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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 688 (Engine Cooling System) >> Repair Instructions >> Turbocharger Coolant Hoses/Pipes Replacement (6.6L Engine) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
    4. Fig 1: Upper Intake Manifold Cover
    G01658019Courtesy of GENERAL MOTORS CORP.
  4. Drain the engine coolant. Refer to Draining & Filling Cooling System .
  5. Disconnect both battery negative cables.

    Important:  After removing the charged air cooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of objects.

  6. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
  7. Remove the outlet duct from the turbocharger and MAF/IAT sensor.
    Fig 2: Outlet Duct From Turbocharger & MAF/IAT Sensor
    G01658020Courtesy of GENERAL MOTORS CORP.
  8. Loosen both of the charged air cooler outlet duct to intake hose clamps.

    Important:  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.

  9. Remove the charged air cooler duct to intake hose.
    Fig 3: Charged Air Cooler Duct To Intake Hose
    G01658021Courtesy of GENERAL MOTORS CORP.
  10. Remove the nut retaining the positive cable to the generator.
  11. Remove the positive cable from the generator.
  12. Disconnect the generator electrical connector.
    Fig 4: Generator Electrical Connector
    G01658022Courtesy of GENERAL MOTORS CORP.
  13. Remove the ribbed idler pulley from the generator bracket.
  14. Remove the generator mounting bracket and secure to the side.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
    15. Fig 5: Generator Mounting Bracket
    G01658023Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the wiring harness connector to the fuel injection control module.
  16. Remove the fuel lines to the fuel injection control module.
  17. Use the J 43181  in order to disconnect the inlet heater hose from the heater core inlet.
    18. Fig 6: Inlet Heater Hose At Heater Core Inlet
    G01658024Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel injection control module wiring harness conduit from the heater pipe.
  19. Remove the bolt retaining the heater pipe to the fuel filter assembly.
  20. Remove the bolt retaining the heater pipe to the thermostat housing.
  21. Remove the heater pipe with O-ring seal from the thermostat housing.
    Fig 7: Heater Pipe At Thermostat Housing
    G01658025Courtesy of GENERAL MOTORS CORP.
  22. Remove the bolt retaining the turbocharger outlet coolant pipe to the turbocharger coolant pipe bracket.
  23. Remove the hose and clamp from the turbocharger outlet coolant pipe to thermostat bypass pipe.
    Fig 8: Turbocharger Outlet Coolant Pipe To Thermostat Bypass Pipe
    G01658026Courtesy of GENERAL MOTORS CORP.
  24. Disconnect the turbocharger outlet coolant hose from the turbocharger.
    Fig 9: Turbocharger Outlet Coolant Hose From Turbocharger
    G01658027Courtesy of GENERAL MOTORS CORP.
  25. Remove the nut retaining the turbocharger outlet coolant pipe.
  26. Remove the coolant pipe from the engine.
    Fig 10: Turbocharger Outlet Coolant Pipe
    G01658028Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
    28. Fig 11: Turbocharger Inlet Coolant Hose
    G01658029Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the turbocharger inlet coolant hose from the turbocharger.
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