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Removal And Installation

WARNING: This page is about a different car, the 2019 RAM 3500 HD and 2019 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

REMOVAL 

  1. Disconnect and isolate the negative battery cable(s). Refer to STANDARD PROCEDURE .
  2. Remove the right battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
  3. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION, 6.7L .
  4. Remove the clean air hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION, 6.7L .
    GC0185631Courtesy of CHRYSLER GROUP, LLC
  5. Loosen the clamp (3) and remove the breather hose (2) from the turbocharger.
    GC0184798Courtesy of CHRYSLER GROUP, LLC
  6. Loosen the clamp nut (1) and remove the right Charge Air Cooler (CAC) hose (2).
  7. Remove the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL AND INSTALLATION .
  8. Remove the A/C suction line. Refer to LINE, A/C SUCTION JUMPER, REMOVAL AND INSTALLATION .
    GC0185677Courtesy of CHRYSLER GROUP, LLC
  9. Cut high temperature cable tie (1) securing NOx sensor wire harness to the turbo oil supply tube.
  10. Cut high temperature cable tie (2) securing the NOx sensor wire harness, turbo actuator harness, and turbo speed sensor harness.
    GC0185609Courtesy of CHRYSLER GROUP, LLC
  11. Cut the high temperature cable tie (1) securing the NOx sensor wire harness, turbocharger actuator wire harness and turbo speed sensor harness to the oil drain tube.
  12. Carefully separate the clip (2) securing the turbocharger speed sensor wire harness connector.
  13. Disconnect the turbocharger speed sensor wire harness connector (4).
    GC0185742Courtesy of CHRYSLER GROUP, LLC
  14. Unscrew the plastic clip (2) securing wire harness to turbocharger actuator.
  15. Disconnect 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.
    GC0184628Courtesy of CHRYSLER GROUP, LLC
  16. Remove the union nuts (1, 3) and the turbocharger coolant return line (2).
  17. Remove the union nuts (4, 6) and the turbocharger oil supply line (5).
    GC0185979Courtesy of CHRYSLER GROUP, LLC
  18. Remove the bolts (1) and the turbocharger oil drain tube (2) from the turbocharger.
  19. Remove the banjo bolts (3, 5) and the coolant supply tube (4).
  20. Remove the exhaust outlet connector elbow from the turbocharger. Refer to CONNECTOR, EXHAUST OUTLET, REMOVAL AND INSTALLATION .
    GC0185128Courtesy of CHRYSLER GROUP, LLC
  21. Using the Turbocharger Bolt Wrench Tool (special tool #9866, Wrench, Turbo Charger Bolt), remove the right side turbocharger to exhaust manifold nuts (1).
    GC0185234Courtesy of CHRYSLER GROUP, LLC
  22. Using the Turbocharger Bolt Wrench Tool (special tool #9866, Wrench, Turbo Charger Bolt), remove the left side turbocharger to exhaust manifold nuts (2).
  23. Remove the turbocharger (1) from the vehicle coming through the right side wheel well.
    GC0184970Courtesy of CHRYSLER GROUP, LLC
  24. If necessary, remove the bolts (1) and the upper heat shield (2).
    GC0186096Courtesy of CHRYSLER GROUP, LLC
  25. If necessary, remove the bolts (2) and the lower heat shield (1).
  26. Clean the turbocharger mating surfaces.
  27. Inspect the turbocharger for damage, if necessary replace the turbocharger. Refer to TURBOCHARGER, INSPECTION, 6.7L .

INSTALLATION 

CAUTION:

Verify that turbocharger and charge air cooler are free of excess oil and debris. Do not allow any water or solvents to enter the turbocharger inlet or outlet. If necessary, clean turbocharger and the charge air cooler.

  1. Clean the turbocharger mating surfaces.
    GC0186096Courtesy of CHRYSLER GROUP, LLC
  2. If removed, install the lower turbocharger heat shield (1) and tighten the bolts (2) to the proper specification. Refer to TORQUE SPECIFICATIONS .
    GC0184970Courtesy of CHRYSLER GROUP, LLC
  3. If removed, install the upper turbocharger heat shield (2) and tighten the bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
  4. Pre-lube the turbocharger with 29.9 - 59.14 ml (1 - 2 oz) of clean engine oil.
    GC0185234Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If old gasket appeared to be leaking, check the turbocharger/exhaust manifold mounting flanges for warping. Using a straight edge across the longest sections of the flange, measure the flatness using a feeler gauge. Warpage shall not exceed 0.1 mm (0.004 in.). When measuring the exhaust manifold flanges, the total sum of exhaust flange and the turbocharger flange cannot exceed 0.1 mm (0.004 in.). If this is the case, the component with the greatest warpage must be replaced.

  5. Using a NEW  gasket, install the turbocharger (1) onto the exhaust manifold studs by coming through right side wheel well and tighten the left side nuts (2) finger tight.
    GC0185128Courtesy of CHRYSLER GROUP, LLC
  6. Install the right side nuts (1) and tighten finger tight.
  7. Using Turbocharger Bolt Wrench Tool (special tool #9866, Wrench, Turbo Charger Bolt), tighten the four nuts using a cross pattern to the proper specification.

    Refer to TORQUE SPECIFICATIONS .

  8. Install the exhaust outlet connector elbow to the turbocharger. Refer to CONNECTOR, EXHAUST OUTLET, REMOVAL AND INSTALLATION .
    GC0157537Courtesy of CHRYSLER GROUP, LLC
  9. Install NEW  O-rings (2) onto the turbocharger drain tube (1). Lubricate with clean engine oil.
  10. Install the turbocharger drain tube (1) into engine block.
    GC0185979Courtesy of CHRYSLER GROUP, LLC
  11. Using a NEW  gasket, install the turbocharger oil drain tube (2) and tighten the bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
  12. Using NEW  sealing washers, install the turbocharger coolant supply line (4) and tighten the banjo bolts (3, 5) to the proper specification. Refer to TORQUE SPECIFICATIONS .
    GC0184628Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Maintain a 10 mm minimum distance between the oil supply line and the turbine housing or exhaust manifold. Maintain a 5 mm minimum distance between the oil supply line and any other component.

  13. Using NEW  O-ring seals, install the turbocharger oil supply line (5) and tighten the union nuts (4, 6) to the proper specification. Refer to TORQUE SPECIFICATIONS .
  14. Using NEW  O-ring seals, install the coolant return line (2) to the turbocharger and tighten the union nuts (1, 3) to the proper specification. Refer to TORQUE SPECIFICATIONS .
    GC0185742Courtesy of CHRYSLER GROUP, LLC
  15. Connect the turbocharger actuator wire harness connector (1).
  16. Screw in the plastic clip (2) securing the turbocharger actuator wire harness.
    GC0185609Courtesy of CHRYSLER GROUP, LLC
  17. Connect the turbocharger speed sensor wire harness connector (4).
  18. Attach clip (2) in its original location to secure the turbo speed sensor connector.
  19. Install high temperature cable tie (1) securing the NOx sensor wire harness, turbo actuator wire harness, and turbo speed sensor wire harness to the oil drain tube.
    GC0185677Courtesy of CHRYSLER GROUP, LLC
  20. Install a NEW  high temperature cable tie (2) securing the NOx sensor wire harness, turbo actuator wire harness, and turbo speed sensor wire harness.
  21. Install a NEW  high temperature cable tie (1) to secure the NOx sensor wire to the oil supply tube.
  22. Install the A/C suction line. Refer to LINE, A/C SUCTION JUMPER, REMOVAL AND INSTALLATION .
  23. Install the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL AND INSTALLATION .
    GC0184798Courtesy of CHRYSLER GROUP, LLC
  24. Install the right Charge Air Cooler (CAC) tube (2) to the turbocharger and tighten the clamp nut (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
    GC0185631Courtesy of CHRYSLER GROUP, LLC
  25. Connect the breather hose (2) to the turbocharger and tighten the clamp (3).
  26. Install the clean air hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION, 6.7L .
  27. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION, 6.7L .
  28. Install the right battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
  29. Connect the negative battery cable(s). Refer to STANDARD PROCEDURE .
  30. Start the engine and check for any cooling or exhaust leaks and confirm the turbocharger is operating properly. Refer to TURBOCHARGER, DIAGNOSIS AND TESTING, 6.7L , EXHAUST SYSTEM - DIAGNOSIS AND TESTING and COOLING - DIAGNOSIS AND TESTING .
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