Removal And Installation: Turbocharger: Installation

NOTE: Make sure that the mating faces are clean and free of foreign material.

NOTE: Failure to inspect the components for debris may result in repeat failures.

NOTE: It may be necessary to use a borescope to inspect the components.

When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace the components as needed.
- CAC and the CAC tubes
- Intake air system
- Exhaust manifolds
- EGR cooler and pipes
- Diesel Oxidation Catalyst (DOC)
- Turbocharger (on engine failure only)
Replace the turbocharger mounting studs.
Torque: 124 lb.in (14 Nm)

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Install the turbocharger assembly and the new upper turbocharger retaining nut.
Torque: Stage 1: 133 lb.in (15 Nm) Stage 2: 17 lb.ft (23 Nm)

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Make sure a new turbocharger oil supply tube assembly with new turbocharger oil supply tube bolts and new turbocharger oil supply tube sealing washers are installed.

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Install the new turbocharger oil feed tube assembly with new turbocharger oil feed tube bolts and new turbocharger oil feed tube sealing washers.
Torque: 177 lb.in (20 Nm)

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Install the turbocharger heat shield and the upper turbocharger heat shield bolts.
Torque: 18 lb.ft (25 Nm)

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Install the lower turbocharger heat shield bolt.
Torque: 17 lb.ft (23 Nm)

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Connect the turbocharger electrical connector.

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Install the new lower turbocharger mounting nuts.
Torque: Stage 1: 133 lb.in (15 Nm) Stage 2: 17 lb.ft (23 Nm)

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Position the stand on the RH back corner of the cylinder block. Use the General Equipment: Vehicle/Axle Stands

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Remove the bolts and the bracket.

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Install a new turbocharger oil drain tube gasket and lubricate the turbocharger oil drain tube O-ring seal with clean engine oil. Refer to: Specifications .

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Install the turbocharger oil drain tube and the turbocharger oil drain tube bolts only finger tight at this stage.

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Install the bracket and the bolts.
Torque: 46 lb.ft (63 Nm)

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Remove the stand and then remove the wooden block between the oil pan and the crossmember. Use the General Equipment: Vehicle/Axle Stands. Use the General Equipment: Wooden Block

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Install the new engine mount nut.
Torque: 85 lb.ft (115 Nm)

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Install the turbocharger oil drain tube bracket bolt finger tight at this stage.

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1. Tighten the upper turbocharger drain tube bolts.
  Torque: 89 lb.in (10 Nm)
2. Tighten the lower turbocharger drain tube bolt.
  Torque: 17 lb.ft (23 Nm)
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Tighten the turbocharger oil drain tube bracket bolt.
Torque: 17 lb.ft (23 Nm)

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Position back and connect the turbocharger outlet tube at the turbocharger.
Torque: 44 lb.in (5 Nm)

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If removed, install and tighten the turbocharger exhaust studs.
Torque: 18 lb.ft (25 Nm)

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NOTE: Install the gasket with the tab at the top inboard corner.

Install a new gasket.

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NOTE: The catalytic converter/DPF engine bracket bolts are 2 different sizes. Install in same position noted from removal.

NOTE: Do not tighten the fasteners at this time.

Install the catalytic converter/DPF and install the engine bracket bolts hand tight.

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Install a new gasket and the heat shield.

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Install the catalytic converter/DPF to DPF fasteners.
Torque: 30 lb.ft (40 Nm)

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Connect the exhaust gas temperature sensor wiring connector.

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NOTE: Typical application shown.

Connect the NOX sensor electrical connector and wiring retainers.

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Install the new catalytic converter/DPF nuts to the TC.
Torque: 30 lb.ft (40 Nm)

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Tighten the catalytic converter/DPF engine bracket bolts.
Torque: 18 lb.ft (25 Nm)

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Install the catalytic converter/DPF to bracket bolts.
Torque: 18 lb.ft (25 Nm)

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Install the fuel vaporizer system glow plug. Refer to: Fuel Vaporizer System Glow Plug .
Connect the 2 hoses to the catalytic converter/DPF.

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Connect the exhaust gas temperature sensor wiring connector and wiring retainer.

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Reposition and attach the power steering reservoir.

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Reposition and connect the hose to the air cleaner.

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Install the air cleaner outlet tube. Refer to: Air Cleaner Outlet Pipe .
Remove the oil filler cap. Install the engine appearance cover, reposition the hose and install the oil filler cap.

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Check the exhaust system for leaks.