Turbocharger: Service and Repair

Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the engine cover from the vehicle.
3. Remove the upper intake manifold.
4. Cover the turbocharger intake duct opening with tape.
5. Disconnect the wastegate vacuum hose.
6. Raise the vehicle. Refer to Vehicle Lifting.
7. Remove the nuts retaining the catalytic converter pipe to the turbocharger.
8. Remove the pipe from the turbocharger.
9. Lower the vehicle.





10. Remove the turbocharger heat shield mounting bolts.
11. Remove the turbocharger heat shield.





12. Remove the exhaust pipe clamps from the exhaust pipes that connect the turbocharger to the exhaust manifolds.
13. Remove the exhaust pipes that connect the turbocharger to the exhaust manifolds.





14. Remove the turbocharger mounting bolts.
15. Remove the turbocharger assembly from the engine block.
16. Remove and discard the seals.
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. Apply anti-seize compound GM P/N 1052771 on all threaded fasteners connected to the turbocharger.
2. Install new turbocharger seals to the engine block.
3. Install the turbocharger assembly to the engine block.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the turbocharger mounting bolts.
^ Tighten the bolts to 65 Nm (48 ft. lbs.).





Important: In order to ensure heat shield clearance, locate the exhaust pipe clamps as shown.

5. Slide the exhaust clamps over the exhaust manifold and turbocharger.
6. Install the right hand side exhaust pipe.
7. Place the clamps in the correct position.





8. Install the left hand side exhaust pipe.
9. Place the clamps in the correct position.
10. Tighten the clamps at the exhaust manifold end first.
^ Tighten the clamps to 10 Nm (90 inch lbs.).





11. Raise the vehicle.
12. Install the catalytic converter pipe and the nuts to the turbocharger.
^ Tighten the pipe nuts to 20 Nm (16 ft. lbs.).
13. Lower the vehicle





14. Install the turbocharger heat shield.
15. Install the turbocharger heat shield mounting bolts and nut.
15.1. Tighten the bolts (right and top) to 30 Nm (22 ft. lbs.).
15.2. Tighten the center bolts to 22 Nm (117 ft. lbs.).
15.3. Tighten the heat shield nut to 30 Nm (22 ft. lbs.).
16. Install the vacuum hose to the wastegate actuator.
17. Install the upper intake manifold.
18. 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.

19. Install the engine cover.