Removal And Installation

REMOVAL 

1. Disconnect and isolate the negative battery cable(s). Refer to STANDARD PROCEDURE .
2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
3. Drain the cooling system. Refer to COOLING - STANDARD PROCEDURE .
4. Remove the right wheel house splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION .

   Courtesy of CHRYSLER GROUP, LLC

5. Cut the high temperature cable tie (3) securing the NOx sensor wire harness, turbocharger actuator wire harness, and the turbocharger speed sensor wire harness.
6. Unscrew the plastic clip (2) securing wire harness to turbocharger actuator.
7. Disconnect the turbocharger actuator wire harness connector (1) from the turbocharger by cleaning the connector to remove debris, pulling the light gray release lever away from the locked position with your thumb nail until it clicks into the unlocked position, then holding the light grey release lever down while pulling the connector apart.

   Courtesy of CHRYSLER GROUP, LLC

8. Remove the bolts (2, 3) and the turbocharger actuator (1).
9. Remove and discard the gasket.

INSTALLATION 

Courtesy of CHRYSLER GROUP, LLC

1. Clean turbocharger actuator housing (2) and turbocharger mounting surfaces.
   CAUTION:

   The electronic turbocharger actuator (2) must be removed from the turbocharger to perform this function. Turbocharger failure could result if the electronic turbocharger actuator (2) is not removed from the turbocharger.

2. Position the turbocharger actuator (2) into the engine compartment so the actuator gear (1) will be free to rotate.
   NOTE:

   Keep fingers away from actuator gear in case of movement.

3. Connect turbocharger actuator wire harness connector.
4. Connect the negative battery cable(s). Refer to STANDARD PROCEDURE .
5. Turn ignition to on position, DO NOT START THE ENGINE.  Using the scan tool, create a freeze frame of all current DTCs and then clear them.
6. Using a scan tool function "Misc functions" under PCM, perform VG Turbocharger Actuator Pre-Alignment/Self Calibrate.
   NOTE:

   This is a two step process, the tool will perform the Pre-align portion first (very quickly) followed by the Self Calibration portion.

   NOTE:

   Do not turn off the ignition or disconnect the tool after performing the turbocharger actuator pre-align portion of the routine.

   Courtesy of CHRYSLER GROUP, LLC

7. Install a NEW  O-ring seals (1) on the turbocharger actuator.

   Courtesy of CHRYSLER GROUP, LLC

8. Install the sector gear travel gauge (3) (provided in actuator kit) onto the turbocharger.
9. With the sector gear travel gauge installed (3), grasp the sector gear (2) by hand and rotate the sector gear (2) toward the turbocharger turbine housing. Be sure the sector gear (2) is rotated all the way toward the install position arrow (1).
   NOTE:

   It is critical for smooth reliable operation of the actuator to use the full amount of the Holset® supplied grease.

   CAUTION:

   Use only turbocharger actuator grease supplied in the service kit. Use of any other type of grease or too much grease may result in damage to turbocharger. Use the full amount of grease supplied with the service kit.

10. Coat the teeth on the sector gear (2) with the full amount of grease supplied in the packet from installation kit.
11. Remove the sector travel gauge. DO NOT  move the sector gear after this point.
12. Install the guide pins onto turbocharger top two mounting screw holes.
13. Insert the bottom two NEW  screws into actuator mounting holes before placing onto turbocharger.
14. Position turbocharger actuator onto guide pins and install the two bottom bolts finger tight.
15. Remove the two guide pins from top holes and install NEW  bolts finger tight.

    Courtesy of CHRYSLER GROUP, LLC

16. Install all four screws (2, 3) and tighten to the proper and go to step 19. Refer to TORQUE SPECIFICATIONS .
17. If this screw (3) is not accessible, tighten the screw (2) to the proper and go to step 18. Refer to TORQUE SPECIFICATIONS .
    NOTE:

    These are the only three screws that are accessible in the 3500 Chassis. 

    NOTE:

    Technician will notice a significant increase in resistance when the cap screw head come into contact with the actuator body. 

18. Using an Allen Wrench, tighten the remaining cap screw (3) until it is flush with the actuator body. After screw (3) has been brought flush with the actuator housing, tighten the screw an additional 90° turn.

    Courtesy of CHRYSLER GROUP, LLC

19. Install the plastic clip (2) securing the wire harness to the turbocharger actuator.
20. Install high temperature cable tie (3) securing turbo actuator harness, NOx sensor wire harness, and turbo speed sensor harness.
21. Connect the turbocharger actuator wire harness connector (1).
22. Now, after actuator is installed, using scan tool, perform the self calibration portion of the "VG Turbocharger Actuator Pre-Alignment/Self Calibrate routine.
    NOTE:

    Clear any DTCs that may appear after Pre-Alignment/Self Calibrate procedure is complete. 

    NOTE:

    Actuator may take multiple attempts to calibrate/learn with turbocharger.

    NOTE:

    If calibration fails, remove Electronic Turbocharger Actuator and go back to step 1 to repeat calibration.

23. Power down the PCM (key off). Automatic Transmission equipped trucks must have key off for at least 10 minutes.
24. Install the right wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION .
25. Remove the support and lower the vehicle.
26. Fill the cooling system. Refer to COOLING - STANDARD PROCEDURE .