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Air Induction Systems: Turbocharger: Installation

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  1. Install the oil return pipe and a NEW gasket to the turbocharger. Install the turbocharger oil return pipe bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Install the coolant return hose to the turbocharger.
  2. If required, lubricate the washers with diesel fuel before installing washers and install the oil feed pipe, bolt, and washers. See Fig 7. Tighten the bolt to specification. If required, install the turbocharger lower heat shield.
  3. Install the turbocharger. Install the turbocharger bolts and tighten to specification. Install a NEW gasket for the oil return pipe. Install the turbocharger oil return pipe nuts and tighten to specification. If installing a new turbocharger, pour about 4-5 ozs. (120-150 cc) of clean engine oil in the turbocharger oil feed pipe opening while rotating the impeller.
  4. Using NEW sealing washers, install the oil feed pipe and bolt to the turbocharger. See Fig 5. Tighten the bolt to specification.
  5. Position the left exhaust pipe. The pipe flanges are different. Ensure the proper pipe flange is towards the turbocharger. Install the left exhaust pipe to the turbocharger with a NEW gasket. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe-to-manifold bolts. Tighten the bolts to specification. Position the left exhaust pipe heat shield, but do not install the bolts.
  6. Install the right exhaust pipe with a NEW gasket to the turbocharger. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts. Install the right exhaust pipe to turbocharger bolts. Tighten the bolts to specification. Install the exhaust outlet with a NEW gasket to the turbocharger. Install the exhaust outlet bolts and nuts. Tighten the bolts/nuts to specification.
  7. Install the exhaust outlet heat shield. Install the upper 2 exhaust outlet heat shield bolts. Tighten the bolts to specification. Install the turbocharger heat shield. Install the turbocharger heat shield bolts. Tighten the bolts to specification. Install the PCV hose to the upper left valve rocker arm cover.
  8. Install the turbocharger outlet coolant hose to the turbocharger. Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve. Install the inlet air heater relay. See INTAKE AIR HEATER RELAY  under MOTORS, RELAYS & SOLENOIDS.
  9. Connect the wire terminal and the nut to intake air heater. Tighten the nut to specification. Position the A/C compressor. Install the A/C compressor bolts. Tighten the bolts to specification. Connect the A/C compressor clutch electrical connector. Connect the A/C cut out switch electrical connector.
  10. Install the drive belt to the drive pulleys. See 6.6L in COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article for drive belt routing. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. Route the drive belt over tension pulley. Slowly release the tension on the tensioner arm. Inspect for proper drive belt installation. Connect the A/C cut out switch electrical connector. Connect the A/C clutch electrical connector.
  11. Remove the tape from the turbocharger openings, if necessary. Install the charged air cooler inlet duct to the turbocharger. Align the mark on the duct with the mark on the turbocharger. Position the clamp for proper clearance. Tighten the clamp to specification. Install the charged air cooler outlet duct to the intake. Align the mark on the duct with the mark on the intake. Position the clamp for proper clearance. Tighten the clamp to specification.
  12. Install the outlet duct to turbocharger. Align the outlet duct alignment indicator to the turbocharger alignment indicator. The outlet duct must be fully seated against the MAF/IAT sensor with the edge of the seal in the vertical position. Install the outlet duct to the MAF/IAT sensor. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor to specification.
  13. Raise and support vehicle. Install the lower exhaust outlet heat shield bolt. Tighten the bolt to specification. Install the right exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward. Install the right exhaust pipe bolts. Tighten the bolts to specification. Install the left exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward. Install the left exhaust pipe bolts. Tighten the bolts to specification.
  14. Position the left exhaust pipe heat shield. Install the left exhaust pipe heat shield bolts. Tighten the bolts to specification. Install the exhaust heat shield to left front of the dash panel. Install the shield nuts. Tighten the nuts to specification.
  15. If equipped with automatic transmission, position the fill tube. Install the fill tube nuts and tighten to specification. Install the exhaust pipe clamp. To assist in positioning the clamp on the flanges use a suitable screw jack to hold the exhaust pipe in position. Tighten the clamp to specification.
  16. Lower the vehicle. Install the upper intake manifold cover. Install the upper intake manifold cover to the outlet duct. Tighten the outlet duct clamp at the upper intake manifold cover to specification. Position the hood in the normal operating position by moving the hood hinge bolts from the service position to the normal operating position.
  17. Tighten the bolts to specification. Connect the negative battery cables. Fill the cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEMS. Road test the vehicle for normal operation. Inspect for coolant, oil, or exhaust leaks.
Fig 1: Identifying Fan Clutch Remover & Installer
G00232246Courtesy of GENERAL MOTORS CORP.
Fig 2: Placing Hood In Service Position
G00232239Courtesy of GENERAL MOTORS CORP.
Fig 3: Releasing Drive Belt Tension
G00232248Courtesy of GENERAL MOTORS CORP.
Fig 4: Turbocharger Exhaust Components
G00149718Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing/Installing Turbocharger Oil Feed Line
G00081877Courtesy of GENERAL MOTORS CORP.
Fig 6: Locating Turbocharger
G00149719Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing/Installing Turbocharger Lower Heat Shield & Oil Feed Pipe
G00232256Courtesy of GENERAL MOTORS CORP.
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