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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 481 (Engine Mechanical - 6.6L V8 Diesel) >> Removal & Installation >> Turbocharger >> Removal

Removal & Installation: 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.
  1. Disconnect both battery cables. Move hood to service position by moving hood hinge bolts to service positions.
  2. Raise vehicle. Remove exhaust pipe to exhaust outlet clamp. Move clamp onto exhaust pipe. On A/T models, remove transmission fluid fill tube to bellhousing nuts. Position transmission fluid fill tube to right side of vehicle. The tube does not require removal from transmission.
  3. On all models, remove 3 nuts and left exhaust heat shield at front of lower dash panel. Remove left exhaust pipe heat shield bolts. Position left exhaust pipe heat shield in order to access left exhaust pipe to exhaust manifold bolts. Do not remove heat shield from vehicle at this time.
  4. Do not bend exhaust pipe at expansion area. Remove left exhaust pipe to exhaust manifold bolts. Remove and discard gasket. Do not bend exhaust pipe at expansion area. Remove right exhaust pipe to exhaust manifold bolts. Remove and discard gasket.
  5. Remove lower bolt for exhaust outlet shield. Lower vehicle. Remove retaining bolt in front of shield. Lift up on front of shield. Lift shield off the rear bracket. Drain engine coolant. See DRAINING & REFILLING COOLING SYSTEM . Remove upper intake manifold sight shield.
  6. After removing the charged air cooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of objects. Remove air cleaner outlet duct from air cleaner and turbocharger. Loosen both charged air cooler outlet duct to intake hose clamps. See Figure.
  7. Do not use a screwdriver or other tool to pry hose loose. The hose can be torn or damage. Loosen hose by twisting. Remove hose from charged air cooler duct to intake manifold tube.
  8. Loosen charged air cooler inlet duct to turbocharger cool air outlet clamp. Do not use a screwdriver or other tool to pry hose loose. The hose can be torn or damage. Loosen hose by twisting. Remove charged air cooler inlet duct to turbocharger cool air outlet hose from turbocharger.
  9. Disconnect A/C compressor clutch electrical connector. Disconnect A/C cut-out switch electrical connector. Remove drive belt. Remove A/C compressor mounting bolts. Move A/C compressor with hoses attached to right side of engine compartment.
  10. Disconnect turbocharger inlet coolant hose from turbocharger coolant bypass valve. Disconnect turbocharger outlet coolant hose from turbocharger.
  11. Disconnect PCV hose from left valve rocker arm cover. Position hose out of the way. Remove wire connector from intake heater. If equipped, remove intake air heater relay.
  12. Remove 3 bolts holding heat shield to turbocharger. Remove turbocharger heat shield. Remove remaining 2 bolts for the exhaust outlet heat shield. Remove exhaust outlet heat shield.
  13. Remove 4 bolts and 2 nuts for exhaust outlet. The exhaust outlet does not require removal in order to remove turbocharger. Move exhaust outlet to one side in order to access the right exhaust pipe to turbocharger bolts. Remove and discard exhaust outlet gasket.
  14. Remove right exhaust pipe to turbocharger bolts. Remove right exhaust pipe. Remove and discard gasket. Move exhaust outlet to one side in order to access left exhaust pipe. Remove left exhaust pipe heat shield from vehicle. Remove left exhaust pipe to turbocharger bolts. Remove left exhaust pipe. Remove and discard gasket.
  15. Remove turbocharger oil supply hose eye bolt, and washers. Move oil supply hose out of the way. Remove turbocharger oil drain pipe nuts at flywheel housing. Remove turbocharger three mounting bolts. Remove turbocharger with turbocharger oil drain pipe.
  16. If replacing turbocharger remove oil drain pipe and coolant hose. Clean gasket surfaces at oil drain pipe to turbocharger, oil drain pipe to flywheel housing and air intake tube, both exhaust pipe flanges, both exhaust manifold flanges, exhaust outlet, turbocharger, exhaust outlet, turbocharger and both exhaust pipes.
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