Turbocharger Coolant Hoses/Pipes Replacement (Inlet)

Turbocharger Coolant Hoses/Pipes Replacement (Inlet)

Removal Procedure

1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac N Fill) (Service and Repair) .




4. Compress the clamp (1) and disconnect the turbocharger inlet cooling hose/pipe (2) from the thermostat housing.




5. Remove the EGR cooler pipe bolt.




6. Reposition the EGR cooler pipe (4) out of the way.
7. Remove the EGR valve adapter pipe bracket bolts (1).
8. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).





Important: Steps 6 and 7 are to allow for movement of the fuel lines and glow plug bracket to gain access to the turbocharger inlet cooling hose/pipe bolt.


9. Remove the left bank fuel return line bracket bolt (1) and the 2 glow plug module bracket bolts (2).




10. Remove the left bank fuel line bracket bolt.




11. Remove the turbocharger inlet cooling hose/pipe bolt and remove the inlet hose/pipe.



Installation Procedure

1. Position the turbocharger inlet cooling hose/pipe to the vehicle.





Notice: Refer to Fastener Notice .

2. Using new brass seals, install the turbocharger inlet cooling hose/pipe.

Tighten the turbocharger inlet cooling hose/pipe bolt to 25 N.m (18 lb ft).





3. Position the left bank fuel line and install the bracket bolt.

Tighten the fuel line bolt to 25 N.m (18 lb ft).





4. Position the glow module bracket to the valve cover, install the 2 bolts (2) and the remaining left bank fuel line bracket bolt (1).

* Tighten the glow plug module bracket bolts to 10 N.m (89 lb in).
* Tighten the fuel line bracket bolt to 25 N.m (18 lb ft).






5. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
6. Install the EGR valve adapter pipe bracket bolts (1).

Tighten the bolts to 9 N.m (80 lb in).

7. Position the EGR cooler pipe (4).




8. Install the EGR cooler pipe bolt.

Tighten the bolt to 9 N.m (80 lb in).





9. Position the turbocharger inlet cooling hose/pipe (2) to the thermostat housing and position the compression clamp (1) to secure.
10. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac N Fill) (Service and Repair) .
11. Install the engine cover. Refer to Engine Cover Replacement .
12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .