Turbocharger: Service and Repair

Removal Procedure





1. Remove the engine cover from the upper intake manifold.





2. Remove the Crankcase Depression Regulator (CDR) valve from the right valve rocker arm cover.
3. Disconnect both the battery negative cables from the batteries. Refer to Battery Replacement.





4. Remove the braces from the turbocharger and the upper and lower intake manifold.

Important: Some quantity of oil will exist inside the vent system. The crankcase vapor consist of vaporized oil that condenses within the vent and intake system. The inside of the air duct and compressor wheel housing will have some oil due to the venting of the crankcase vapors.

5. Loosen the clamps on the hose between the air cleaner assembly and the turbocharger.





Important: Silicone sealant is used on the hose between the upper intake manifold and the turbocharger.

6. Remove the hose between the upper intake manifold and the turbocharger assembly.
6.1. Use a small flat bladed screwdriver to break the seal on the hose between the upper intake manifold and the turbocharger.
6.2. Slide the hose and the clamps toward the upper intake manifold.





7. Remove the oil feed line from the turbocharger and position to the side.
8. Partially raise the vehicle. Refer to Vehicle Lifting.
9. Remove the right front tire from the vehicle.





10. Remove the splash guard between the wheelhouse and the frame.
11. Remove the exhaust pipe from the turbocharger.





12. Remove the oil return line from the turbocharger.





13. Remove the turbocharger from the right exhaust manifold.
14. Clean the all mounting bolts for the turbocharger.
15. Clean and inspect the sealing surface of the exhaust manifold.


Installation Procedure

Important: Check and make sure that the intake and exhaust systems leading to and from the turbocharger do not have any foreign material that may cause damage to the turbocharger during all levels of operation. At the same time, check and make sure that all sealing and mating surfaces are clean and no damage exist. If any damage is found, replace the damaged part.





1. Install the turbocharger on the left exhaust manifold.
2. Apply a small amount of high temperature anti seize compound, GM P/N 1052771 on all the threaded fasteners for the turbocharger.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the turbocharger bolts in the right exhaust manifold.
^ Tighten the bolts to 58 Nm (43 ft. lbs.).





4. Install the oil return line and gasket to the turbocharger and engine block.
^ Tighten all the bolts to 26 Nm (19 ft. lbs.).
5. Install the exhaust pipe to the turbocharger.





6. Install the splash guard between the wheel housing and the frame.
7. Install the right front tire on the vehicle.
8. Lower the vehicle. Refer to Vehicle Lifting.





Important: Before installing the oil feed line on the turbocharger, pour a small amount of clean engine oil (1 to 2 cc) into the oil feed hole while turning the compressor wheel by hand to lubricate the bearings in the turbocharger.

9. Install the oil feed line to the turbocharger.
^ Tighten the fitting to 17 Nm (13 ft. lbs.).





Important: Apply a small amount of silicone sealant, GM P/N 9985943 or equivalent, to a clean turbocharger compressor inlet and the upper intake manifold. This is done to prevent to prevent oil leakage from the closed breather system.

10. Install the hose (with clamps) between the turbocharger and the upper intake manifold:
10.1. Slide the hose over the upper intake manifold.
10.2. Slide the hose back toward the turbocharger compressor inlet.
11. Center the hose and tighten the clamps.
^ Tighten the hose clamps to 6 Nm (50 inch lbs.).





12. Install the bolt for long brace from the turbocharger to the upper intake manifold.
^ Tighten the bolt to 50 Nm (37 ft. lbs.).
13. Install the nut for the long brace on the lower intake manifold.
^ Tighten the nut to 40 Nm (30 ft. lbs.).
14. Install the short brace from the turbocharger to the upper intake manifold.
15. Install the bolts for the short brace in the turbocharger and the upper intake manifold.
^ Tighten the bolts to 25 Nm (19 ft. lbs.).
16. Install the vacuum line to the wastegate actuator.





17. Install the CDR valve to the right vale rocker arm cover.
18. Install the air intake duct to the turbocharger assembly.





19. Install the engine cover to the upper intake manifold.
20. Connect both the battery negative cables to the batteries. Refer to Battery Replacement.
21. Start and run the engine at an idle for at least 2 minutes after completing the installation of the turbocharger. While running the engine, check for any oil leaks at the oil feed or return line and repair as necessary.