Turbocharger Coolant Hoses/Pipes Replacement Inlet

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.



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).




Note: 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.

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

Caution: Refer to Fastener Caution in the Preface section.




2. Using new brass seals, install the turbocharger inlet cooling hose/pipe bolt and tighten to 25 N·m (18 lb ft).



3. Position the left bank fuel line and install the bracket bolt then tighten 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) and tighten to 9 N·m (80 lb in).
7. Position the EGR cooler pipe (4).



8. Install the EGR cooler pipe bolt and tighten 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.
11. Install the engine cover. Refer to Engine Cover Replacement.
12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.

Turbocharger Coolant Hoses/Pipes Replacement Outlet

1. Remove the engine cover. Refer to Engine Cover Replacement.



2. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
3. Remove the EGR cooler pipe bolt.



4. Reposition the EGR cooler pipe (4) out of the way.
5. Remove the EGR valve adapter pipe bracket bolts (1).
6. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
7. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement.
8. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
9. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.



10. Remove the turbocharger outlet cooling hose/pipe bolt from the valve cover.



11. Remove the turbocharger outlet cooling hose/pipe bolt.
12. Compress the clamp and disconnect the turbocharger cooling hose/pipe from the thermostat bypass pipe.



13. Remove the turbocharger outlet cooler pipe to turbocharger nut.




Note: Steps 11 and 12 are to allow movement of the fuel lines and glow plug bracket to gain access to the turbocharger inlet cooling hose/pipe bolt.

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



15. Remove the left bank fuel line bracket bolt.



16. Remove the turbocharger outlet cooling hose/pipe to turbocharger bolt and remove the inlet hose/pipe.

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

Caution: Refer to Fastener Caution in the Preface section.




2. Using new brass seals, install the turbocharger inlet cooling hose/pipe bolt and tighten to 25 N·m (18 lb ft).



3. Position the left bank fuel line and install the bracket bolt and tighten to 25 N·m (18 lb ft).



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

4.1.	Tighten the glow plug module bracket bolts to 10 N·m (89 lb in).

4.2.	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) and tighten to 9 N·m (80 lb in).
7. Position the EGR cooler pipe (4).



8. Install the EGR cooler pipe bolt and tighten to 9 N·m (80 lb in).



9. Install the turbocharger outlet cooler pipe to the turbocharger nut and tighten to 9 N·m (80 lb in).



10. Compress the clamp and connect the turbocharger cooling hose/pipe to the thermostat bypass pipe.



11. Install the turbocharger outlet cooling hose/pipe to the valve cover and tighten turbocharger outlet pipe bolt to 9 N·m (80 lb in).
12. Install the turbocharger outlet cooling hose/pipe bolt and tighten to 9 N·m (80 lb in).
13. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
14. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
15. Install the EGR cooler tube replacement. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
16. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement.
17. Install the engine cover. Refer to Engine Cover Replacement.
18. Perform the turbocharger learn procedure. Refer to Turbocharger Learn.