Turbocharger System: Turbocharger: Removal: Removal

WARNING: This page is about a different car, the 2016 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Removing/Installing Engine Cover

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Disconnect and isolate the negative battery cable.
Remove the engine cover (1).

Fig 2: Removing/Installing Intake Manifold Silencer
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Remove the intake manifold silencer pad (1).
Remove the air cleaner body and the air intake hose from turbocharger elbow. Refer to BODY, AIR CLEANER, REMOVAL .
Remove the right fuel injector silencer pad (1).
Disconnect the CAC inlet hose from turbocharger.
Remove the left fuel injector silencer pad.
Drain the coolant. Refer to STANDARD PROCEDURE .
Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
Remove the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
Remove the left front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
Remove the transmission. Refer to REMOVAL .

Fig 3: Remove/Install Diesel Particulate Filter (DPF)
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Remove the nuts (2) and the Diesel Particulate Filter (DPF) elbow (3) from the turbocharger.

Fig 4: EGR Cooler Tube & Bolts
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Remove the EGR cooler tube bolts (2).
Remove the support and lower the vehicle.

Fig 5: Turbocharger-To-EGR Cooler Tube Bolts
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Remove the bolts (1) and the EGR cooler tube (2).
Remove the left exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL .
Remove the right exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL .

Fig 6: Fuel Rail Cross-Over Line & Bolt
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Remove the bolt (2) that secures the cross-over fuel tube to the intake manifold.
Remove the fuel rail cross-over tube (1) and discard the tube.

Fig 7: Air Outlet Temperature Sensor
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Disconnect the turbocharger outlet temperature sensor wire harness connector (1).

Fig 8: Turbocharger Outlet Elbow & Bolts
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Remove the bolts (2) and the turbocharger outlet elbow (1).
Disconnect the turbocharger actuator wire harness connector.
Remove the exhaust pressure sensor. Refer to SENSOR, EXHAUST PRESSURE, REMOVAL .

Fig 9: Turbocharger Oil Supply Line & Upper Banjo Bolt
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Remove the upper banjo bolt (1) and the turbocharger oil supply line (2).

Fig 10: Coolant Tube & Upper Banjo Bolt
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Remove the upper banjo bolt (1) securing the coolant tube (3) to the turbocharger.
Raise and support the vehicle.

Fig 11: Upper Banjo Bolt & Turbocharger Supply Lines
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Remove the banjo bolt (2) at the engine block for the turbocharger oil supply line (3).

Fig 12: Coolant Tube & Lower Banjo Bolt
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Remove the lower banjo bolt (1) securing the coolant tube (2) to turbocharger.

Fig 13: Actuator, Turbo, Heat Shield & Bolts
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Remove the turbo mounting bolts (3).
NOTE:
The turbocharger oil return line is fitted into a rubber grommet on the engine block. Care must be used when removing the turbocharger, that the return line is not damaged.
With care, lift the turbo upwards and away from the engine block, to remove the turbocharger oil return tube from the engine block.

Fig 14: Remove/Install Turbocharger
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If necessary, remove the bolts (4) and the turbocharger oil return line (3).
If necessary, remove and discard the gasket (2).