Turbocharger: Service and Repair
Removal Procedure1. Disconnect the negative battery cable.
^ For the front battery, refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
^ For the auxiliary battery, refer to Battery Cable Replacement (Battery Cable Aux. Negative) in Starting and Charging.
2. Remove the engine cover from the vehicle.
3. Remove the Crankcase Depression Regulator (CDR) valve.
4. Remove the air cleaner assembly from the vehicle.
5. Remove the air cleaner intake duct from the turbocharger.
6. Remove the transmission oil level indicator and tube from the upper intake manifold.
7. Remove the upper intake manifold from turbocharger.
8. Remove the turbocharger heat shield mounting bolts.
9. Remove the turbocharger heat shield.
10. Remove the exhaust pipe clamps from the exhaust pipes that connect the turbocharger to the exhaust manifolds,
11. Remove the exhaust pipes that connect the turbocharger to the exhaust manifolds.
12. Remove the turbocharger mounting bolts.
13. Remove the turbocharger assembly from the engine block.
Important: Usually some quantity of oil will exist inside the vent system. The crankcase vapor consists of vaporized oil that condenses within the vent and intake system. The inside of the air intake duct and compressor wheel housing can be quite oily due to the venting of the crankcase vapors.
Installation Procedure
Important: Perform the following steps before installing the turbocharger:
^ Check the intake and exhaust systems leading to and from the turbocharger in order to ensure that there is no debris. Even small debris can cause severe wheel damage if drawn in during high speed operation.
^ Make sure the turbocharger and exhaust manifold flanges are clean and free of any foreign material.
^ Use high temperature anti-seize compound GM P/N 1052771 on all threaded fasteners connected to the turbocharger. Inspect the oil feed and return passages in the engine block and the turbocharger. Make sure these passages are clean and open.
^ Always replace the O-ring between the turbocharger and the engine block.
1. Install the turbocharger assembly to the engine block.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the turbocharger mounting bolts.
^ Tighten the bolts to 65 Nm (48 ft. lbs.).
3. Install the exhaust pipes that connect the exhaust manifolds to the turbocharger.
4. Install the exhaust pipe clamps.
^ Tighten the clamps to 10 Nm (90 inch lbs.).
5. Install the vacuum line to the waste gate actuator.
6. Install the turbocharger heat shield.
7. Install the turbocharger heat shield mounting bolts and nut.
7.1. Tighten the bolts (right and top) to 30 Nm (22 ft. lbs.).
7.2. Tighten the center bolts to 22 Nm (17 ft. lbs.).
7.3. Tighten the heat shield nut to 30 Nm (22 ft. lbs.).
8. Install the upper intake manifold on the turbocharger.
9. install the transmission oil level indicator tube to the upper intake manifold.
10. Install the air cleaner intake duct to the turbocharger.
11. Install the air cleaner assembly in the vehicle.
12. Install the CDR valve on the valve rocker arm rocker cover.
13. Connect the battery negative cables to the batteries.
Important: Run the engine at an idle for at least 2 minutes after completing the installation of the turbocharger. This will allow the oil to lubricate the bearing inside the turbocharger. While running the engine, check for any leaks.
14. Install the engine cover in the vehicle.