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Turbocharger System: Turbocharger: Installation

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
GC0157540Courtesy of CHRYSLER GROUP, LLC
CAUTION:

Insure 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. and

  1. Clean the turbocharger mating surfaces.
  2. Pre-lube the turbocharger with 29.9 - 59.14 ml (1 - 2 oz) clean engine oil.
    NOTE:

    If old gasket appeared to be leaking, check the turbocharger/exhaust manifold mounting flanges for warping. Using a straight edge and feeler gauge measure along the two longest sides of the flanges for warpage. Spec is 0.1 mm (0.004 in.) for the turbocharger flange and 0.05 mm (0.002 in.) maximum.

  3. Using a NEW  gasket, install the turbocharger onto the exhaust manifold studs by coming through right side wheel well and tighten the nuts finger tight.
  4. Using Turbocharger Bolt Wrench Tool (special tool #9866, Wrench, Turbo Charger Bolt), tighten the nuts using a cross pattern to 43 N.m (32 ft. lbs.).
  5. Raise and support the vehicle.
    GC0157540Courtesy of CHRYSLER GROUP, LLC
  6. Inspect the oil drain tube O-rings for nicks or cuts. Replace if necessary. Lubricate the O-rings seals with clean oil.
  7. Install the turbocharger drain tube (5) into engine block.
  8. Using a NEW  gasket, install the turbocharger drain tube bolts (1) and tighten to 24 N.m (18 ft. lbs.).
  9. Using NEW  sealing washers (2), install the lower turbocharger coolant line (3) and tighten the banjo bolt (4) to 24 N.m (18 ft. lbs.).
    GC0155304Courtesy of CHRYSLER GROUP, LLC
  10. Using a NEW  gasket and a NEW  clamp (2), connect the exhaust pipe to the turbocharger exhaust outlet (1) with the clamp facing down as shown in illustration. Tighten the clamp (2) to 17 N.m (13 ft. lbs.). Using a rubber mallet, hit the exhaust pipe to turbocharger clamp three times around the perimeter of the clamp (2) and tighten the clamp (2) to 17 N.m (13 ft. lbs.).
  11. Install the exhaust steady rest bracket to the transmission and tighten the bolts to 43 N.m (32 ft. lbs.).
  12. Install the right engine mount. Refer to INSULATOR, ENGINE MOUNT, FRONT, INSTALLATION, 6.7L  or INSULATOR, ENGINE MOUNT, REAR, INSTALLATION, 6.7L .
    GC0157541Courtesy of CHRYSLER GROUP, LLC
  13. Remove support and lower the vehicle.
  14. Using NEW  sealing washers, install the coolant line (2) to the turbocharger and tighten the banjo bolt (7) and fitting (3) to 24 N.m (18 ft. lbs.).
    NOTE:

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

  15. Install the turbocharger oil pressure line (5) and tighten the fittings (1, 4) to 24 N.m (18 ft. lbs.).
    GC0155256Courtesy of CHRYSLER GROUP, LLC
  16. Connect the turbocharger actuator wire harness connector (1).
  17. Position the NOx wire harness and the turbocharger speed sensor wire harness into retainer clip.
  18. Install the bolt (2) to turbocharger actuator and tighten to 11 N.m (8 ft. lbs.).
    GC0155205Courtesy of CHRYSLER GROUP, LLC
  19. Position the NOx wire harness and the turbocharger speed sensor wire harness into the retainer and close retainer clip (1).
  20. Using a cable tie (2), tie the NOx sensor wire harness and turbocharger speed sensor wire harness together.
    GC0155287Courtesy of CHRYSLER GROUP, LLC
  21. Connect the turbocharger speed sensor wire harness connector (1).
  22. Install the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, INSTALLATION .
    GC0108588Courtesy of CHRYSLER GROUP, LLC
  23. Install the right Charge Air Cooler (CAC) tube (2) to the turbocharger and tighten the clamp (1) to 11 N.m (8 ft. lbs.).
  24. Install the right side wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE .
    GC0108071Courtesy of CHRYSLER GROUP, LLC
  25. Install the inlet tube (2) to the turbocharger and tighten the clamp (1) to 11 N.m (8 ft. lbs.).
  26. Connect the breather hose (3).
  27. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION, 6.7L .
  28. Fill the cooling system. Refer to STANDARD PROCEDURE .
    GC0161582Courtesy of CHRYSLER GROUP, LLC
  29. Install the engine cover (3). Tighten bolts (1) to 10 N.m (89 in. lbs.).
  30. Install the engine oil dip stick (2).
  31. Install the right battery tray. Refer to TRAY, BATTERY, INSTALLATION .
  32. Connect both of the negative battery cables.
  33. Start the engine and check for any cooling or exhaust leaks and confirm the turbocharger is operating properly. For cooling, refer to DIAGNOSIS AND TESTING . For exhaust, refer to DIAGNOSIS AND TESTING . For turbocharger, refer to TURBOCHARGER, DIAGNOSIS AND TESTING, 6.7L .
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