WARNING: To prevent personal injury or death, read all safety instructions in the “Safety Information” section of this manual.
WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures.
WARNING: To prevent personal injury or death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
WARNING: To prevent personal injury or death, disconnect ground (-) cable from battery before doing service or diagnostic procedures.
WARNING: To prevent personal injury or death, allow engine to cool before working with components.
WARNING: To prevent personal injury or death, inspect turbocharger with engine off,
and turbocharger not spinning. Turbocharger
components may be extremely hot. Turbocharger wheels are very sharp and spin at high speeds.
WARNING: To prevent personal injury or death, support turbocharger assembly during removal and installation.
WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a threat
to the environment. Recycle or dispose
of engine fluids and filters according to
applicable regulations. Never put engine
fluids in the trash, on the ground, in sewers, or bodies of water.
Clean Engine
1. Disconnect the negative battery cable.
2. Cap all engine openings to prevent water and degreasing agents from entering engine.
3. Cover exposed electrical connectors and the ECM using plastic and duct tape.
4. Use an appropriate detergent mixed in the correct ratio and apply to engine using a hot pressure washer or similar cleaning equipment.
Drain Coolant
Figure 42 Coolant drain plug
1. Place a coolant drain pan under the oil system module.
2. Remove M18 coolant drain plug from the bottom of the oil system module. Open radiator cap to allow system to drain quicker.
3. Remove and discard coolant drain plug O-ring.
4. Install a new O-ring on the coolant drain plug.
5. After coolant has drained, install coolant drain plug in the oil system module.
6. Tighten coolant drain plug to special torque (page 64).
7. Recycle or dispose of coolant according to applicable regulations.
Drain Oil
Figure 43 Oil drain plug removal
1. Place an oil drain pan beneath the oil drain plug.
2. Remove the M25 oil pan drain plug and discard O-ring.
3. Inspect drain plug and replace if necessary.
4. Install a new O-ring on the oil drain plug.
5. After oil has drained, install oil drain plug in the oil pan.
6. Tighten oil drain plug to special torque (page 64).
7. Recycle or dispose of oil according to applicable regulations.
Removal
Variable Geometry Turbocharger (VGT)
Figure 44 VGT actuator connector and
turbocharger air intake duct 1. Turbocharger air intake duct 2. Breather tube
3. Lock tab (up to unlock) 4. Release tab (push to release) 5. VGT actuator
1. Loosen worm gear clamps on the turbocharger air intake duct and breather tube. Pull turbocharger air intake duct assembly off the VGT and crankcase breather.
2. Push lock tab up to unlock VGT actuator connector.
3. Press the release tab and pull sensor harness connector out of the VGT actuator connector.
Figure 45 Turbocharger oil supply tube assembly
1. Turbocharger oil supply tube nut 2. M8 x 25 bolt (2)
4. Remove the turbocharger oil supply tube nut from the fitting on top of the oil filter header.
5. Remove two M8 x 25 bolts connecting the turbocharger oil supply tube assembly to the VGT oil supply port and remove the tube assembly.
Figure 46 VGT oil drain tube, bracket, and bolt 1. M8 x 16 bolt
2. Oil drain tube bracket 3. Oil drain tube
6. Remove M8 x 16 bolt from VGT oil drain tube bracket and remove bracket.
7. Pull oil drain tube out of crankcase.
Figure 47 VGT mounting
1. M10 VGT mounting nut (4) 2. Turbocharger mounting gasket 3. VGT mounting stud
NOTE: To aid removal of the turbocharger, loosen four M10 nuts ¼ turn then tap each nut using a socket or flat punch and hammer. This will knock the “peaks” of the threads down, allowing the nuts to unthread easily.
WARNING: To prevent personal injury or death, support the turbocharger assembly during removal and installation.
8. Remove three of four M10 mounting nuts holding the VGT assembly to the exhaust manifold.
9. Support the VGT assembly and remove the fourth M10 nut holding the VGT to the exhaust manifold.
10. Remove the VGT assembly and oil drain tube.
11. Cap openings on turbocharger assembly. If plastic caps are not available, use duct tape to cover openings.
EGR Coolant Supply Tube
Figure 48 EGR coolant supply tube
1. Exhaust side EGR cooler assembly
2. M8 x 25 bolt (front cover EGR coolant supply port)
3. M8 nut, 2-piece tube support, and flat washer
4. M8 x 25 bolt
1. Remove M8 nut and 2-piece tube support.
2. Remove M8 x 25 bolt from front cover EGR coolant supply port.
3. Remove M8 x 25 bolt from the exhaust side EGR cooler.
4. Pull EGR coolant supply tube down and out of the exhaust side EGR cooler.
5. Pull EGR coolant supply tube back and out of the front cover.
Oil Filter
Figure 49 Oil filter 1. Oil filter header 2. Heat exchanger 3. Oil filter (spin-on) 4. Oil filter gasket
1. Place an oil drain pan under the oil filter.
2. Rotate oil filter counterclockwise with an oil filter wrench (page 64) and remove oil filter.
3. Remove oil filter gasket if stuck to the oil filter header.
4. Recycle or dispose of oil and filter according to applicable regulations.
Oil System Module Assembly
Figure 50 Oil system module and coolant tube 1. Turbocharger oil supply tube fitting
2. M8 x 30 stud bolt 3. M8 x 30 bolt (7)
4. M8 x 30 coolant tube bolt 5. M8 x 20 stud bolt
1. Place a drain pan under the oil system module.
2. Remove seven M8 x 30 bolts and one M8 x 30 stud bolt holding the oil system module to the crankcase. Remove oil system module from the crankcase.
3. Remove M8 x 30 coolant tube bolt and M8 x 20 stud bolt.
4. Pull coolant tube out of front cover.
5. Recycle or dispose of oil and coolant according to applicable regulations.