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Turbocharger System: Turbocharger: Installation: Installation

WARNING: This page is about a different car, the 2013 RAM 3500 HD and 2013 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Bolts, Sealing Washers, Turbocharger Coolant Tube, Banjo Bolt & Turbocharger Drain Tube
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.
  3. Replace the banjo fitting seals (2) on the turbocharger coolant lines.
  4. Using a new gasket, position the turbocharger onto the exhaust manifold studs by lowering the turbocharger through the engine compartment.
    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 (0.0039 inch) for the turbocharger flange and 0.05 mm (0.002 inch) maximum.

  5. Install the turbocharger mounting nuts. Using Turbocharger Tool (special tool #9866, Wrench, Turbo Charger Bolt), using a cross pattern, tighten the nuts to 43 N.m (32 ft. lbs.).
  6. Install the intake air heater relay to the battery tray. Refer to HEATER, AIR INTAKE, INSTALLATION .
  7. Raise and support the vehicle.
  8. Inspect the oil drain tube O-rings for nicks or cuts. Replace if necessary. Oil the O-rings with new oil.
  9. Position the turbocharger drain tube (5) into engine block.
  10. Using a new gasket, install the turbocharger drain tube mounting bolts (1). Tighten bolts (1) to 24 N.m (18 ft. lbs.).
    Fig 2: Turbocharger Exhaust Outlet & V-Clamp
    GC0155304Courtesy of CHRYSLER GROUP, LLC
  11. Using a gasket and new clamp (2), connect the exhaust pipe to the turbocharger exhaust outlet (1) with the clamp facing down as shown in the 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.).
  12. Install the exhaust steady rest bracket to the transmission. Tighten bolts to 43 N.m (32 ft. lbs.).
  13. Install the right side engine mount. Refer to INSULATOR, ENGINE MOUNT, FRONT, INSTALLATION, 6.7L  and INSULATOR, ENGINE MOUNT, REAR, INSTALLATION, 6.7L .
    Fig 3: Union Nuts, Coolant Tube, Turbocharger Oil Supply Line, Cable tie & Banjo Bolt
    GC0157541Courtesy of CHRYSLER GROUP, LLC
  14. Using new sealing washers, install the coolant line (2) to the turbocharger. Tighten the banjo bolt (7) and fitting (3) 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 (1, 4). Tighten the fitting to 24 N.m (18 ft. lbs.).
    Fig 4: Turbocharger Actuator Wire Harness Connector & Bolt
    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 and install bolt to turbocharger actuator. Tighten bolt to 11 N.m (97 in. lbs.).
    Fig 5: Clip & Cable Tie
    GC0155205Courtesy of CHRYSLER GROUP, LLC
  18. Position the NOx wire harness and the turbocharger speed sensor wire harness and close retainer clip (1).
  19. Using a cable tie (2), tie the NOx sensor wire harness and turbocharger speed sensor wire harness together.
    Fig 6: Speed Sensor Wire Harness Connector, Speed Sensor & Cable Tie
    GC0155287Courtesy of CHRYSLER GROUP, LLC
  20. Connect the turbocharger speed sensor wire harness connector (1).
    Fig 7: Identifying Clamp, Outlet Tube & Breather Hose
    GC0108071Courtesy of CHRYSLER GROUP, LLC
  21. Install the outlet tube (2) to the turbocharger. Tighten the clamp (1) to 11 N.m (97 in. lbs.).
  22. Connect the breather hose (3).
    Fig 8: Identifying Clamp & Outlet Tube
    GC0108588Courtesy of CHRYSLER GROUP, LLC
  23. Install the Charge Air Cooler (CAC) inlet tube to the turbocharger inlet. Tighten the clamp to 11 N.m (8 ft. lbs.).
  24. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION, 6.7L .
  25. Install the right side wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION or SHIELD, SPLASH, REAR WHEELHOUSE, INSTALLATION .
  26. Lower the vehicle.
  27. Fill the cooling system. Refer to STANDARD PROCEDURE .
    Fig 9: Engine Cover, Bolts & Oil Dipstick
    GC0155408Courtesy of CHRYSLER GROUP, LLC
  28. Install the engine cover (2) and fasteners (1, 4).
  29. Install the engine oil dip stick (3).
  30. Position and connect the right hand side positive battery cable
  31. Connect the negative battery cable on both batteries.
  32. Check for any cooling or exhaust leaks and confirm the turbocharger is operating properly. Refer to TURBOCHARGER, DIAGNOSIS AND TESTING, 6.7L .
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