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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 409 (Engine Controls - Removal & Installation - Diesel) >> Air Induction Systems >> Turbocharger >> Removal

Air Induction Systems: Turbocharger: Removal

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.
CAUTION: After removing the charged air cooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of objects.
NOTE: The Fan Clutch Remover and Installer Set (J-46406) is required to remove and install fan blade assembly. See Figure.
NOTE: The exhaust outlet does not require removal in order to remove the turbocharger.
  1. Disconnect negative battery cables. Move hood to service position by moving bolts to service position locations. See Figure. Raise and support vehicle. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  2. Remove the 3 nuts and the left exhaust heat shield at the front of the lower dash panel. Remove the left exhaust pipe heat shield bolts. 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.
  3. Remove the left exhaust pipe to exhaust manifold bolts. Do not bend the exhaust pipe at the expansion area. Remove and discard the gasket. Remove the right exhaust pipe to exhaust manifold bolts. Remove and discard the gasket. Remove the lower bolt for the exhaust outlet shield. Lower the vehicle.
  4. Loosen the outlet duct clamp at the upper intake manifold cover. Remove the upper intake manifold cover from the outlet duct. Remove upper intake manifold cover. Drain the engine coolant. Loosen the outlet duct clamps at the turbocharger and the Mass Air Flow/Intake Air Temperature (MAF/IAT) sensor.
  5. Remove the outlet duct from the turbocharger and MAF/IAT sensor. See Figure. Loosen the charged air cooler outlet duct to intake hose clamp. Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  6. Remove the hose from the charged air cooler duct to the intake manifold tube. Loosen the charged air cooler inlet duct to turbocharger cool air outlet clamp. Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.
  7. Remove drive belt by installing a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. See Figure. Remove the drive belt from the drive pulleys. Slowly release the tension on the tensioner arm.
  8. Disconnect the Air Conditioning (A/C) compressor clutch electrical connector. Disconnect the A/C cut out switch electrical connector. Remove the A/C compressor bolts. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
  9. Disconnect the turbocharger inlet coolant hose from the turbocharger coolant bypass valve. Disconnect the turbocharger outlet coolant hose from the turbocharger. Disconnect the PCV hose from the left valve rocker arm cover. Position the hose out of the way. Remove the wire connector from the intake heater. Remove the intake air heater relay, if necessary. See INTAKE AIR HEATER RELAY  under MOTORS, RELAYS & SOLENOIDS.
  10. Remove the 3 bolts holding the heat shield to the turbocharger. Remove the turbocharger heat shield. Remove the remaining 2 bolts for the exhaust outlet heat shield. Remove the exhaust outlet heat shield. Remove the 4 bolts and the 2 nuts for the exhaust outlet. Move the exhaust outlet to one side in order to access the right exhaust pipe to turbocharger bolts.
  11. Remove and discard the exhaust outlet gasket. Remove the right exhaust pipe to turbocharger bolts. Remove the right exhaust pipe. Remove and discard the gasket. See Figure.
  12. Move the exhaust outlet to one side in order to access the left exhaust pipe. Remove the left exhaust pipe heat shield from the vehicle. Remove the left exhaust pipe to turbocharger bolts. Remove the left exhaust pipe. Remove and discard the gasket. Remove the turbocharger oil feed hose eye bolt, and washers. See Figure.
  13. Move the oil supply hose out of the way. Remove the turbocharger oil return pipe nuts at the flywheel housing. Remove the turbocharger three mounting bolts. Remove the turbocharger with the turbocharger oil return pipe. See Figure.
  14. If replacing the turbocharger, remove the oil return pipe and the coolant return hose. 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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