Ram Truck 1500, 2500 & 3500 (2006-2008)

Turbocharger

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Removal & Installation



5.9L Diesel Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cables.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Disconnect the exhaust pipe from the turbocharger elbow.
  8.  
  9. Disconnect the exhaust system from the exhaust hangers and move the system rearward.
  10.  
  11. Remove the exhaust elbow from the turbo.
  12.  
  13. Remove the bolts from the turbocharger oil drain tube. Remove oil drain tube from engine.
  14.  
  15. Disconnect wastegate command valve connector.
  16.  
  17. Remove two lower turbocharger mounting nuts.
  18.  
  19. Lower the vehicle.
  20.  
  21. Disconnect the turbocharger air inlet hose.
  22.  
  23. Disconnect the turbocharger oil supply line from the turbocharger.
  24.  
  25. Disconnect the charge air cooler inlet pipe from the turbocharger compressor outlet.
  26.  
  27. Remove two upper turbocharger mounting nuts.
  28.  
  29. Remove the turbocharger and gasket from the exhaust manifold from the top of the vehicle.
  30.  
  31. If the turbocharger is not to be installed immediately, cover the opening to prevent material from entering into the manifold.
  32.  
  33. If replacing the turbocharger, transfer the turbocharger oil supply fitting to the new assembly. Tighten fitting to 27 ft. lbs. (36 Nm).
  34.  
  35. Clean and inspect the sealing surface.
  36.  
  37. Using a straight edge and feeler gauge, measure the flatness between the two longest sections of the turbocharger mounting flange. Specification is 0.0039 inch. (0.1 mm) maximum.
  38.  
  39. Using a straight edge and feeler gauge, the exhaust manifold flange. Specification is 0.0039 inch (0.1 mm) maximum. The combined measurements of the turbocharger and the exhaust manifold flanges must not exceed the maximum spec of either of the two flanges. Example: if the turbocharger flange measured 0.005 mm and the exhaust manifold flange measures 0.005 mm then the spec.
    WARNING
    The Wastegate Command Valve, and Command Valve O-ring are the only serviceable components on the turbocharger. The turbocharger itself is serviced as a component. Do not attempt to repair the turbocharger as turbocharger and/or engine damage can result.

  40.  

To install:


WARNING
Insure that turbocharger and charge air cooler are free of excess oil and debris. Do not allow any water or solvents to enter the turbocharger inlet or outlet If necessary clean turbocharger.

  1. Using a new gasket, install the turbocharger. Tighten the turbocharger mounting nuts to 32 ft. lbs. (43 Nm).
  2.  
  3. Raise vehicle on hoist.
  4.  
  5. Inspect oil drain tube O-rings for nicks or cuts. Replace if necessary.
  6.  
  7. Using a new gasket, install the oil drain tube to the turbocharger. Tighten the drain tube bolts to18 ft. lbs. (24Nm).
    NOTE
    Always use a new clamp when installing the exhaust elbow.

  8.  
  9. Install the exhaust elbow.
  10.  
  11. Reinstall the exhaust system on the exhaust hangers.
  12.  
  13. Connect the exhaust pipe to the turbocharger and tighten the bolts to 100 inch lbs. (11 Nm).
  14.  
  15. Connect wastegate command valve connector.
  16.  
  17. Lower the vehicle.
  18.  
  19. Pre-lube the turbocharger . Pour 50 to 60 cc (2 to 3 oz.) clean engine oil in the oil supply line fitting. Carefully rotate the turbocharger impeller by hand to distribute the oil thoroughly.
  20.  
  21. Install turbocharger oil return tube.
  22.  
  23. Install and tighten the oil supply line to 18 ft. lbs. (24Nm).
  24.  
  25. Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 95 inch lbs. (11 Nm).
  26.  
  27. Position the air inlet hose to the turbocharger. Tighten the clamp to 35 inch lbs. (4 Nm).
  28.  
  29. Connect the battery negative cables.
  30.  
  31. Start the engine to check for leaks.
  32.  

6.7L Diesel Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cables.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove air filter housing.
  8.  
  9. Remove charge air cooler inlet tube at turbocharger inlet.
  10.  
  11. Disconnect turbocharger speed sensor electrical connector.
  12.  
  13. Disconnect turbocharger actuator electrical connector.
  14.  
  15. Remove turbocharger oil supply line.
  16.  
  17. Remove turbocharger coolant lines at engine block.
  18.  
  19. Remove RH engine mount.
  20.  
  21. Remove exhaust steady rest bracket from transmission.
  22.  
  23. Remove V-clamp from turbocharger exhaust outlet.
  24.  
  25. Remove turbocharger drain tube mounting bolts at turbocharger. Remove tube from cylinder block.
  26.  
  27. Lower the vehicle.
  28.  
  29. Using Tool 9866, remove turbocharger mounting nuts.
  30.  
  31. Remove turbocharger from vehicle
  32.  

To install:


WARNING
Insure that turbocharger and charge air cooler are free of excess oil and debris. Do not allow any water or solvents to enter the turbocharger inlet or outlet If necessary, clean turbocharger

  1. Clean turbocharger mounting surface and exhaust manifold flange surface.
  2.  
  3. Using a new gasket, position turbocharger on exhaust manifold studs.
  4.  
  5. Install turbocharger mounting nuts. Using Turbocharger Tool 9866, using across pattern, tighten nuts to 32 ft. lbs. (43Nm).
  6.  
  7. Install turbocharger speed sensor. Tighten bolt to 70 in. lbs. (8 Nm).
  8.  
  9. Install coolant supply and return lines. Tighten banjo fittings 18 ft. lbs. (24 Nm).
  10.  
  11. Inspect oil drain tube O-rings for nicks or cuts. Replace if necessary.
  12.  
  13. Position turbocharger drain tube into engine block.
  14.  
  15. Using a new gasket, install turbocharger drain tube mounting bolts. Tighten to 95 in. lbs. (11 Nm).
  16.  
  17. Install RH engine mount.
  18.  
  19. Using a new V-clamp, connect exhaust pipe to turbocharger exhaust out let. Tighten clamp to 95 inch lbs. (11 Nm).
  20.  
  21. Lower the vehicle.
  22.  
  23. Install charge air tube to turbocharger inlet. Tighten clamp to 95 inch lbs. (11 Nm).
  24.  
  25. Install oil return line. Tighten fitting to 27 ft. lbs. (36 Nm).
  26.  
  27. Pre-lube turbocharger with 1-2 oz. (29.9-59.14 ml) clean engine oil.
  28.  
  29. Install turbocharger oil pressure line. Tighten fitting to 27 ft. lbs. (36 Nm).
  30.  
  31. Connect turbocharger actuator electrical connector.
  32.  
  33. Connect valve cover breather tube.
  34.  
  35. Install the air filter housing.
  36.  
  37. Connect the negative battery cables.
  38.  
  39. Fill the cooling system.
  40.  
  41. Check for leaks and proper operation.
  42.  

 
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