Turbocharger: Service and Repair

Removal

1. Negative battery cable.
2. Upper intake manifold cover.
3. Self tapping screw holding CDR valve tube on top of turbocharger.
4. CDR valve and tube assembly from the air cleaner extension and right rocker cover.

Important
^ Usually some quantity of oil will exist inside of 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 (rubber inlet elbow) and compressor wheel housing can be quite oily due to the venting of the crankcase vapors.

5. Air cleaner extension (rubber elbow) from air cleaner and compressor inlet.
6. Two bolts retaining the air cleaner to the wheel well and lift the air cleaner assembly off the front air intake duct.

^ This will allow easier access to the turbocharger flange nuts and exhaust clamp.

Notice: The right front wheel and inner splash shield can be removed for easier access to the turbocharger back flange nut.

7. Vacuum hose from the waste-gate actuator.
8. Long and short turbocharger braces.
9. Hose clamps at the intake extension/turbocharger compressor connector hose.

^ Slide connector hose over intake extension.

10. Exhaust clamp at turbocharger
11. Oil feed hose.
12. Oil return pipe.
13. Turbocharger flange nuts.
14. Turbocharger assembly from exhaust manifold.

Installation

Important
^ Before the turbocharger is installed, perform the following steps:

A. Check the intake and exhaust systems leading to and from the turbocharger to ensure that no debris has entered the system. Any debris can cause severe damage during high speed operation.
B. Make sure that the turbocharger and exhaust manifold flanges are clean and free of any foreign material. Use a high temperature anti-seize compound on all threaded fasteners connected to the turbocharger.

1. Turbocharger assembly to the exhaust manifold.
2. Nuts to the exhaust manifold.

Tighten
Exhaust manifold mounting nuts to 50 Nm (37 lbs.ft.).

3. Gasket on oil return pipe. Then the oil return pipe to the bottom of the turbocharger.

Tighten
Oil drain tube bolts to 26 Nm (19 lbs. ft.).

Important
^ Fill the oil feed hole at the top of the turbocharger with a small amount of engine oil (1cc to 2cc) while rotating the compressor wheel. This action will lubricate the turbocharger shaft bearings.

4. Oil feed hose to top of turbocharger.

Tighten
Oil feed hose fitting to 17 Nm (13 lbs. ft.).

5. Exhaust pipe to turbocharger with clamp.

Tighten
Exhaust pipe clamp to 8 Nm (71 lbs. in.).

Important
^ When starting the engine, allow it to idle for two minutes so oil can flow into the oil feed hose.

6. Inner splash shield and right front wheel (if removed).

Important
^ Apply silicone sealant (GM P/N 9985675) or equivalent to turbocharger compressor outlet hose before installation to prevent oil leakage from the closed breather system.

7. Slide the connector hose over the compressor outlet. Make sure the connector hose is centered between the compressor outlet and the inlet extention housing.

Tighten
Connector hose clamps to 1.7 Nm (15 lbs. in.).

8. Long turbocharger brace by guiding the flat end of the brace under the heater inlet.
9. Nut on the stud.
10. Bolt into the end of the brace.

Tighten
Long turbocharger brace nut to 34 Nm (26 lbs. ft.).
Long turbocharger brace bolt to 50 Nm (37 lbs. ft.).

11. Short turbocharger brace to extension and compressor housing.
12. Short turbocharger brace bolts.

Tighten
Short turbocharger brace bolts to 25 Nm (19 lbs. ft.)

13. Vacuum hose to waste-gate actuator.
14. Slide air cleaner onto the front air inlet duct and attach it to the fenderwell.
15. Large diameter air cleaner bolt.
16. Short diameter air cleaner bolt.

Tighten
Larger diameter air cleaner bolt to 30 Nm (22 lbs. ft.).
Smaller diameter air cleaner bolt to 5 Nm (45 lbs. in.).

17. Air cleaner extension (rubber elbow) onto the air cleaner and compressor inlet.

Tighten
Extension clamps to 1.7 Nm (15 lbs. in.).

18. CDR valve and tube assembly on right rocker cover and extension.

^ Start self-tapping screw through CDR tube bracket and thread into bracket on turbocharger housing.

19. Upper intake manifold.
20. Intake manifold cover bolts.

Tighten
Intake manifold cover bolts to 11 Nm (90 lbs. in.).

21. Negative battery cable.

Important:
^ Run engine at idle for at least 2 minutes after completing installation of turbocharger. While running the engine, check for any oil leaks at the oil supply and return hoses.