Complete replacement of the turbocharger assembly on a 2014 Ram 2500 6.7L Cummins diesel, including removal of exhaust components, oil lines, coolant lines, and intercooler plumbing.

Warnings

Tools required

Parts

• Turbocharger assembly × 1 — Use OEM Holset HE351VE or equivalent
• Turbo-to-manifold gasket × 1 — Use OEM specification
• Turbo-to-downpipe gasket × 1 — Use OEM specification
• Oil feed line crush washers × 2 — Use OEM specification
• Oil return line gasket × 1 — Use OEM specification
• Coolant line O-rings × 4 — Use OEM specification
• Exhaust manifold nuts (if corroded) × 8 — M8 brass nuts
• V-band clamp (intake side) × 1 — Use OEM specification
• Anti-seize compound (copper-based) × 1 — High-temperature rated
• Engine oil (for turbo priming) × 1 — Mopar 5W-20 Synthetic Blend
• Thread locker (blue, medium strength) × 1 — Loctite 243 or equivalent

Fluids

• Mopar OAT Coolant (Purple) — 2 qt
• Mopar 5W-20 Synthetic Blend — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels.
2. Allow engine to cool completely (minimum 2 hours after shutdown).
3. Disconnect both battery terminals, negative first, and isolate cables.
4. Drain approximately 2 quarts of coolant from radiator petcock to lower coolant level below turbo lines.
5. Spray all exhaust fasteners with penetrating oil and allow to soak (ideally 24 hours before removal).
6. Remove engine cover and air filter housing for access.
7. Remove front grille and support core radiator assembly to gain working room (recommended but not strictly required).
8. Place drain pan under turbocharger oil return area.

Procedure

1. 1

   Disconnect intake and intercooler system
   Remove the intake air tube from turbo inlet. Loosen V-band clamp on compressor outlet and disconnect intercooler pipe. Remove intake grid heater wiring connector. Support intercooler pipes to prevent strain on connections.
2. 2

   Disconnect exhaust downpipe
   Working from underneath vehicle, remove the four bolts connecting turbo outlet to exhaust downpipe. Use penetrating oil if bolts are corroded. Support downpipe weight with jack or wire to prevent stress on hangers. Remove and discard downpipe gasket.
   ⚠Exhaust bolts may be severely corroded. Apply heat carefully if bolts will not break free with reasonable force.
   Torque spec

   Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
3. 3

   Remove turbo oil drain line
   Locate oil return line at bottom of turbocharger. Remove bolts securing drain tube to turbo and to engine block. Carefully work drain line free, being careful not to damage mating surfaces. Inspect line for sludge buildup or damage. Remove and discard gasket.
   ⚠Oil will drain from return line. Have drain pan positioned to catch approximately 1 quart of oil.
   Torque spec

   Oil Return Line10 Nm (7 lb-ft)
4. 4

   Disconnect turbo oil feed line
   Locate oil feed line at top of turbocharger (banjo bolt connection). Remove banjo bolt and carefully pull line away from turbo. Remove and discard both crush washers (one on each side of banjo fitting). Cap or plug oil feed port on turbo to prevent contamination.
   ℹ️Do not reuse crush washers. Always install new washers on reassembly to prevent oil leaks.
   Torque spec

   Oil Feed Line20 Nm (15 lb-ft)
5. 5

   Disconnect coolant lines
   Identify coolant supply and return lines to turbo CHRA (center housing rotating assembly). Remove fittings at turbocharger connections. Have drain pan ready as coolant will drain from lines. Remove and discard O-rings from fittings.
   ⚠Coolant may still be warm. Expect approximately 1 quart of coolant to drain from lines.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
6. 6

   Disconnect turbo actuator and sensors
   Disconnect electrical connector from turbo variable geometry (VGT) actuator. Remove any boost pressure sensors or exhaust temperature sensors mounted on or near turbocharger. Label all connectors for proper reassembly. Remove actuator rod from linkage if necessary for clearance.
   Torque spec

   Sensor Bolts15 Nm (11 lb-ft)
7. 7

   Remove heat shields
   Remove heat shields from turbocharger and exhaust manifold area. These are typically secured with multiple small bolts. Set shields aside for cleaning and reinstallation. Inspect shields for damage or excessive corrosion.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
8. 8

   Remove turbo mounting hardware
   Working from top and bottom as needed, remove bolts/nuts securing turbocharger to exhaust manifold. Start with easily accessible fasteners first. Apply anti-seize to stud threads as each nut is removed to ease future service. Note that there are typically 4-6 mounting points. Support turbo weight as final fasteners are removed.
   ⚠️Turbo will become free once final fastener is removed. Ensure unit is properly supported to prevent dropping and injury.
   ⚠If studs break during removal, they must be extracted before new turbo can be installed. Use stud extractor set if needed.
   Torque spec

   Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
9. 9

   Remove turbocharger assembly
   Carefully maneuver turbocharger away from exhaust manifold. It may require rotation and careful manipulation to clear engine bay components. Work slowly and use assistant if available. Once clear, remove unit from vehicle. Remove and discard turbo-to-manifold gasket.
10. 10

    Clean and inspect mounting surfaces
    Thoroughly clean exhaust manifold mounting surface using plastic gasket scraper and wire brush. Remove all old gasket material and carbon buildup. Inspect manifold for cracks, warping, or damaged stud threads. Clean oil feed and return ports. Inspect downpipe flange and clean mating surface. Check that all studs in exhaust manifold are tight and in good condition.
    ℹ️Any cracks in exhaust manifold must be addressed before turbo installation or exhaust leaks will occur.
11. 11

    Prepare new turbocharger
    Remove protective caps from new turbocharger oil inlet, oil drain, and coolant ports. Pour approximately 50ml of clean engine oil into turbo oil inlet port and rotate compressor wheel by hand several times to distribute oil to bearings. Apply anti-seize compound to oil drain flange bolts. Install new turbo-to-manifold gasket on turbo or manifold studs. Apply anti-seize to exposed threads on exhaust manifold studs.
    ⚠️Never install turbocharger without pre-oiling the bearings. Failure to prime will cause immediate bearing failure on first start.
12. 12

    Install turbocharger to manifold
    Carefully position new turbocharger onto exhaust manifold studs, ensuring gasket remains properly seated. Align oil drain port and other connections as unit is positioned. Start all turbo-to-manifold nuts by hand to ensure proper thread engagement. Tighten mounting nuts in a crossing pattern to specified torque. Apply anti-seize compound to fastener threads during installation.
    ⚠Do not fully tighten any single fastener before all are hand-started. Tighten in progressive steps using cross-pattern.
    Torque spec

    Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
13. 13

    Reconnect oil feed line
    Install new crush washers on both sides of banjo fitting (one against turbo housing, one under banjo bolt). Position oil feed line to turbo and install banjo bolt. Torque to specification. Verify line routing does not contact heat shields or moving components.
    ℹ️Crush washers must be new and properly positioned or oil leaks will occur under pressure.
    Torque spec

    Oil Feed Line20 Nm (15 lb-ft)
14. 14

    Reconnect oil drain line
    Install new gasket on oil return flange. Position oil drain line to turbo and engine block, ensuring line has smooth bend without kinks or sharp angles. Install and torque bolts to specification. Verify drain line slopes downward toward engine for proper oil return flow.
    ⚠Oil drain line must have gravity-assisted flow back to engine. Any kinks or upward angles will cause oil leakage past turbo seals.
    Torque spec

    Oil Return Line10 Nm (7 lb-ft)
15. 15

    Reconnect coolant lines
    Install new O-rings on coolant line fittings, lubricating lightly with clean coolant. Connect coolant supply and return lines to turbocharger CHRA. Torque fittings to specification. Do not overtighten as this can damage O-rings.
    Torque spec

    Coolant Line Fittings15 Nm (11 lb-ft)
16. 16

    Connect downpipe and intake system
    Position new downpipe gasket on turbo outlet flange. Raise and align exhaust downpipe to turbo. Install and torque four mounting bolts in crossing pattern to specification. Connect intercooler pipe to compressor outlet and secure V-band clamp. Install intake air tube to turbo inlet. Ensure all connections are secure with no gaps.
    Torque spec

    Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
17. 17

    Reconnect actuator and sensors
    Reconnect VGT actuator electrical connector. Reinstall any boost pressure sensors or exhaust temperature sensors, torquing to specification. Connect actuator rod to linkage mechanism and verify smooth operation through full range of motion. Reinstall heat shields using proper hardware and torque values.
    Torque spec

    Sensor Bolts15 Nm (11 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)
18. 18

    Refill coolant and perform leak check
    Refill cooling system with proper Mopar OAT Purple coolant to correct level. Reconnect battery terminals (positive first, then negative). Turn ignition to ON position without starting engine and allow fuel system to prime (wait for lift pump to stop running). Check all connections visually for proper installation before starting engine.

Reassembly

1. Reinstall engine cover and air filter housing after verification testing is complete.
2. Reinstall front grille and core support assembly if removed during preparation.
3. Top off coolant level after initial heat cycle and coolant system burping.
4. Check engine oil level and add as needed to compensate for oil trapped in new turbo.
5. Verify all exhaust connections are tight and no leaks are present after first test drive.

Verification

• Before first start, disable fuel system (unplug fuel solenoid or crank position sensor) and crank engine for 15-20 seconds to build oil pressure and prime turbocharger bearings. Watch oil pressure gauge to confirm pressure builds.
• Reconnect fuel system and start engine. Listen for unusual noises from turbo area. Any grinding, squealing, or rattling indicates improper installation.
• Allow engine to idle for 5 minutes and carefully inspect all connections for oil, coolant, or exhaust leaks. Check around oil feed line, drain line, coolant fittings, and exhaust flanges.
• Monitor coolant temperature and verify cooling system is functioning properly. Burp air from cooling system as needed.
• Test drive vehicle and verify boost builds properly under moderate acceleration. Boost pressure should reach approximately 25-30 PSI under full throttle (altitude dependent).
• After test drive, allow engine to cool and recheck all fastener torques. Verify no leaks developed during heat cycling.
• Check and clear any diagnostic trouble codes. VGT actuator may need to be relearned using scan tool depending on vehicle programming.

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