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Removal & Installation: 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.
  1. Install turbocharger oil drain pipe and NEW gasket to turbocharger. Install turbocharger oil drain pipe bolts. Install turbocharger inlet coolant hose to turbocharger. See Fig 1.
  2. Install turbocharger oil supply hose to engine block. Install turbocharger oil supply hose eye bolt and washers. See Fig 2. Install turbocharger lower heat shield to engine block.
  3. Install turbocharger to engine. Install turbocharger 3 mounting bolts. Install a NEW gasket for the oil drain pipe. Install turbocharger oil drain pipe nuts.
  4. If installing a new turbocharger, pour about 4-5 ozs. (120-150 cc) of clean engine oil in turbocharger supply hose opening while rotating the impeller. Using NEW sealing washers, install oil supply hose and bolt to turbocharger.
  5. Position left exhaust pipe. The pipe flanges are different. Ensure proper pipe flange is towards turbocharger. Install left exhaust pipe to turbocharger with NEW gasket. Align gasket at turbocharger with tab on gasket facing inward. To aid in installing pipe to turbocharger temporarily, install one of the pipe to manifold bolts.
  6. Position left exhaust pipe heat shield, but do not install bolts. Install right exhaust pipe with NEW gasket to turbocharger. Align gasket at turbocharger with 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 right exhaust pipe to turbocharger bolts.
  7. Install exhaust outlet with a NEW gasket to turbocharger. Install exhaust outlet bolts and nuts. Install exhaust outlet heat shield. Install upper 2 exhaust outlet heat shield bolts.
  8. Install turbocharger heat shield. Install turbocharger heat shield bolts. Connect PCV hose to upper left valve rocker arm cover. Connect turbocharger outlet coolant hose to turbocharger. Connect turbocharger inlet coolant hose to turbocharger coolant bypass valve. Install inlet air heater relay.
  9. Connect wire terminal and nut to intake air heater. Position A/C compressor. Install A/C compressor mounting bolts. Install drive belt. Connect A/C cut-out switch electrical connector. Connect A/C clutch electrical connector.
  10. Install charged air cooler inlet duct to turbocharger cool air outlet hose to turbocharger. Position clamp as shown for proper clearance.
  11. Install hose to charged air cooler outlet duct to intake manifold tube. The hose is marked DUCT which connects to charged air cooler outlet duct. The hose is marked ENG which connects to turbocharger. Align marks on hose with alignment marks on pipe and tube. Position clamps as shown for proper clearance.
  12. Install air cleaner outlet duct to air cleaner. Install air cleaner outlet duct to turbocharger. Align duct to air cleaner. Raise vehicle. Install lower bolt for exhaust outlet heat shield.
  13. Install right exhaust pipe with a NEW gasket to exhaust manifold. Align tab on exhaust pipe gasket facing outward. Install right exhaust pipe bolts. Install left exhaust pipe with a NEW gasket to exhaust manifold. Align tab on exhaust pipe gasket facing outward. Install left exhaust pipe bolts.
  14. Position left exhaust pipe heat shield. Install left exhaust pipe heat shield bolts. Install exhaust heat shield to left front of dash panel. Install shield nuts. Position transmission fluid fill tube, if equipped. Install transmission fluid fill tube nuts.
  15. Install exhaust outlet to exhaust pipe clamp. To assist in positioning clamp on flanges, use a suitable screw jack to hold exhaust pipe in position. Lower vehicle. Fill cooling system. See DRAINING & REFILLING COOLING SYSTEM .
  16. Install upper intake manifold sight shield. Position hood in normal operating position by moving hood hinge bolts from service position to normal operating position. Connect both battery negative cables. Road test vehicle for normal operation. Inspect for coolant, oil, or exhaust leaks.
Fig 1: Exploded View Of Turbocharger Components
G00081876Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Turbocharger Oil Supply Line
G00081877Courtesy of GENERAL MOTORS CORP.
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