Notice: If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.

1. Tilt the cab. Refer to Cab Tilting in General Information.

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 cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the air inlet hose from the air intake duct.
4. Remove the air inlet hose from the turbocharger.
5. Remove the air inlet from the charge air cooler.
6. Remove the exhaust from the turbocharger. Refer to Exhaust Manifold Replacement .
7. Remove the heat shield at the starter.
8. Remove the coolant feed line.
9. Remove the coolant return line.
10. Remove the oil feed line.
11. Remove the oil return line.
12. Remove the exhaust manifold with the turbocharger. Refer to Exhaust Manifold Replacement in Engine Exhaust.
13. Remove the turbocharger from the exhaust manifold.

Inspect for the following conditions:

•	The turbocharger for any cracks at the gasket mating surfaces

Bearing Radial Clearance

1. Use a dial indicator with an offset plunger and a magnetic base. Adjust the plunger so that the indicator touches the turbocharger main shaft and readjust the gage to zero.
2. Hold the turbocharger, move the compressor wheel up and down, and read the radial clearance. Clearance should be 0.076-0.152 mm (0.003-0.006 in).

Compressor End Play

1. Use a dial indicator with a magnetic base. Adjust the plunger so that the indicator touches the turbocharger main shaft and readjust the gauge to zero.
2. Move the turbocharger mainshaft back and forth and read the end play. Clearance should be 0.025-0.076 mm (0.001-0.003 in).
3. If the bearing radial clearance or the compressor end play is out of specifications, replace the turbocharger center section assembly.

Important: Scribe an alignment mark across the compressor housing (1), center assembly (9), and the turbine housing (5). These parts must be reassembled in the original location.

1. Remove the bolts, lock plates, and clamps from the turbocharger.
2. Remove the compressor housing (5).
3. Remove the turbine housing (1).

Important: 

1. Install the turbine housing (5) to the center assembly (9). Align the scribe marks made at disassembly.
2. Install the compressor housing (1) to the center assembly (9).

Notice: Refer to Fastener Notice in the Preface section.

3. Install the clamps, plates, and bolts.

Tighten

•	Tighten the bolts to the compressor housing to 23 N·m (17 lb ft).

•	Tighten the bolts to the turbine housing to 23 N·m (17 lb ft).

Assembly for proper operation--Turn the compressor wheel by hand. The wheels must rotate freely without binding or noise.

1. Install the gasket with the plain side towards the exhaust manifold.
2. Install the turbocharger to the exhaust manifold.
3. Install the washer and nuts to the exhaust manifold studs.

Tighten
Tighten the nuts to 52 N·m (38 lb ft).

4. Install the oil drain tube and the gaskets to the turbocharger and the oil pan.

Tighten
Tighten the bolts to 27 N·m (20 lb ft).

Important: Pre-lubricate the turbocharger bearings with 118.3 ml (4 oz) of clean engine oil. Pour the clean engine oil into the oil feed port.

Turn the compressor wheel by hand to distribute the oil in the turbocharger. Failure to do so could cause damage to the turbocharger.
5. Install the exhaust manifold and turbocharger assembly. Refer to Exhaust Manifold Replacement in Engine Exhaust.
6. Install the oil feed line to the turbocharger.
7. Install the joint bolt to the oil feed line.

Tighten
Tighten the joint bolts to 18 N·m (13 lb ft).

8. Connect the gasket to the exhaust pipe adapter.
9. Connect the exhaust pipe adapter to the turbocharger.
10. Install the bolts and washers.

Tighten
Tighten the bolts to 26 N·m (19 lb ft).

11. Connect the heat shield to the starter.
12. Install the coolant feed lines.
13. Install the coolant return lines.
14. Connect the air inlet hose to the charge air cooler.
15. Connect the air inlet hose to the turbocharger.
16. Connect the air inlet hose to the air intake duct.
17. Connect the negative battery cables.
18. Lower the cab.