TURBOCHARGER REMOVAL


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. REMOVE EXHAUST RETARDER ASSEMBLY

    Click here

  3. REMOVE EGR COOLER SUB-ASSEMBLY

    Click here

  4. REMOVE GENERATOR ASSEMBLY


  5. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH


    1. Remove the 4 bolts and engine side cover sub-assembly RH.

  6. REMOVE ENGINE UNDER COVER RH


    1. A01CGQM

      Remove the 2 bolts, nut and engine under cover RH.

  7. REMOVE AIR HOSE ASSEMBLY


    1. A01CH5L

      Slide the clamp and disconnect the ventilation hose from the air hose assembly.

    2. Loosen the 2 hose clamps.

    3. Remove the bolt and air hose assembly.

  8. REMOVE NO. 2 AIR HOSE


    1. A01CJCS

      Loosen the 2 hose clamps and remove the No. 2 air hose from the intake pipe and intercooler assembly.

  9. REMOVE INTAKE PIPE


    1. A01CIR6E01
      Text in Illustration
      *1 No. 2 Intake Air Connector Bracket

      Remove the 2 bolts and No. 2 intake air connector bracket.

    2. Remove the 2 nuts, intake pipe and gasket.

  10. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01CHFO

      Remove the union bolt, 2 gaskets, bolt and No. 1 turbo water pipe sub-assembly.

    2. Remove the O-ring from the No. 1 turbo water pipe sub-assembly.

  11. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01CHGQ

      Disconnect the engine oil pressure switch connector.

    2. Remove the 2 union bolts, 4 gaskets, bolt and turbo oil inlet pipe sub-assembly.

  12. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01CJHH

      Disconnect the connector from the turbocharger sub-assembly.

    2. Detach the wire harness clamp.

    3. A01CH24

      Remove the 2 union bolts, 4 gaskets and No. 2 turbo water pipe sub-assembly.

  13. REMOVE TURBO OIL OUTLET PIPE


    1. A01CIWGE01
      Text in Illustration
      *1 No. 2 Water By-pass Pipe Sub-assembly

      Remove the 2 bolts and disconnect the No. 2 water by-pass pipe sub-assembly from the turbo oil outlet pipe.

    2. Remove the 2 bolts, 2 gaskets and turbo oil outlet pipe.

  14. REMOVE NO. 1 TURBO INSULATOR


    1. A01CIKP

      Remove the 3 bolts and No. 1 turbo insulator.

  15. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01CHNS

      Remove the 4 nuts, 4 spacers, turbocharger sub-assembly and gasket.

    2. Replace the 6 stud bolts.

      Tech Tips

      If a stud bolt is deformed or the threads are damaged, replace it.