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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1620 (Engine Cooling System) >> Repair Instructions >> Turbocharger Coolant Hoses/Pipes Replacement (6.6L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Connect the turbocharger coolant return hose and clamp to the turbocharger coolant bypass valve.
  2. Connect the turbocharger coolant return hose and clamp to the turbocharger.
    Fig 1: Connect Turbocharger Coolant Return Hose
    G02109090Courtesy of GENERAL MOTORS CORP.
  3. Install the turbocharger coolant feed pipe.
    NOTE: Refer to FASTENER NOTICE .
  4. Install the turbocharger coolant feed pipe nut.

    Tighten 

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

    Fig 2: Install Turbocharger Coolant Feed Pipe & Nut
    G02109091Courtesy of GENERAL MOTORS CORP.
  5. Connect the turbocharger coolant feed hose and clamps to the turbocharger and the coolant pipe.
    Fig 3: Connect Turbocharger Coolant Feed Hose & Clamps
    G02109092Courtesy of GENERAL MOTORS CORP.
  6. Install the turbocharger coolant return hose and clamps.
  7. Install the turbocharger coolant feed pipe bracket bolts.

    Tighten 

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

    Fig 4: Install Turbocharger Coolant Feed Pipe Bracket Bolts, Return Hose & Clamps
    G02109093Courtesy of GENERAL MOTORS CORP.
  8. Install a NEW O-ring seal to the heater inlet pipe.
  9. Install the heater inlet pipe to the thermostat housing.
  10. Install the heater inlet pipe to thermostat housing bolt.

    Tighten 

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

    Fig 5: Install Heater Inlet Pipe
    G02109094Courtesy of GENERAL MOTORS CORP.
  11. Install the heater inlet pipe to fuel filter bolt.

    Tighten 

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

  12. Connect the inlet heater hose to the heater inlet.
  13. Install the fuel injection control module wiring harness conduit to the heater pipe.
    Fig 6: Install Fuel Injection Control Module Wiring Harness Conduit
    G02109095Courtesy of GENERAL MOTORS CORP.
  14. Install the generator bracket and bolts.

    Tighten 

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

  15. Install the ribbed idler pulley and bolt.

    Tighten 

    Tighten the bolt to 43 N.m (32 lb ft).

    Fig 7: Installing Ribbed Idler Pulley & Bolt
    G02109096Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel lines (2) to the fuel injection control module.
  17. Install the fuel line bolts.

    Tighten 

    Tighten the bolts to 35 N.m (26 lb ft).

    Fig 8: Install Fuel Lines
    G02109097Courtesy of GENERAL MOTORS CORP.
  18. Connect the fuel injection control module electrical connectors (2).
    Fig 9: Connect Fuel Injection Control Module Electrical Connectors
    G02109098Courtesy of GENERAL MOTORS CORP.
  19. Install the generator positive cable and nut.

    Tighten 

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

    Fig 10: Install Generator Positive Cable & Nut
    G02109099Courtesy of GENERAL MOTORS CORP.
  20. Connect the generator electrical connector (1).
    Fig 11: Connect Generator Electrical Connector
    G02109100Courtesy of GENERAL MOTORS CORP.
  21. Remove the tape from the turbocharger openings.
  22. Install the charged air cooler outlet duct to the intake.
  23. Align the mark on the duct (3) with the alignment mark on the intake.
  24. Position the clamp (1) as shown for proper clearance.

    Tighten 

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

    Fig 12: Alignment Mark & Clamp
    G02109101Courtesy of GENERAL MOTORS CORP.
  25. Install the outlet duct to the turbocharger.
  26. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
    Fig 13: Outlet Duct & Turbocharger Alignment Marks
    G02109102Courtesy 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.
  27. Install the outlet duct to the MAT/IAT sensor.
  28. Tighten the outlet duct clamps at the turbocharger and the MAT/IAT sensor.

    Tighten 

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

    Fig 14: Install Outlet Duct
    G02109103Courtesy of GENERAL MOTORS CORP.
  29. Install the upper intake manifold cover.
  30. Install the upper intake manifold cover to the outlet duct.
  31. Tighten the outlet duct clamp at the upper intake manifold cover.

    Tighten 

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

  32. Fill the cooling. Refer to Draining and Filling Cooling System .
  33. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) or  BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY)  .
    Fig 15: Install Upper Intake Manifold Cover
    G02109104Courtesy of GENERAL MOTORS CORP.
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