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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 >> Removal Procedure

Removal 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.
IMPORTANT: If a turbocharger failure is thought to be caused due to lack of oil, the camshaft bearing should be checked. The number 4 camshaft bearing bore feeds the turbocharger oil supply (feed) pipe. If this camshaft bearing spins in the bore, the turbocharger will be starved for oil. This will cause a failure of the turbocharger. Failure to diagnosis this condition will result in repeat turbocharger failures.
  1. Disconnect 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.
  2. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
    3. Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Loosen the exhaust pipe clamp. Slide the clamp onto the exhaust pipe.
    5. Fig 2: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  5. If equipped with an automatic transmission, remove the fill tube to bellhousing nuts.
    6. Fig 3: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  6. Position the fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  7. Remove the left exhaust heat shield nuts (2) and shield (3) at the front of the lower dash panel.
    8. Fig 4: View Of Left Exhaust Heat Shield & Nuts
    GM707396Courtesy of GENERAL MOTORS CORP.
  8. Remove the left exhaust pipe heat shield bolts.
    9. Fig 5: View Of Left Exhaust Pipe Heat Shield & Bolts
    GM668426Courtesy of GENERAL MOTORS CORP.
  9. Position the left exhaust pipe heat shield in order to access the left exhaust pipe to exhaust manifold bolts. Do not remove the heat shield from the vehicle at this time.
    10. IMPORTANT: Do not bend the exhaust pipe at the expansion area.
  10. Remove the left exhaust pipe to exhaust manifold bolts (2).
  11. Remove and discard the gasket.
    12. Fig 6: View Of Left Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM785649Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not bend the exhaust pipe at the expansion area.
  12. Remove the right exhaust pipe to exhaust manifold bolts (1).
    13. Fig 7: View Of Right Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM777476Courtesy of GENERAL MOTORS CORP.
  13. Remove and discard the gasket.
  14. Remove the lower bolt (2) for the exhaust outlet shield.
    15. Fig 8: View Of Exhaust Outlet Shield & Bolts
    GM668425Courtesy of GENERAL MOTORS CORP.
  15. Lower the vehicle.
  16. Loosen the outlet duct clamp at the upper intake manifold cover.
  17. Remove the upper intake manifold cover from the outlet duct.
  18. Remove the upper intake manifold cover.
    19. Fig 9: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  19. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
    20. IMPORTANT: After removing the turbocharger ducts, cover the turbocharger openings with tape to prevent entry of objects.
  20. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
  21. Remove the outlet duct from the turbocharger.
    22. Fig 10: View Of Outlet Duct
    GM813244Courtesy of GENERAL MOTORS CORP.
  22. Loosen the charged air cooler outlet duct to intake hose clamp (1).
    23. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  23. Remove the charged air cooler outlet duct from the intake.
    24. Fig 11: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  24. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
    25. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  25. Remove the charged air cooler inlet duct from the turbocharger.
    26. Fig 12: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  27. Disconnect the A/C cut out switch electrical connector.
  28. Remove the drive belt. Refer to Drive Belt Replacement .
  29. Remove the A/C compressor bolts.
  30. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
    31. Fig 13: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  31. Remove the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
    32. Fig 14: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS CORP.
  32. Remove the turbocharger outlet coolant hose from the turbocharger.
    33. Fig 15: View Of Turbocharger Outlet Coolant Hose
    GM668428Courtesy of GENERAL MOTORS CORP.
  33. Remove the positive crankcase ventilation (PCV) hose from the left valve rocker arm cover.
    34. Fig 16: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  34. Position the hose out of the way.
  35. Remove the wire connector from the intake heater.
  36. If equipped, remove the intake 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.
  37. Remove the turbocharger heat shield bolts.
  38. Remove the turbocharger heat shield.
    39. Fig 17: View Of Turbocharger Heat Shield & Bolt
    GM660382Courtesy of GENERAL MOTORS CORP.
  39. Remove the remaining exhaust outlet heat shield bolts (1, 3).
    40. Fig 18: View Of Exhaust Outlet Shield & Bolts
    GM668425Courtesy of GENERAL MOTORS CORP.
  40. Remove the exhaust outlet heat shield.
  41. Remove the exhaust outlet bolts and nuts.
    42. IMPORTANT: The exhaust outlet does not require removal in order to remove the turbocharger.
  42. Move the exhaust outlet to one side in order to access the right exhaust pipe to turbocharger bolts.
  43. Remove and discard the exhaust outlet gasket.
    44. Fig 19: View Of Exhaust Outlet Nuts, Bolts & Gasket
    GM654540Courtesy of GENERAL MOTORS CORP.
  44. Remove the right exhaust pipe to turbocharger bolts (2).
  45. Remove the right exhaust pipe.
    46. Fig 20: View Of Right Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM777476Courtesy of GENERAL MOTORS CORP.
  46. Remove and discard the gasket.
  47. Move the exhaust outlet to one side in order to access the left exhaust pipe.
  48. Remove the left exhaust pipe heat shield from the vehicle.
  49. Remove the left exhaust pipe to turbocharger bolts (1).
    50. Fig 21: View Of Left Exhaust Pipe To Exhaust Manifold & Turbocharger Bolts
    GM785649Courtesy of GENERAL MOTORS CORP.
  50. Remove the left exhaust pipe.
  51. Remove and discard the gasket.
  52. Remove the turbocharger oil feed pipe bolt and washers.
    53. Fig 22: View Of Turbocharger Oil Feed Pipe, Bolts & Washers
    GM660383Courtesy of GENERAL MOTORS CORP.
  53. Move the oil feed pipe out of the way.
  54. Remove the turbocharger oil return pipe nuts at the flywheel housing.
    55. Fig 23: View Of Turbocharger Oil Return Pipe & Nuts
    GM668429Courtesy of GENERAL MOTORS CORP.
  55. Remove the turbocharger bolts.
  56. Remove the turbocharger with oil return pipe.
    57. Fig 24: View Of Turbocharger & Bolts
    GM798881Courtesy of GENERAL MOTORS CORP.
  57. If required, remove the turbocharger lower heat shield.
    58. Fig 25: View Of Turbocharger Lower Heat Shield
    GM798882Courtesy of GENERAL MOTORS CORP.
  58. If required, remove the oil feed pipe bolt, washers, and pipe.
  59. If the turbocharger has failed, perform the following steps the verify the condition of the number 4 camshaft bearing before installing a new turbocharger.
    1. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole through the turbocharger oil supply hole in the block.
    2. Turn the engine over by hand 1/2 turn and inspect for camshaft bearing movement, indicating a spun camshaft bearing.
    3. If the bearing is spun the engine MUST be replaced.
  60. If replacing the turbocharger, remove the following items:
    • The oil return pipe
    • The coolant return hose
    61. Fig 26: View Of Turbocharger Components
    GM697717Courtesy of GENERAL MOTORS CORP.
  61. Clean the following gasket surfaces:
    • The oil return pipe to turbocharger
    • The oil return pipe to flywheel housing
    • The air intake tube
    • Both exhaust pipe flanges
    • Both exhaust manifold flanges
    • The exhaust outlet
    • Turbocharger, exhaust outlet
    • Turbocharger, both exhaust pipes
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