Technical information

ManualsBrandsDodge ManualsAutomobile2008 DH Ram

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system,

or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of Chrysler LLC.

SUBJECT:

6.7L Turbocharger Cleaning Procedure

OVERVIEW:

This bulletin involves the cleaning of the turbocharger, using Cummins Engine Update Kit

10138-UPD, to address excess soot accumulation. The procedure cleans the internal

components on the exhaust side of the turbocharger.

MODELS:

2007 - 2008 (DH/D1) Ram Truck (2500 / 3500)

NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales

code ETJ)

SYMPTOM/CONDITION:

The turbocharger may require cleaning due to excessive soot accumulation.

DIAGNOSIS:

1. Set the parking brake. Start the vehicle engine.

2. Connect the StarSCAN® to the vehicle Diagnostic Link Connector (DLC).

3. From the “Home” screen on the StarSCAN® select:

a. “ECU View” button.

b. “PCM Powertrain Control Module” button.

c. “View DTC's” button.

4. Record all Diagnostic Trouble Codes (DTC's) that are present in the Engine

Control Module (ECM) / Powertrain Control Module (PCM).

NOTE: It is IMPORTANT to record (capture) all DTC's present in the ECM / PCM prior

to proceeding further with this diagnosis.

NOTE: Refer to Service Bulletins (SB) 11-002-08 and to 11-002-07 for detailed

Turbocharger, Engine and Exhaust Aftertreatment System repair procedures.

Performing a complete repair when cleaning (or replacing) a turbocharger

includes thorough cleaning and/or inspection of several other Engine and

Exhaust Aftertreatment System components. The Engine and Exhaust

Aftertreatment Systems must be cleaned so that the systems operate as if in

a “LIKE NEW” condition. DO NOT omit a component or step in the cleaning

process.

NUMBER: 11-001-08

GROUP: Exhaust

DATE: May 21, 2008

Summary of content (17 pages)

PAGE 1
NUMBER: GROUP: DATE: 11-001-08 Exhaust May 21, 2008 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of Chrysler LLC. SUBJECT: 6.
PAGE 2
11-001-08 -2- 5. Is DTC P1451, P2463, or P242F present in the PCM? a. If YES >>> then refer to Service Bulletin (SB) 11-002-07 (or later bulletin) to address this concern and before proceeding further with this Service Bulletin. In addition to other repairs, SB 11-002-07 (or later bulletin) may direct the technician to perform a thorough Engine and Exhaust Aftertreatment System cleaning and a mobile regeneration. Proceed to the next step ONLY after SB 11-002-07 has been reviewed. b.
PAGE 3
-3NPN Shop Vacuum with a Crevice Attachment NPN Pencil Magnet 11-001-08 NOTE: The spray nozzle in the Turbocharger Cleaning Kit uses a very small orifice for the cleaner to pass through. The design of the nozzle is important for the proper application of the chemical. If the orifice in the spray nozzle becomes restricted, carefully inspect and clean the filtering screen at the entrance to the nozzle of any debris. If careful, the nozzle may be disassembled for cleaning, should this be needed.
PAGE 4
11-001-08 -4- SECTION B - INSTALL A TURBOCHARGER CLEANING PORT: WARNING:At no time should a combustible cleaner be used. To introduce a combustible cleaner to the engine and/or exhaust aftertreatment system may cause damage to those systems and possible personal injury. 1. At the air filter housing cover, disconnect the Mass Air Flow (MAF) and the Inlet Air Temperature / Pressure (TBAP) sensors electrical connectors from the engine harness (Fig. 2). 2.
PAGE 5
-5- 11-001-08 Fig. 3 6.7L TURBOCHARGER ACTUATOR 1 - TURBOCHARGER ACTUATOR ELECTRICAL CONNECTOR 2 - TURBOCHARGER ACTUATOR 3 - MOUNTING BOLTS 4 - TURBOCHARGER 7. Locate the Closed Crankcase Ventilation (CCV) tube hold down cap screw on the steel section of the CCV tube. Remove the CCV tube hold down cap screw. 8. Rotate the CCV tube upward and out of the way of the turbocharger. 9.
PAGE 6
11-001-08 -6- Fig. 4 TURBOCHARGER SPEED SENSOR 1 - ATTACHING BOLT 2 - TURBOCHARGER SPEED SENSOR 11. Remove the turbocharger speed sensor. Verify that the speed sensor o-ring remains with the speed sensor and does not remain in the turbocharger center section / bearing housing. Fig.
PAGE 7
-7- 11-001-08 12. Install the drill/tap guide into the turbocharger center section / bearing housing (Fig. 5). Secure the drill/tap guide in place with the previously removed turbocharger speed sensor attaching bolt. Tighten bolt to 10 Nm (89 in. lbs.). NOTE: There are two different size guide bushings that come with the drill/tap guide. The guide bushing with the smaller inner diameter center bore is used for guiding the drill bit.
PAGE 8
11-001-08 -8- Fig. 6 DRILLING CLEANING PORT 1 - DRILL - USE LOW / SLOW SPEED WHEN DRILLING - DO NOT OVER DRILL HOLE. - MAXIMUM DEPTH IS 42 MM OR 1 5/8 INCHES 2 - DRILL AND TAPPING GUIDE 3 - TURBOCHARGER 15. Using a drill on SLOW speed, and the shop vacuum to collect filings, drill a hole through the turbocharger center housing casting to the correct depth. Continue to drill until the drill stop just makes contact with the turbocharger housing (Fig. 6). 16. Remove the drill bit from the drill/tap guide.
PAGE 9
-9- 11-001-08 19. Install the tap handle to the drive end of the tap. If additional clearance is desired, install the female end of a 3 inch or 6 inch long 1/4 inch drive socket extension to the tap and then install the male end of the 1/4 inch extension to the tap handle. Fig. 7 TAPPING CLEANING PORT 1 - THREAD TAP AND TAP HANDLE (A 1/4 IN.
PAGE 10
11-001-08 -10- 21. Remove the tap from the drill/tap guide. Remove the tap bushing from the drill/tap guide. First, vacuum any excess metal filings. Next, using a pencil magnet with a magnetic tip smaller than the drilled hole, insert the magnet through the drilled hole and remove shavings as possible. DO NOT use the magnet during the process of drilling and taping as this would cause the drill/tap fixture and the turbocharger housing to become magnetized. 22.
PAGE 11
-11- 11-001-08 SECTION C - TURBOCHARGER CLEANING PROCEDURE: WARNING:At no time should a combustible cleaner be used. To introduce a combustible cleaner to the engine and/or exhaust aftertreatment system may cause damage to those systems and possible personal injury. CAUTION: Use ONLY Mopar Diesel Turbocharger Cleaner to perform this repair. Mopar Diesel Turbocharger Cleaner is a specially made WATER BASED solvent.
PAGE 12
11-001-08 -12- CAUTION: The turbocharger, exhaust, and surrounding components are at high temperatures. Use the proper protection and care when working on or around the turbocharger and exhaust system. 1. Raise the vehicle on a suitable lift. 2. Remove both exhaust system oxygen sensors (Fig. 8). 3. Temporarily install an oxygen sensor plug into each empty oxygen sensor hole. Tighten plugs to 41 Nm (30 ft. lbs.). 4. Lower the vehicle. 5. Connect the vehicle tailpipe to the shop exhaust ventilation system.
PAGE 13
-13- 11-001-08 Fig. 9 CLEANING NOZZLE INSTALLED 1 - CLEANING TOOL NOZZLE 2 - CLEANING TOOL HOSE - ROUTE AWAY FROM BATTERY TERMINALS 3 - TURBOCHARGER 10. Install the nozzle of the turbocharger cleaning tool into the turbocharger cleaning port tapped hole (Fig. 9). Use care not to cross-thread the tapped hole. Tighten nozzle to 5.6 Nm (50 in. lbs.). NOTE: The spray nozzle in the Turbocharger Cleaning Kit uses a very small orifice for the cleaner to pass through.
PAGE 14
11-001-08 -14- Fig. 10 CLEANING TOOL HOSE ROUTING 1 - TURBOCHARGER WATER BASE CHEMICAL CLEANER - HOLD CAN BOTTOM UP TO DISPENSE 2 - BATTERY - USE A FENDER COVER TO ISOLATE BATTERY TERMINALS FROM CLEANING TOOL HOSE 3 - EGR COOLER BY-PASS VALVE ASSEMBLY CABLE HOUSING SLEEVES - ROUTE CLEANING TOOL HOSE UNDER SLEEVE LOOP TO KEEP CLEANING TOOL HOSE AWAY FROM BATTERY TERMINALS 4 - TURBOCHARGER CLEANING TOOL HOSE - ROUTE AWAY FROM BATTERY TERMINALS 13.
PAGE 15
-15- 11-001-08 Fig. 11 CLEANING CHEMICAL AND TOOL 1 - TURBOCHARGER WATER BASE CHEMICAL CLEANER - USE ONLY A WATER BASE CHEMICAL 2 - CLEANING TOOL HOSE - ROUTE AWAY FROM BATTERY TERMINALS 3 - CLEANING TOOL CAN TAP VALVE - SHOWN IN “OPEN” POSITION 16. Install a can of the Diesel Turbocharger Cleaner to the turbocharger cleaning tool tap (Fig. 11). 17. Hold the Diesel Turbocharger Cleaner can UPSIDE DOWN (can nozzle is to point towards the ground).
PAGE 16
11-001-08 -16- NOTE: The use of the proper Mopar plug is critical. Use of an unapproved plug of different material type and/or thread may cause damage to the turbocharger. 26. 27. 28. 29. Remove the protective fender cover from the right battery. Raise the vehicle. Remove both oxygen sensor plugs from the exhaust system. CLEAN BOTH OXYGEN SENSORS using a clean cloth and compressed air. Do not use any type of liquid cleaner to clean the oxygen sensor tips.
PAGE 17
-17- 11-001-08 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Description Amount 09-44-01-93 Turbocharger, Install Cleaning Port and Clean (B) 2.1 Hrs. 09-44-01-94 Turbocharger, Clean (B) FAILURE CODE: ZZ Service Action 1.5 Hrs.