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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1023 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> 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.
  1. Install the oil return pipe and a NEW gasket to the turbocharger.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the turbocharger oil return pipe bolts.

    Tighten:  Tighten the bolts to 21 N.m (16 lb ft).

  3. Install the coolant return hose to the turbocharger.
    4. Fig 1: View Of Turbocharger Components
    GM697717Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the washers with diesel fuel before installing.
  4. If required, install the oil feed pipe, bolt, and washers.

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

  5. If required, install the turbocharger lower heat shield.
    6. Fig 2: View Of Turbocharger Lower Heat Shield
    GM798882Courtesy of GENERAL MOTORS CORP.
  6. Install the turbocharger.
  7. Install the turbocharger bolts.

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

    8. Fig 3: View Of Turbocharger & Bolts
    GM798881Courtesy of GENERAL MOTORS CORP.
  8. Install a NEW gasket for the oil return pipe.
  9. Install the turbocharger oil return pipe nuts.

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

    10. Fig 4: View Of Turbocharger Oil Return Pipe & Nuts
    GM668429Courtesy of GENERAL MOTORS CORP.
  10. If installing a NEW turbocharger, pour about 120-150 cc (4-5 oz) of clean engine oil in the turbocharger oil feed pipe opening while rotating the impeller.
  11. Using NEW sealing washers, install the oil feed pipe and bolt to the turbocharger.

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

    12. Fig 5: View Of Turbocharger Oil Feed Pipe, Bolts & Washers
    GM660383Courtesy of GENERAL MOTORS CORP.
  12. Position the left exhaust pipe. The pipe flanges are different. Ensure the proper pipe flange is towards the turbocharger.
  13. Install the left exhaust pipe to the turbocharger with a NEW gasket. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.

    Tighten:  Tighten the bolts (1) to 53 N.m (39 lb ft).

    14. Fig 6: View Of Left Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM785649Courtesy of GENERAL MOTORS CORP.
  14. Position the left exhaust pipe heat shield, but do not install the bolts.
  15. Install the right exhaust pipe with a NEW gasket to the turbocharger. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.
  16. Install the right exhaust pipe to turbocharger bolts (2).

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

    17. Fig 7: View Of Right Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM777476Courtesy of GENERAL MOTORS CORP.
  17. Install the exhaust outlet with a NEW gasket to the turbocharger.
  18. Install the exhaust outlet bolts and nuts.

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

    19. Fig 8: View Of Exhaust Outlet Nuts, Bolts & Gasket
    GM654540Courtesy of GENERAL MOTORS CORP.
  19. Install the exhaust outlet heat shield.
  20. Install the upper 2 exhaust outlet heat shield bolts (1, 3).

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

    21. Fig 9: View Of Exhaust Outlet Shield & Bolts
    GM668425Courtesy of GENERAL MOTORS CORP.
  21. Install the turbocharger heat shield.
  22. Install the turbocharger heat shield bolts.

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

    23. Fig 10: View Of Turbocharger Heat Shield & Bolt
    GM660382Courtesy of GENERAL MOTORS CORP.
  23. Install the PCV hose to the upper left valve rocker arm cover.
    24. Fig 11: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  24. Install the turbocharger outlet coolant hose to the turbocharger.
    25. Fig 12: View Of Turbocharger Outlet Coolant Hose
    GM668428Courtesy of GENERAL MOTORS CORP.
  25. Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
    26. Fig 13: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS CORP.
  26. Install the inlet air heater relay. Refer to Intake Air Heater (IAH) Relay Replacement (Federal Emissions) or Intake Air Heater (IAH) Relay Replacement (California Emissions) in Engine Controls - 6.6L.
    27. NOTE: Refer to Fastener Notice in Cautions and Notices.
  27. Connect the wire terminal and the nut to intake air heater.

    Tighten:  Tighten the nut to 4 N.m (35 lb in).

  28. Position the A/C compressor.
  29. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    30. Fig 14: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  30. Install the drive belt. Refer to Drive Belt Replacement .
  31. Connect the A/C cut out switch electrical connector.
  32. Connect the A/C clutch electrical connector.
  33. Remove the tape from the turbocharger openings, if necessary.
  34. Install the charged air cooler inlet duct to the turbocharger.
  35. Align the mark on the duct (2) with the mark on the turbocharger.
  36. Position the clamp (1) as shown for proper clearance.

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

    37. Fig 15: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  37. Install the charged air cooler outlet duct to the intake.
  38. Align the mark on the duct (3) with the mark on the intake.
  39. Position the clamp (1) as shown for proper clearance.

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

    40. Fig 16: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  40. Install the outlet duct to turbocharger.
  41. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
    42. Fig 17: View Of Outlet Duct & Turbocharger Alignment Indicators
    GM813246Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The outlet duct must be fully seated against the MAT/IAT sensor with the edge of the seal in the vertical position.
  42. Install the outlet duct to the MAT/IAT sensor.
  43. Tighten the outlet duct clamps at the turbocharger and the MAT/IAT sensor.

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

    44. Fig 18: View Of Outlet Duct
    GM813244Courtesy of GENERAL MOTORS CORP.
  44. Raise the vehicle.
  45. Install the lower exhaust outlet heat shield bolt (2).

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

    46. Fig 19: View Of Exhaust Outlet Shield & Bolts
    GM668425Courtesy of GENERAL MOTORS CORP.
  46. Install the right exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
  47. Install the right exhaust pipe bolts (2).

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

    48. Fig 20: View Of Right Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM777476Courtesy of GENERAL MOTORS CORP.
  48. Install the left exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
  49. Install the left exhaust pipe bolts (1).

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

    50. Fig 21: View Of Left Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM785649Courtesy of GENERAL MOTORS CORP.
  50. Position the left exhaust pipe heat shield.
  51. Install the left exhaust pipe heat shield bolts.

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

    52. Fig 22: View Of Left Exhaust Pipe Heat Shield & Bolts
    GM668426Courtesy of GENERAL MOTORS CORP.
  52. Install the exhaust heat shield (3) to left front of the dash panel.
  53. Install the shield nuts (2).

    Tighten:  Tighten the nuts to 9 N.m (80 lb ft).

    54. Fig 23: View Of Left Exhaust Heat Shield & Nuts
    GM707396Courtesy of GENERAL MOTORS CORP.
  54. If equipped, position the fill tube.
  55. Install the fill tube nuts.

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

    56. Fig 24: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  56. Install the exhaust pipe clamp.

    To assist in positioning the clamp on the flanges use a suitable screw jack to hold the exhaust pipe in position.

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

    57. Fig 25: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  57. Lower the vehicle.
  58. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  59. Install the upper intake manifold cover.
  60. Install the upper intake manifold cover to the outlet duct.
  61. Tighten the outlet duct clamp at the upper intake manifold cover.

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

    62. Fig 26: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  62. Position the hood in the normal operating position by moving the hood hinge bolts from the service position (2) to the normal operating position (1).

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

    63. Fig 27: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  63. Connect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  64. Road test the vehicle for normal operation.
  65. Inspect for coolant, oil, or exhaust leaks.
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