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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1020 (Engine Mechanical - 6.6L (LLY)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Turbocharger Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. If the turbocharger was replaced, install the oil return pipe, bolts, and a NEW gasket.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

    2. Fig 1: View Of Oil Return Pipe Bolts
    GM1336136Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the washer with diesel fuel prior to installing.
  2. Install the oil feed pipe, washer, and bolt, if necessary.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

    3. Fig 2: View Of Oil Feed Pipe Bolt, Washer & Pipe
    GM1335581Courtesy of GENERAL MOTORS CORP.
  3. Install the turbocharger lower heat shield, if necessary.
  4. Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
  5. Install the turbocharger (with the oil return pipe).
    6. Fig 3: View Of Turbocharger W/Oil Return Pipe
    GM1335579Courtesy of GENERAL MOTORS CORP.
  6. Install the turbocharger bolts.

    Tighten:  Tighten the bolts to 108 N.m (80 lb ft).

  7. Install the turbocharger oil return pipe nuts at the top of the flywheel housing.

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

  8. If installing a NEW turbocharger, add about 120-150 cc (4-5 oz) of clean engine oil in the turbocharger oil feed pipe opening while rotating the impeller.
  9. Position the oil feed pipe to the turbocharger.
  10. Install a NEW turbocharger oil feed pipe washer and the banjo bolt.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

    11. Fig 4: View Of Turbocharger Oil Feed Pipe Banjo Bolt
    GM1335577Courtesy of GENERAL MOTORS CORP.
  11. Install the left exhaust pipe and a NEW gasket.
  12. Install the left exhaust pipe to turbocharger bolts.

    Tighten:  Tighten the bolt to 53 N.m (39 lb ft).

    13. Fig 5: View Of Left Exhaust Pipe
    GM1334832Courtesy of GENERAL MOTORS CORP.
  13. Install the right exhaust pipe and a NEW gasket.
  14. Install the right exhaust pipe to turbocharger bolts.

    Tighten:  Tighten the bolt to 53 N.m (39 lb ft).

    15. Fig 6: View Of Right Exhaust Pipe
    GM1334842Courtesy of GENERAL MOTORS CORP.
  15. Install the exhaust outlet.
    16. Fig 7: View Of Exhaust Outlet
    GM1341232Courtesy of GENERAL MOTORS CORP.
  16. Tighten the exhaust outlet clamp.

    Tighten:  Tighten the clamp to 15 N.m (11 lb ft).

    17. Fig 8: View Of Exhaust Outlet Clamp
    GM1334826Courtesy of GENERAL MOTORS CORP.
  17. Install the exhaust outlet heat shield.
  18. Install the remaining exhaust outlet heat shield bolts.

    Tighten:  Tighten the bolt to 8 N.m (71 lb in).

    19. Fig 9: View Of Exhaust Outlet Shield
    GM1334821Courtesy of GENERAL MOTORS CORP.
  19. Install the PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  20. If the cooling outlet hose eye bolts were removed, install the longer bolt (1) with 2 holes, in the top location. Install the shorter bolt (2) in the lower location.
    21. Fig 10: View Of Cooling Outlet Hose Eye Bolts
    GM1457469Courtesy of GENERAL MOTORS CORP.
  21. Install the turbocharger outlet coolant pipe banjo bolt and washers.

    Tighten:  Tighten the bolt to 26 N.m (19 lb ft).

  22. Install the turbocharger outlet coolant hose to the turbocharger and position the hose clamp.
    23. Fig 11: View Of Turbocharger Outlet Coolant Pipe
    GM1335578Courtesy of GENERAL MOTORS CORP.
  23. Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
    24. Fig 12: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
  24. Install the turbocharger upper heat shield.
  25. Install the turbocharger upper heat shield bolts.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    26. Fig 13: View Of Turbocharger Upper Heat Shield
    GM1335576Courtesy of GENERAL MOTORS CORP.
  26. Remove the tape from the turbocharger openings.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  27. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  28. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    29. Fig 14: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  29. Install the charged air cooler outlet duct to the intake.
    30. Fig 15: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
  30. Tighten the charged air cooler outlet duct to intake hose clamp.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

  31. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  32. Install the lower bolt for the exhaust outlet shield.

    Tighten:  Tighten the bolt to 8 N.m (71 lb in).

    33. Fig 16: View Of Exhaust Outlet Shield
    GM1334821Courtesy of GENERAL MOTORS CORP.
  33. Install a NEW exhaust manifold gasket.
  34. Install the right exhaust pipe to exhaust manifold bolts.

    Tighten:  Tighten the bolts to 53 N.m (39 lb ft).

    35. Fig 17: View Of Right Exhaust Pipe
    GM1334842Courtesy of GENERAL MOTORS CORP.
  35. Install a NEW exhaust manifold gasket.
  36. Install the left exhaust pipe to exhaust manifold bolts.

    Tighten:  Tighten the bolts to 53 N.m (39 lb ft).

    37. Fig 18: View Of Left Exhaust Pipe
    GM1334832Courtesy of GENERAL MOTORS CORP.
  37. Install the heat shield.
  38. Install the left exhaust pipe heat shield bolts.

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

    39. Fig 19: View Of Left Exhaust Pipe Heat Shield
    GM660364Courtesy of GENERAL MOTORS CORP.
  39. If equipped with an automatic transmission, position the fill tube to the studs.
  40. Install the transmission fill tube to bellhousing nuts.

    Tighten:  Tighten the nuts to 18 N.m (13 lb ft).

    41. Fig 20: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  41. Slide the clamp onto the exhaust pipe. Tighten the exhaust pipe clamp.

    Tighten:  Tighten the clamp to 40 N.m (30 lb ft).

    42. Fig 21: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  42. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  43. If a NEW turbocharger was installed, perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure in Engine Controls - 6.6L (LLY).
  44. Road test the vehicle for normal operation.
  45. Inspect for coolant, oil, or exhaust leaks. Correct as necessary.
  46. Perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure Engine Controls - 6.6L (LLY).
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