Removal And Installation: Turbocharger: Removal
- With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
- Position the hose aside, remove the oil filler cap and remove the engine appearance cover. Reinstall the oil filler cap.
- Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
- Disconnect and position aside the hose from the ACL (air cleaner) housing.
- Detach the power steering reservoir and position aside.
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NOTE: Do not use silicone based sprays or lubricants on any components installed onto or around the diesel exhaust system or intake air distribution and filtering system. Silicone reacts with the Nitrogen Oxides (NOx) sensors and may cause permanent damage to the NOx sensors.NOTE: The catalytic converter works like a catalytic converter/DPF. The fuel vaporizer system glow plug adds diesel fuel to the catalytic converter/ DPF which helps clean the exhaust system emissions.NOTE: If the catalytic converter is not being replaced, the 2 exhaust gas temperature sensors and the 2 NOX sensors do not need to be removed from the catalytic converter. Disconnecting the electrical connectors is still necessary.NOTE: Clean all exhaust connections before reassembly.
Disconnect the exhaust gas temperature sensor wiring connector and wiring retainer.
- Disconnect the 2 hoses to the catalytic converter/DPF.
- Remove the fuel vaporizer system glow plug, Refer to: Fuel Vaporizer System Glow Plug .
- Remove and discard the catalytic converter nuts to the TC.
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NOTE: Typical application shown.
Disconnect the NOX sensor electrical connector and wiring retainers.
- Disconnect the exhaust gas temperature sensor wiring connector.
- Remove the catalytic converter/DPF to DPF fasteners.
- Remove the heat shield and discard the gasket.
- Remove the catalytic converter/DPF to bracket bolts.
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NOTE: The catalytic converter/DPF engine bracket bolts are 2 different sizes. Note the position for installation.
Remove the catalytic converter/DPF engine bracket bolts and position the catalytic converter/ DPF out of the way.
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NOTE: Note the position of the gasket for installation.
Remove and discard the gasket.
- If needed, remove the turbocharger exhaust studs.
- Disconnect the turbocharger outlet tube at the turbocharger and position aside.
- Remove the turbocharger oil drain tube bracket bolt.
- Remove and discard the engine mount nut.
- Position the stand on the RH back corner of the cylinder block. Position a wooden block between the oil pan and the crossmember for added safety. Use the General Equipment: Vehicle/Axle Stands. Use the General Equipment: Wooden Block
- Remove the bolts and the bracket.
- Remove the turbocharger oil drain tube bolts and remove the turbocharger oil drain tube.
- Remove and discard the turbocharger oil drain tube gasket. Replace the turbocharger oil drain tube O-ring seal as necessary.
- Install the bracket and the bolts.
- Remove the stand. Use the General Equipment: Vehicle/Axle Stands
- Remove the lower turbocharger mounting nuts and discard the lower turbocharger mounting nuts.
- Disconnect the turbocharger electrical connector.
- Remove the lower turbocharger heat shield bolt.
- Remove the upper turbocharger heat shield bolts and the turbocharger heat shield.
- Remove the turbocharger oil feed tube assembly and discard the turbocharger oil feed tube assembly.
- Remove the upper turbocharger retaining nut and the turbocharger assembly. Discard the upper turbocharger retaining nut.