stage 2 fuel filter assembly fuel line
(see Figure 22).

Fuel line and
connection

NOTE: Although the fuel lines and
fuel filter assemblies have been
drained, some residual fuel may
still drain out.

c. Disconnect the fuel line shown in
Figure 22 and 23.


Shop cloth

To remove the fuel line, pinch the
tabs on both sides of the fuel line
connector, and then pull off (see
Figure 23).

Stage 2
fuel filter
Figure 22

CAUTION: Make sure nothing
(dirt, debris, etc.) gets inside the
fuel system. Particles as small
as 3 microns may damage fuel
system components.

Fuel line
connector
Figure 23

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d. Carefully move and secure the fuel
line out of the way with a tie strap (see
Figure 24).


Put a plug in the fuel line.



Cap the fuel line’s connection on
the stage 2 fuel filter assembly (no
picture shown).

Plug

Tie strap

Figure 24

e. Remove the last stage 2 fuel filter
assembly bolt (see Figure 25).


The stage 2 fuel filter assembly will
sit close to its normally bolted-on
position.

Bolt

CAUTION: Do not lean on the
stage 2 fuel filter assembly at any
time while it is unbolted.

Figure 25

17. Remove the bolt, and then unclamp and
disconnect the breather tube from the
valve cover (see Figure 26).


Bolt

The breather tube will be removed with
the air inlet connection assembly later
on.

Clamp

Breather
tube
Figure 26

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18. Remove the three (3) EGR valve inlet
pipe bolts (see Figure 27).


The third bolt cannot be seen in
Figure 27.

Figure 27

Dipstick tube plug

19. Remove the exhaust pressure sensor
tube (see Figure 28 and 29).

Tube

a. Unfasten the flare nut.


The flare nut can be accessed
from the engine bay area or from
under the vehicle.

Bolt 2

b. Remove Bolt 1.

Flare nut

c. Remove Bolt 2.
Figure 28

Bolt 1

Tube
Bolt 2
Figure 29

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20. Remove the three (3) EGR bypass tube
bolts (see Figure 30).


The third bolt cannot be seen in
Figure 30.

Figure 30

Dismount
THIS end

21. Loosen the bolt, and then dismount
the UPPER rotary turbine control valve
linkage (see Figure 31).
CAUTION: Do not unbolt the LOWER
rotary turbine control valve linkage. If
unbolted, the rotary turbine control valve
linkage must be replaced.

Figure 31

22. Remove both water transfer connection
bolts (see Figure 32).
23. Remove the EGR bypass valve coolant
tube bolt (see Figure 32).

Step 23

Step 22
Figure 32

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24. Remove the air intake connection bolt
(see Figure 33).

Figure 33

25. Remove the air inlet connection
assembly bolt (see Figure 34).

Figure 34

26. Loosen the air outlet hose clamp nut,
and then separate from the intake
manifold inlet (see Figure 35).


Make sure to cover both openings
with tape.

Figure 35

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Upper
radiator
hose

27. Disconnect the EGR temperature
sensor connector (see Figure 36 and
37).


This sensor is located under the front
of the intake manifold.

NOTE: The EGR temperature sensor
may need to be disconnected during
removal of the intake manifold. Its
locking tab may not be accessible
otherwise.

Hidden
EGR temp
sensor
connector
Figure 36

EGR temp
sensor connector

Cap –
“Air inlet”
assembly
Figure 37

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28. Remove the eight (8) intake manifold
bolts, and then carefully remove the
intake manifold assembly.

Stage 2
fuel filter



See bolt locations in Figure 38 and
39.



If not done yet, disconnect the EGR
temperature sensor connector during
intake manifold removal (see page
18, step 27).

CAUTION: Due to its weight and
location, use proper lifting equipment
or assistance when lifting and removing
the intake manifold assembly.

Figure 38

NOTE: The EGR bypass valve coolant
tube may come out with the intake
manifold assembly. This is okay.


See page 16, step 23 for tube
identification.
EGR valve

NOTE: Three of the intake manifold
bolts on the “EGR valve” side cannot
be seen in Figure 39.

Figure 39

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29. Remove any remaining intake manifold gaskets, and then install plugs and caps (yellow
and red colored) where shown in Figure 40.

CAUTION: Failure to cover all engine, coolant, and fuel system openings may allow
dirt/debris to enter, causing engine and/or fuel system damage.

Add plugs
and caps
where shown

Figure 40

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30. Unbolt the high pressure turbocharger
from the low pressure turbocharger (see
Figure 41).

Figure 41

31. Disconnect the vacuum hose (see
Figure 42).

Vacuum hose

Figure 42

32. Loosen the charge-air cooler outlet tube
clamp, and then separate from the
turbocharger compressor outlet (see
Figure 43).


Make sure to cover both openings
with tape.

Figure 43

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33. Disconnect the connectors for the low
pressure turbocharger boost pressure
sensor and high pressure turbocharger
speed sensor (see Figure 44).

Connectors
Figure 44

Clamp screw

34. Loosen the clamp, and then remove
the air inlet connection assembly (see
Figure 45).


Leave the cap on.

Air inlet
connection
assembly

Leave this
cap on

Figure 45

35. Cover the low pressure turbocharger
inlet (see Figure 46).

Cap
Figure 46

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“High pressure”
banjo bolt

36. Remove the banjo bolts for the high
pressure and low pressure
turbochargers (see Figure 47 and 48).


Also remove the banjo bolts’ copper
gaskets.
 These gaskets will not be reused.



Cover the low pressure turbocharger
oil hole with tape.

IMPORTANT: Both banjo bolts must be
removed in order to remove the HP
turbocharger assembly.

Figure 47

“Low pressure”
banjo bolt

Figure 48

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Step 38

37. Remove the three (3) bolts, and then
remove the low pressure turbocharger
boost pressure sensor tube (see
Figure 49).


Clamp
Bolt

Bolt

Cover the hole with tape (see
Figure 50).
Bolt

38. Unbolt, unclamp, and then remove the
high pressure turbocharger speed
sensor (see Figure 49).


Bolt

Step 37

Cover the hole with tape (see
Figure 50).

Figure 49

39. Remove the T45 TORX® bolt (see
Figure 50).
Tape

Step 39
Figure 50

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40. Unfasten the oil drain line bolt (see
Figure 51).

Bolt

41. Remove the high pressure turbocharger
assembly from the vehicle.

Oil drain line

Figure 51

42. Cover the following openings:


Oil drain line-to-block hole



Low pressure turbocharger exhaust
port



Low pressure turbocharger outlet

Plug

 See Figure 52 and 53 for all
locations.

Figure 52

Tape

Tape

Plug
Cap

Figure 53

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43. Remove the bolts, and then remove the
oil drain line (see Figure 54).
Oil drain line
Bolts
Bolt

Figure 54

44. Remove the bolts, and then separate
the high pressure turbocharger from the
turbocharger compressor outlet
connection assembly (see Figure 55
and 56).
Bolts

Figure 55

Turbocharger
compressor outlet
connection assembly

High pressure
turbocharger

Figure 56

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HP Turbocharger: Compressor Housing and Wheel Inspection

Inspect where shown below. A flashlight should be sufficient, but use borescope J-51951
as needed (see page 27 and 28).

HP turbocharger

Figure 1A