1. Open the hood.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Remove the crankcase depression regulator (CDR) valve. Refer to CDR Valve Replacement in Engine Controls.



5. Remove the air cleaner intake duct from the turbocharger. Refer to Air Cleaner Intake Duct Replacement in Engine Controls.
6. Remove the upper intake manifold. Refer to Intake Manifold Removal in Engine Mechanical-6.5L.



7. Remove the turbocharger heat shield mounting bolts.
8. Remove the turbocharger heat shield.



9. Remove the exhaust pipe clamps from the exhaust pipes that connect the turbocharger to the exhaust manifold.
10. Remove the exhaust pipes that connect the turbocharger to the exhaust manifold.



11. Remove the turbocharger mounting bolts.
12. Remove the turbocharger assembly from the cylinder block.

Important: Usually some quantity of oil will exist inside the vent system. The crankcase vapor consists of vaporized oil that condenses within the vent and intake system. The inside of the air intake duct and compressor wheel housing can be quite oily due to the venting of the crankcase vapors.

Important: Perform the following steps before installing the turbocharger:

1. Install the turbocharger assembly to the cylinder block.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the turbocharger mounting bolts.

Tighten
Tighten the bolts to 65 N·m (48 lb ft).




3. Install the exhaust pipes that connect the exhaust manifolds to the turbocharger.
4. Install the exhaust pipe clamps.

Tighten
Tighten the clamps to 10 N·m (90 lb in).

5. Install the vacuum line to the wastegate actuator.



6. Install the turbocharger heat shield.
7. Install the turbocharger heat shield mounting bolts and nut.

Tighten

1. Tighten the bolts (right and top) to 30 N·m (22 lb ft).
2. Tighten the center bolts to 22 N·m (17 lb ft).
3. Tighten the heat shield nut to 30 N·m (22 lb ft).
8. Install the upper intake manifold. Refer to Intake Manifold Installation in Engine Mechanical-6.5L.



9. Install the air cleaner intake duct to the turbocharger. Refer to Air Cleaner Intake Duct Replacement in Engine Controls.



10. Install the CDR valve. Refer to CDR Valve Replacement in Engine Controls.
11. Connect the battery cable. Refer to Battery Cable Replacement in Engine Electrical.

Important: Run the engine at an idle for at least 2 minutes after completing the installation of the turbocharger. This will allow the oil to lubricate the bearing inside the turbocharger. While running the engine, check for any leaks.

12. Install the engine cover.
13. Close the hood.