6.7L Diesel Engine - Service Information: Removal & Installation RAM Pickup 2500

REMOVAL

Note. There is no filter minder on the air intake for the 6.7L. There will be an EVIC message which will display when the filter restriction reaches it's maximum. The customer will be required to replace it within 250 miles (402 KM).

Scheme 522

Scheme 523

1. The housing cover is equipped with over center clips (1) and is hinged with plastic tabs. Unlatch clips (1) from top of air cleaner housing (2) and tilt housing cover up for removal.
2. Remove air cleaner filter (1) from air cleaner housing (2).

Scheme 524

1. Clean out the inside of air cleaner housing (2).
2. Install the new air filter element. Make sure the air filter element is fully seated in housing.
3. Position air cleaner cover alignment tabs (1) into the housing slots (2) in all four locations and make sure the air cleaner cover is properly seated.
4. Latch the over center clips (1)) to clamp air cleaner cover (2).

Scheme 525

Scheme 526

1. Disconnect both negative battery cable.
2. Remove the intake air housing bolt (1).
3. Disconnect the Mass Air Flow (MAF) (3) sensor.
4. Disconnect the TBAP (2) sensor.
5. Loosen clamp (4) and disconnect the intake air tube (5) from the air cleaner body (1).
6. Lift up and remove air cleaner body (1).

Scheme 527

1. Disconnect the breather hose (3).
2. Loosen the clamp (1) and remove the outlet tube (2) from the turbocharger.

INSTALLATION

1. Position the air cleaner body (1) rear pegs to battery tray and push down to lock in place.
2. Install the intake air tube (5) to the air cleaner body (1). Tighten clamp (4) 4 N.m (35 in. lbs.).
3. Connect the TBAP (2) sensor.
4. Connect the Mass Air Flow (MAF) (3) sensor.
5. Install the housing bolt (1). Tighten bolt (1) 8 N.m (71 in. lbs).
6. Connect both negative battery cable.

1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets.
2. Lubricate the valve tips and install the crossheads in their original locations.
3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N.m (27 ft. lbs.). 1 - ROCKER ARM 2 - PEDESTAL
4. Verify valve lash adjustment. Refer to «Standard Procedure»(ref-457798-S18641070362012030200000) .
5. Install cylinder head cover. Refer to «COVER(S), Cylinder Head , Installation , 6.7L»(ref-457798-S32938384582012030200000) .
6. Connect both negative battery negative cables.

Scheme 528

The intake valves (1) are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The exhaust valves are made of iron alloys (2). The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (2).

The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible.

Scheme 529

Scheme 530

Scheme 531

1. Remove cylinder head. Refer to «Cylinder Head , Removal , 6.7L»(ref-457798-S31157007602012030200000) .
2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench.
3. Install the valve spring compressor base 8313A (1) as shown in illustration. 1 - SPECIAL TOOL 8319
4. Install the valve spring compressor (special tool #8319, Compressor, Valve Spring) top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs and remove the locks.
5. Rotate the compressor nut counterclockwise to relieve tension on the springs. Remove the spring compressor (1). 1 - VALVE RETAINING LOCKS 2 - VALVE 3 - SEAL 4 - SPRING 5 - RETAINER
6. Remove the retainers (5), springs (4), valve seals (3) (if necessary), and valves (2). Arrange or number all components so they can be installed in their original locations.
7. Repeat the procedure on all cylinders to be serviced.

1. Install rocker housing. Refer to «COVER(S), Cylinder Head , Installation , 6.7L»(ref-457798-S32938384582012030200000) .
2. Install fuel injectors and high pressure fuel lines. Refer to «INJECTOR(S), Fuel , Installation»(ref-457834-S31272152972012030200000) .
3. Lubricate the valve tips and install the crossheads in their original locations.
4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N.m (27 ft. lbs.).
5. Verify valve lash adjustment. Refer to «Standard Procedure»(ref-457798-S18641070362012030200000) .
6. Install cylinder head cover gasket onto rocker housing. Refer to «COVER(S), Cylinder Head , Installation , 6.7L»(ref-457798-S32938384582012030200000) .
7. Install injector solenoid nuts.
8. Connect injector harness connectors.
9. Install cylinder head cover. Refer to «COVER(S), Cylinder Head , Installation , 6.7L»(ref-457798-S32938384582012030200000) .
10. Connect both negative battery cables.

Scheme 532

1. Prior to removing the piston and connecting rod assemblies, measure and record piston protrusion. Piston protrusion (A) must be with in 0.151 - 0485 mm (0.006 - 0.019 in.). Measuring piston protrusion prior to disassembly will aid in determining if the cylinder block, if required, can be resurfaced.
2. Measure the overall flatness of the engine block.
3. The engine block must be within 0.076 mm (0.003 in) end-to-end and 0.051 mm (.002 in.) side-to-side.
4. Inspect for any localized dips or imperfections. If present, the cylinder head deck MUST be resurfaced. NOTE: The combustion deck of the block can ONLY be resurfaced if after the resurface, the correct piston protrusion can be achieved. No specific head gasket with an increased thickness is available for combustion deck resurfacing. If the combustion deck can NOT be resurfaced such that the correct piston protrusion an be reached, the cylinder block MUST be replaced.

Scheme 533

Scheme 534

1. New piston rings may not seat in glazed cylinder bores.
2. De-glazing gives the bore the correct surface finish required to seat the rings. The size of the bore is not changed by proper de-glazing.
3. Cover the lube and tappet holes in the top of the block with waterproof tape.
4. If crankshaft is installed, wrap connecting rod journals with clean cloth. Cover cloth with waterproof tape.
5. A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
6. Use a drill, a fine grit Flex-hone and a mixture of equal parts of mineral spirits and SAE 30W engine oil to de-glaze the bores.
7. The crosshatch angle is a function of drill speed and how fast the hone is moved vertically.
8. Vertical strokes MUST be smooth continuous passes along the full length of the bore.
9. Inspect the bore after 10 strokes.
10. Use a strong solution of hot water and laundry detergent to clean the bores. Clean the cylinder bores immediately after de-glazing.
11. Rinse the bores until the detergent is removed and blow the block dry with compressed air.
12. Check the bore cleanliness by wiping with a white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all residue is removed. Wash the bores and the complete block assembly with solvent and dry with compressed air. Place a clean shop towel around the top main bearing saddle to deflect water and residue from piston cooling nozzels. Remove directed piston cooling nozzles if installed.
13. Be sure to remove the tape covering the lube holes, rod journals, and piston cooling nozzles after the cleaning process is complete.

1. Remove the gear housing cover. Refer to «COVER(S), Engine Timing , Removal , 6.7L»(ref-457798-S07738960262012030200000) .
2. Split the gear and remove it from the crankshaft.

Scheme 535

1. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth.
2. If removed, install a new alignment pin. Drive the pin in using a ball- peen hammer, leaving it protruding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch) above the crankshaft. WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY. CAUTION: DO NOT heat the gear longer than 45 minutes.
3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F). Do not use torch, gear failure will occur.
4. Apply a thin coat of lubricant to the nose of the crankshaft.
5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder.

Non-High Output Engine

1. Remove the accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
2. Remove the four bolts and the vibration damper.

Scheme 536

1. Remove the accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) . NOTE: Ensure that the friction shim stays with the damper when it is removed. It will need to be reinstalled with the damper.
2. Remove the four bolts (1), vibration damper (4), and friction shim (5).

Scheme 537

Note. The Crankshaft damper is of viscous design and the speed indicator is incorporated into the crankshaft damper.

1. Inspect the damper hub for cracks and replace if any are found.
2. If the crankshaft damper is leaking fluid, discard and replace the crankshaft damper.

Note. The damper must be installed so the hole is located over the dowel pin.

1. Install the crankshaft damper and bolts. Tighten bolts to 40 N.m (30 ft. lbs.) plus an additional 60° in a crisscross pattern.
2. Install the accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .

Scheme 538

1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel.
2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket.
3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft.
4. Remove the seal pilot.
5. Install the installation tool over crankshaft. 1 - SEAL PILOT TOOL 2 - INSTALLATION TOOL 3 - SEAL 4 - RETAINER
6. Using a ball peen hammer, strike the tool (2) at the 12, 3, 6, and 9 o'clock positions until the alignment tool bottoms out on the retainer. NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring.
7. Install the flywheel or converter drive plate, and clamping ring. Tighten the bolts to 137 N.m (101 ft. lbs.).
8. Install the clutch cover and disc (if equipped). Refer to «DISC, Clutch , Installation»(ref-457790-S33835974732012030200000) .
9. Install the transmission and transfer case (if equipped).
10. Connect the negative battery cables.
11. Check engine oil level and adjust, if necessary.
12. Start engine and check for oil leaks.

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

1. Determine the piston diameter and obtain the appropriate ring set. The piston rings can be identified as shown in illustration. 1 - PISTON 2 - CYLINDER BORE 3 - DEPTH
2. Position each ring in the cylinder and use a piston (1) to square it with the bore at a depth (3) of 89.0 mm (3.5 in.). PISTON RING GAP CHART TOP RING 0.30 - 0. 46 mm (0.012 - 0.018 in.) INTERMEDIATE RING 0.82 - 1.18 mm (0.032 - 0.047 in.) OIL CONTROL RING 0.22 - 0.58 mm (0.010 - 0.023 in.)
3. Use a feeler gauge to measure the piston ring gap. 1 - OIL CONTROL RING 2 - EXPANDER 3 - PISTON
4. The top surface of all of the compression rings are identified with the word TOP or the supplier's MARK. Assemble the rings with the word TOP or the supplier's MARK up.
5. Lubricate the piston rings and piston ring grooves with clean CJ-4 engine oil.
6. Position the oil ring expander (2) in the oil control ring (1) groove (bottom groove). NOTE: There is no (TOP) mark on the oil ring.
7. Install the oil control ring (1) with the end gap OPPOSITE the ends on the expander. 1 - PISTON RING INSTALLATION TOOL
8. Install the intermediate piston ring in the second groove.
9. Install the top piston ring in the top groove. 1 - TOP RING 2 - INTERMEDIATE RING 3 - OIL CONTROL RING
10. Install the piston rings with ring gaps 120 degrees apart. Do not position ring gaps over the wrist pin hole.

Scheme 544

The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles.

Scheme 545

1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel.
2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket.
3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft.
4. Remove the seal pilot.
5. Install the installation tool over crankshaft. 1 - SEAL PILOT TOOL 2 - INSTALLATION TOOL 3 - SEAL 4 - RETAINER
6. Using a ball peen hammer, strike the tool (2) at the 12, 3, 6, and 9 o'clock positions until the alignment tool bottoms out on the retainer. NOTE: Always install a new clamping ring, never reuse the old clamping ring.
7. Install the flywheel or converter drive plate, and clamping ring. Tighten the bolts to 137 N.m (101 ft. lbs.).
8. Install the clutch cover and disc (if equipped). Refer to «DISC, Clutch , Installation»(ref-457790-S33835974732012030200000) .
9. Install the transmission and transfer case (if equipped).
10. Lower vehicle.
11. Connect battery negative cables.
12. Check engine oil level and adjust, if necessary.
13. Start engine and check for oil leaks.

Note. This procedure requires use of Miller Tool (special tool #8502, Remover/Installer) Tappet Replacement Kit.

Scheme 546

Scheme 547

Scheme 548

1. Remove camshaft. Refer to «CAMSHAFT, Engine , Removal , 6.7L»(ref-457798-S10272284532012030200000) . 1 - TROUGH
2. Insert the trough (1) (provided with tool kit) the full length of the camshaft bore. Make sure the cap end goes in first and the open side faces up (towards tappets).
3. Remove only one tappet at a time. Remove rubber band from one cylinder pair and attach tappet dowel not being removed to the next cylinder pair.
4. Raise dowel rod (disengage from tappet) and allow tappet to fall into trough.
5. Carefully remove trough (do not rotate) and tappet. If the tappet is not being replaced, mark it so it can be installed in its original location. 1 - TROUGH
6. Reinstall trough (1) and repeat procedure on remaining tappets.

1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench.
2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed.

1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine.
2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal.
3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn.

Scheme 549

1. Disconnect the battery cables (1, 3).
2. Remove the intake air assembly.
3. Remove the inner radiator shroud retaining bolts.
4. Remove the inner radiator shroud.
5. Raise and support the vehicle. 1 - Mount 2 - Insulator 3 - Bolt
6. Remove the front suspension track bar. Refer to «TRACK BAR, Front , Removal»(ref-457771-S23210263792012030200000) .
7. Remove the right and left engine mount through bolt. Refer to «INSULATOR, Engine Mount, Front , Removal , 6.7L»(ref-457798-S00144816962012030200000) or «INSULATOR, Engine Mount, Rear , Removal , 6.7L»(ref-457798-S26177312272012030200000) .
8. Remove the steering gear retaining bolts. Refer to «Gear, Independent Front Suspension , Installation»(ref-457772-S12875292612012030200000) or «Gear, Link and Coil , Installation»(ref-457772-S26733534862012030200000) .
9. Drain the engine oil.
10. Lower the vehicle.
11. Install the engine lift fixture.
12. Use the engine lift fixture to raise the engine.
13. Raise the vehicle on the hoist.
14. Remove the oil pan retaining bolts.
15. Lower the oil pan enough to allow the removal of the oil pan gasket.
16. Remove the oil pan gasket.

1. Clean the oil pan gasket surfaces to be sure the surfaces are free of debris and oil.
2. Install a new oil pan gasket.
3. Install the oil pan bolts in a cross pattern. Refer to «PAN, Oil , Installation , 6.7L»(ref-457798-S21581093052012030200000) .
4. Install the steering gear retaining bolts. Refer to «Gear, Independent Front Suspension , Installation»(ref-457772-S12875292612012030200000) or «Gear, Link and Coil , Installation»(ref-457772-S26733534862012030200000) .
5. Lower the vehicle.
6. Lower the engine into the mounts.
7. Remove the engine lift fixture.
8. Fill the engine with oil.
9. Raise and support the vehicle. 1 - Mount 2 - Insulator 3 - Bolt
10. Install the left and right engine mount through bolt. Refer to «INSULATOR, Engine Mount, Front , Installation , 6.7L»(ref-457798-S36236120172012030200000) and «INSULATOR, Engine Mount, Rear , Installation , 6.7L»(ref-457798-S10640448912012030200000) .
11. Install the front suspension track bar. Refer to «TRACK BAR, Front , Installation»(ref-457771-S15827102542012030200000) .
12. Lower the vehicle.
13. Install the radiator shroud.
14. Install the radiator shroud bolts.
15. Install the intake air assembly. Refer to «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
16. Connect the battery cables (1, 3).

Scheme 550

To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick.

Note. Note: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes.

1. Position vehicle on level surface.
2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick.
3. Wipe dipstick clean.
4. Replace dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the SAFE RANGE area on the dipstick.
7. Replace dipstick.

1. Disconnect the battery negative cables.
2. Disconnect the oil pressure switch harness connector.
3. Remove the oil pressure switch from the engine block.

1. Using a new O-ring, install the oil pressure switch. Tighten to 18 N.m (159 in. lbs.) .
2. Connect oil pressure switch harness connector.
3. Connect the battery negative cables.
4. Start engine and check for oil leaks at the switch.

Scheme 551

1. Disconnect the battery negative cables.
2. Remove the threaded plug (2), spring (4) and valve (5). Insert a finger or a seal pick to lift the plunger from the bore.

Note. If the plunger is stuck in the bore, it will be necessary to remove the filter head.

1. Install the plunger, spring, and plug as shown in illustration. Tighten the plug to 80 N.m (59 ft. lbs.).
2. Connect the battery negative cables.
3. Start the engine and verify that it has oil pressure.

Scheme 552

1. Disconnect the battery negative cables.
2. Drain the coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
3. Raise vehicle on hoist.
4. Remove the EGR cooler. Refer to «COOLER, EGR , Removal»(ref-457792-S12900673252012030200000) .
5. Remove the air filter housing. Refer to «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
6. Remove the air filter inlet hose from the turbo inlet.
7. Remove the delta-P line bracket capscrew nuts and remove the delta-P line from the exhaust manifold and thermostat housing.
8. Remove the heat shield and noise panel (if equipped) from the exhaust manifold.
9. Remove the turbocharger. Refer to «TURBOCHARGER , Removal , 6.7L»(ref-457798-S17873990682012030200000) .
10. Remove the two (2) rear exhaust manifold capscrew lock plates.
11. Remove the Cab Heater tubing/bracket from the exhaust manifold stud.
12. Remove the exhaust manifold.

1. Clean the exhaust manifold gasket surfaces.
2. Clean the cylinder head exhaust port gasket surfaces.
3. Clean the turbo mounting flange on the exhaust manifold.
4. Clean the turbo mounting flange on the turbocharger.
5. Install the exhaust manifold to turbocharger gasket and capscrews.
6. Install the exhaust manifold gasket. NOTE: The five exhaust manifold capscrews with studs are used at the No. 1 and No. 2 cylinder locations for the heat shield mounting and one on the rear lower corner of the manifold for the cabin heater tube bracket.
7. Install the exhaust manifold spacers and capscrews.
8. Starting from the center and moving in a pattern outward, tighten the exhaust manifold bolts to 43 N.m (32 ft. lbs.)
9. Install the exhaust manifold capscrew lock plates.
10. Install the exhaust manifold heat shields/noise panels. Tighten the mounting nuts to 24 N.m (18 ft. lbs.).
11. Install the turbocharger. Refer to «TURBOCHARGER , Installation , 6.7L»(ref-457798-S04492679172012030200000) .
12. Attach the mounting tabs and start the delta-P tube to exhaust manifold and thermostat capscrews.
13. Tighten the delta-P line bracket nut to 24 N.m (18 ft. lbs.).
14. Tighten the delta-P line bracket bolt to 10 N.m (89 in. lbs.).
15. Tighten the delta-P flare nuts to 10 N.m (89 in. lbs.).
16. Install the EGR cooler. Refer to «COOLER, EGR , Installation»(ref-457792-S13222462612012030200000) .
17. Install the air filter housing. Refer to «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
18. Fill the coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
19. Connect the battery negative cables.
20. Start the engine to check for leaks.

Scheme 553

Scheme 554

1. Disconnect both negative battery cables.
2. Disconnect the Charge Air Cooler (CAC) tube (4) from the EGR air flow control valve.
3. Remove the EGR crossover tube. Refer to «TUBE, Exhaust Gas Recirculation (EGR), Crossover , Removal»(ref-457800-S05224501002012030200000) .
4. Disconnect EGR air flow control valve harness connector.
5. Disconnect the EGR valve harness connector.
6. Disconnect the boost pressure sensor harness connector.
7. Remove bolt and nut securing oil dipstick tube.
8. Remove bolts (1) and the intake manifold (2).

1. Clean all gasket mating surfaces.
2. Using a new gasket, install the intake manifold (2). Tighten bolts to 24 N.m (18 ft. lbs.).
3. Install bolt securing the oil dip stick tube-to-intake manifold and tighten to 24 N.m (18 ft. lbs.).
4. Connect the boost pressure sensor harness connector.
5. Connect the EGR valve harness connector.
6. Connect EGR air flow control valve harness connector.
7. Install the EGR crossover tube. Refer to «TUBE, Exhaust Gas Recirculation (EGR), Crossover , Installation»(ref-457800-S16437621272012030200000) .
8. Connect the Charge Air Cooler (CAC) tube (4) to the EGR air flow control valve. Tighten clamp to 11 N.m (97 in. lbs.).
9. Connect both negative battery cables.

Scheme 555

1. Position the charge air cooler (2). Install the bolts (1) and tighten to 2 N.m (17 in. lbs.) torque.
2. Install the air intake system tubes (4) to the charge air cooler (2). With the clamps in position, tighten the clamps to 11 N.m (95 in. lbs.) torque.
3. Install the transmission auxiliary cooler (if equipped). Refer to «COOLER, Transmission Oil , Installation»(ref-457792-S13626886762012030200000) .
4. Install the A/C condenser (if A/C equipped). Refer to «CONDENSER, A/C , Installation»(ref-457787-S28795394962012030200000) . Recharge A/C system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.
7. Install the front grille assembly. Refer to «GRILLE , Installation»(ref-457777-S17835290622012030200000) .

Scheme 556

1. Remove RH engine mount. Refer to «INSULATOR, Engine Mount, Front , Removal , 6.7L»(ref-457798-S00144816962012030200000) and «INSULATOR, Engine Mount, Rear , Removal , 6.7L»(ref-457798-S26177312272012030200000) .
2. Remove turbocharger drain tube (2) mounting bolts.
3. Remove turbocharger drain tube (2) from the turbocharger (1).

1. Clean turbocharger drain tube (2) mounting surfaces.
2. Install new O-rings on turbocharger drain tube (2). Lubricate with clean engine oil.
3. Install turbocharger drain tube (2) into cylinder block.
4. Install new gasket and turbocharger drain tube (2) mounting bolts at turbocharger (1).
5. Tighten bolts to 24 N.m (18 ft. lbs.).
6. Install RH engine mount. Refer to «INSULATOR, Engine Mount, Front , Installation , 6.7L»(ref-457798-S36236120172012030200000) and «INSULATOR, Engine Mount, Rear , Installation , 6.7L»(ref-457798-S10640448912012030200000) .
7. Start engine and check for leaks.

Scheme 557

1. Disconnect negative battery cable.
2. Remove turbocharger oil supply line.
3. Disconnect speed sensor electrical connector.
4. Remove turbocharger speed sensor mounting bolt (1).
5. Remove turbocharger speed sensor (2).

1. Install turbocharger speed sensor.
2. Install turbocharger speed sensor mounting bolt.
3. Tighten bolt to 10 N.m (89 in. lbs.) .
4. Connect speed sensor electrical connector.
5. Install turbocharger oil supply line. Tighten fitting to 24 N.m (18 ft. lbs.)

Scheme 558

The electronically controlled Variable Geometry (VG) turbocharger is a water cooled, exhaust-driven, oil lubricated compressor that increases the pressure and density of the air entering the engine. With the increase of air entering the engine, more fuel can be injected into the cylinders, which creates more power during combustion.

The VG turbocharger allows the engine to operate in a wide power and speed range to achieve the best power, torque, and engine operating conditions.

The VG turbocharger can also provide engine braking and to reduce engine warm up time.

The VG turbocharger assembly consists of

1. Turbocharger assembly
2. Variable Geometry Nozzle (7)
3. Water Cooled Bearing housing
4. Electronically Controlled Actuator

1. Prior to installation, inspect the turbocharger for any damage. Refer to «TURBOCHARGER , Inspection , 6.7L»(ref-457798-S31052887292012030200000) .
2. Clean the turbocharger mating surfaces.
3. Replace the banjo fitting seals on the turbocharger coolant lines.
4. Using a new gasket, position the turbocharger onto the exhaust manifold studs by lowering the turbocharger through the engine compartment. NOTE: If old gasket appeared to be leaking, check the turbocharger/exhaust manifold mounting flanges for warping. Using a straight edge and feeler gauge measure along the two longest sides of the flanges for warpage. Specification is 0.1 mm (0.0039 inch) for the turbocharger flange and 0.05 mm(0.002 inch) maximum.
5. Install the turbocharger mounting nuts. Using Turbocharger Tool (special tool #9866, Wrench, Turbo Charger Bolt), using a cross pattern, tighten the nuts to 43 N.m (32 ft. lbs.)
6. Install the grid heater relay to the battery tray.
7. Inspect the oil drain tube O-rings for nicks or cuts. Replace if necessary. Oil the O-rings with new oil.
8. Raise and support the vehicle.
9. Position the turbocharger drain tube (2) into engine block.
10. Using a new gasket, install the turbocharger drain tube (2) mounting bolts. Tighten the mounting bolts to 24 N.m (18 ft. lbs.).
11. Using a new clamp (1), connect the exhaust pipe to the turbocharger exhaust outlet with the clamp facing down as shown in illustration. Tighten the clamp (1) to 17 N.m (13 ft. lbs). Using a rubber mallet, hit the exhaust pipe to turbocharger clamp three times around the perimeter of the clamp (1) and tighten the clamp (1) to 17 N.m (13 ft. lbs).
12. Install the exhaust steady rest bracket to the transmission. Tighten bolts to 43 N.m (32 ft. lbs.).
13. Install the right hand side engine mount. Refer to «INSULATOR, Engine Mount, Front , Installation , 6.7L»(ref-457798-S36236120172012030200000) and «INSULATOR, Engine Mount, Rear , Installation , 6.7L»(ref-457798-S10640448912012030200000) .
14. Install the right side wheelhouse splash shield. Refer to «SHIELD, Splash, Front Wheelhouse , Installation»(ref-457777-S41868690352012030200000) or «SHIELD, Splash, Rear Wheelhouse , Installation»(ref-457777-S42947914752012030200000) .
15. Lower the vehicle.
16. Remove the engine support fixture tool (special tool #8534B, Fixture, Driveline Support) (1). NOTE: Exhaust pipe removed for clarity.
17. Install the coolant lines at the engine block and turbocharger. Tighten the banjo fittings 24 N.m (18 ft. lbs.).
18. Install the turbocharger oil return line. Tighten the fitting to 36 N.m (27 ft. lbs.).
19. Install the turbocharger oil pressure line (3). Tighten the fitting to 36 N.m (27 ft. lbs.).
20. Connect the turbocharger actuator electrical connector.
21. Connect the turbocharger speed sensor electrical connector.
22. Install the charge air tube to turbocharger inlet (4). Tighten the clamp to 11 N.m (8 ft. lbs.).
23. Pre-lube the turbocharger with 29.9 - 59.14 ml (1 - 2 oz.) clean engine oil.
24. Install the intake air tube at the turbocharger (5). Tighten the clamp to 11 N.m (8 ft. lbs.).
25. Connect the crankcase vent hose at the turbocharger air intake.
26. Install the air filter housing. Refer to «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
27. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
28. Position and connect the right hand side positive battery cable
29. Connect the negative battery cable on both batteries.
30. Check for any cooling or exhaust leaks and confirm the turbocharger is operating properly. Refer to «TURBOCHARGER , Diagnosis and Testing , 6.7L»(ref-457798-S17015519442012030200000) .