Turbocharger Installation

Special Tool 

EN-49942  Holding Wrench

For equivalent regional tools, refer to Special Tools .

1. Clean the sealing surfaces.
2. Replace the connect fittings on the turbocharger coolant feed pipe and the turbocharger coolant return pipe. Refer to Turbocharger Disassemble  and Turbocharger Assemble .
3. Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).
   Fig 1: Turbocharger Assembly And Turbocharger Gasket

   Courtesy of GENERAL MOTORS COMPANY
   NOTE: Mind the turbocharger oil return pipe.
4. Connect the turbocharger oil return pipe to the engine while installing the turbocharger.
   Fig 2: Turbocharger Oil Return Pipe

   Courtesy of GENERAL MOTORS COMPANY
5. Install the turbocharger coolant feed pipe hollow screw along with 2 NEW seal rings (1) and (2).
6. Install the 8 NEW turbocharger nuts (1).
   Fig 3: Turbocharger Nuts

   Courtesy of GENERAL MOTORS COMPANY
7. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).
   Fig 4: Turbocharger Nut Tightening Sequence

   Courtesy of GENERAL MOTORS COMPANY
   CAUTION: Refer to Fastener Caution .
   CAUTION: Refer to Torque-to-Yield Fastener Caution .
8. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.
9. Connect the turbocharger coolant return hose (6) to the oil cooler coolant inlet pipe and install the turbocharger coolant return pipe bolt (7) to the oil cooler. Tighten the turbocharger coolant return pipe bolt to 8 N.m (71 lb in).
   Fig 5: Turbocharger Oil Feed Pipe Components

   Courtesy of GENERAL MOTORS COMPANY
10. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
11. Install the turbocharger oil feed pipe hollow screw (4) in compound with 2 NEW seal rings (1) and (3).
12. Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten to 8 N.m (71 lb in).
13. Tighten the turbocharger oil feed pipe hollow screw to 20 N.m (15 lb ft).
14. Install the EN-49942  holding wrench (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942  holding wrench to the turbocharger coolant feed pipe hollow screw.
    Fig 6: Holding Wrench And Ratchet Wrench

    Courtesy of GENERAL MOTORS COMPANY
    NOTE: The EN-49942  holding wrench (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twisting of the turbocharger coolant feed pipe during the fastening procedure.
15. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m (22 lb ft).
    Fig 7: Ratchet Wrench, Holding Wrench And Coolant Feed Pipe

    Courtesy of GENERAL MOTORS COMPANY
    NOTE: EN-49942  holding wrench (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe while the fastening procedure.