » Remove and DISCARD

Compressor Air Intake Turbocharger Replacement — figure 28

59. Turbocharger Nut (1) » Remove and DISCARD [3x]

Compressor Air Intake Turbocharger Replacement — figure 29

60. Remove the 3 turbocharger studs (3).
61. Reposition the turbocharger to allow access to the inboard turbocharger oil feed pipe bolt.
62. Cover the exhaust manifold opening to prevent debris from entering the system.

Compressor Air Intake Turbocharger Replacement — figure 30

63. Turbocharger Oil Feed Pipe Bolt (1) » Remove [2x]
64. Turbocharger Oil Feed Pipe (2) » Remove
65. Turbocharger Oil Feed Pipe Gasket (3) » Remove and DISCARD

Compressor Air Intake Turbocharger Replacement — figure 31

66. Catalytic Converter Gasket (1) » Remove and DISCARD

Compressor Air Intake Turbocharger Replacement — figure 32

67. Turbocharger (1) » Remove
68. Turbocharger Gasket (2) » Remove and DISCARD

Compressor Air Intake Turbocharger Replacement — figure 33

69. Turbocharger Coolant Feed and Return Pipe Bolt (1) » Remove [2x]
70. Turbocharger Coolant Feed Pipe (2) » Remove
71. Turbocharger Coolant Feed and Return Pipe Gasket (3) » Remove and DISCARD
72. Clean and inspect all mating surfaces. Cleaning and Inspection Procedure - Required

Compressor Air Intake Turbocharger Replacement — figure 34

1. Inspect the charge air cooler inlet air hose (2): 1.1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 1.2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found. 1.3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing. Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Compressor Air Intake Turbocharger Replacement — figure 35

1. Clean all sealing surfaces.
2. Clean all threads if necessary.
3. Inspect the wastegate regulator mechanism (1) for functionality.
4. Inspect the turbine blades for damage or foreign material.
5. Inspect the turbine blade shaft for excessive radial and axial end play.
6. Inspect the compressor air intake turbocharger for cracks or other damage.
7. Inspect the compressor air intake turbocharger mating surface for flatness.

Compressor Air Intake Turbocharger Replacement — figure 36

8. Clean the exhaust gas recirculation valve (1).
9. Inspect the exhaust gas recirculation valve (1).
10. Replace the exhaust gas recirculation valve (1) if any damage is found.

Compressor Air Intake Turbocharger Replacement — figure 37

11. Clean the exhaust gas recirculation valve (1).

12. Inspect the exhaust gas recirculation valve (1).

13. Replace the exhaust gas recirculation valve (1) if any damage is found. Installation Procedure

14. Turbocharger Coolant Feed and Return Pipe Gasket (3) » Install NEW

15. Turbocharger Coolant Feed Pipe (2) » Install

Caution

Refer to Fastener Caution.

3. Turbocharger Coolant Feed and Return Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

4. Remove the turbocharger studs (3) [2x]

5. Turbocharger Gasket (2) » Install NEW

6. Catalytic Converter Gasket (1) » Install NEW

7. Remove cover from exhaust manifold.

8. Position turbocharger in vehicle to allow installation of oil feed pipe.

9. Turbocharger Oil Feed Pipe Gasket (3) » Install NEW

10. Turbocharger Oil Feed Pipe (2) » Install

11. Turbocharger Oil Feed Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

12. Install and tighten the turbocharger studs (3) [3x]. Fastener Specifications

13. Turbocharger (1) » Install

14. Turbocharger Nut (1) » Install NEW and tighten [3x] — Fastener Specifications

15. Exhaust Gas Recirculation Valve Cooler Gasket (2) » Install NEW

16. Exhaust Gas Recirculation Valve (1) » Install

Caution

Refer to Fastener Caution.

17. Exhaust Gas Recirculation Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

18. Exhaust Gas Recirculation Pipe Bolt (2) » Install and tighten [2x] — Fastener Specifications

19. Connect the electrical connector (1).

20. Exhaust Gas Recirculation Outlet Pipe Gasket (2) » Install NEW

21. Exhaust Gas Recirculation Pipe (1) » Install

22. Exhaust Gas Recirculation Pipe Nut (1) » Install and tighten — Fastener Specifications

23. Exhaust Gas Recirculation Pipe Nut (1) » Install and tighten — Fastener Specifications

24. Install the exhaust pressure differential sensor hose to the exhaust gas recirculation pipe.

25. Exhaust Pressure Sensor Hose Clamp (1) @ Exhaust Pressure Differential Sensor Pipe » Engage — Hose Clamp Replacement Guidelines - Spring Type

26. Install the heater inlet hose bracket (2).

27. Install and tighten the exhaust gas recirculation valve bracket nut (1). Fastener Specifications

28. Reposition harness and secure retainers to the heater inlet hose bracket (2).

29. Turbocharger Coolant Feed Hose (2) @ Water Outlet » Install

30. Turbocharger Coolant Feed Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

31. Exhaust Pressure Differential Sensor Bracket (2) » Install

32. Exhaust Pressure Differential Sensor Bracket Stud (1) » Install and tighten [2x] — Fastener Specifications

33. Connect electrical connectors and attach retainers as needed.

34. Engine Wiring Harness Bracket Nut (2) » Install and tighten [3x] — Fastener Specifications

35. Turbocharger Bracket Brace (3) » Install

36. Turbocharger Bracket Nut (2) » Install and tighten [2x] — Fastener Specifications

37. Turbocharger Bracket Bolt (1) » Install and tighten — Fastener Specifications

38. Positive Crankcase Ventilation Hose (2) @ Turbocharger » Install

39. Positive Crankcase Ventilation Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

40. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

41. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe » Install

42. Turbocharger Coolant Feed and Return Pipe Bolt (3) » Install and tighten — Fastener Specifications

43. Exhaust Pipe Clamp (1) » Install NEW and tighten — Fastener Specifications

44. Partially raise the vehicle.

45. Catalytic Converter Brace Bracket Nut (1) » Tighten [2x] — Fastener Specifications

46. Catalytic Converter Brace Bracket Nut (1) » Tighten [2x] — Fastener Specifications

47. Catalytic Converter Brace Bracket Nut (3) » Install — Fastener Specifications

48. Install the ground strap (2) onto lower stud.

49. Catalytic Converter Brace Bracket Nut (1) » Install — Fastener Specifications

50. Front Wheelhouse Liner - Right Side » Install — Front Wheelhouse Liner Replacement

51. Air Cleaner Outlet Duct (2) » Install

52. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

53. Air Cleaner Outlet Front Duct (2) » Install

54. Air Cleaner Outlet Duct Clamp (1) » Tighten [2x] — Fastener Specifications

55. Intake Manifold Resonator (2) » Install

56. Engage the retainer spring (1).

57. Charge Air Cooler Inlet Air Hose (2) » Install

58. Charge Air Cooler Inlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

59. Plenum Front Panel Outer Reinforcement » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

60. Turbocharger Heat Shield (1) » Install

61. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

62. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

63. Exhaust Gas Recirculation Cooler Temperature Sensor (2) » Install and tighten — Fastener Specifications

64. Connect the exhaust gas recirculation cooler temperature sensor retainer (1).

65. Oil Filler Cap » Remove

66. Intake Manifold Cover (2) » Install

67. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

68. Oil Filler Cap » Install

69. Fill the cooling system to the proper level. Cooling System Draining and Filling

70. Start the engine and check for coolant leaks.

71. Inspect the exhaust system for leaks.