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 .
Fig 1: Turbocharger Assembly And Turbocharger Gasket
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Mind the turbocharger oil return pipe.

3. Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).
Fig 2: Turbocharger Oil Return Pipe
Courtesy of GENERAL MOTORS COMPANY
4. Connect the turbocharger oil return pipe to the engine while installing the turbocharger.
5. Install the turbocharger coolant feed pipe hollow screw along with 2 NEW seal rings (1) and (2).
Fig 3: Turbocharger Nuts
Courtesy of GENERAL MOTORS COMPANY
6. Install the 8 NEW turbocharger nuts (1).
Fig 4: Turbocharger Nut Tightening Sequence
Courtesy of GENERAL MOTORS COMPANY
CAUTION:

Refer to Fastener Caution .

CAUTION:

Refer to Torque-to-Yield Fastener Caution .

7. Tighten the 8 turbocharger nuts in a sequence as shown to 8 N.m (71 lb in).
8. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.
Fig 5: Turbocharger Oil Feed Pipe Components
Courtesy of GENERAL MOTORS COMPANY
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).
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).
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.

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 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.

15. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to 30 N.m (22 lb ft).