Exhaust Pipe: Service and Repair

Turbocharger Inlet Y-Pipe





Material





Removal
1. Remove the turbocharger assembly.
2. Remove the fuel injector control module bracket from the LH valve cover.





3. NOTE: There is a metal gasket between the exhaust inlet pipe and the exhaust gas recirculation (EGR) cooler.

Remove the exhaust inlet pipe-to-EGR cooler clamp.





4. Remove the LH exhaust inlet pipe-to exhaust manifold nuts.





5. Remove the RH exhaust inlet pipe-to exhaust manifold nuts.
6. Carefully remove the exhaust inlet pipe assembly from the vehicle.

Installation

1. NOTE: When installing the exhaust inlet pipe into the vehicle, do not bend or twist the flex bellows.

Install the exhaust inlet pipe. Position the pipe to the exhaust manifolds.
2. Apply anti-seize lubricant to the exhaust inlet pipe bolts, then install the bolts and nuts. Do not tighten the nuts at this time.





3. Install the metal gasket on the EGR cooler and align the exhaust inlet pipe to the EGR cooler. Position the clamp and tighten to specification.
4. Install the fuel injector control module bracket.
5. Install the turbocharger assembly.
^ Place the turbocharger onto the mounting bracket. Make sure the exhaust inlet pipe is correctly aligned to the turbocharger. If it is not, loosen the mounting bracket and reposition the turbocharger and the mounting bracket for correct alignment. Complete the turbocharger installation.





6. Make sure the exhaust inlet pipe is correctly aligned to the exhaust manifolds. Using hand tools, alternately tighten the nuts to draw the pipe to the exhaust manifold. There should be an equal gap spacing between the pipe flange and the exhaust manifold flange at both the top and bottom bolts.








7. Alternately tighten the exhaust inlet pipe-to-exhaust manifold nuts to specification.
8. Check the system for leaks.