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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 994 (Engine Mechanical - 6.6L (LLY)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Turbocharger Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.
IMPORTANT: If a turbocharger failure is thought to be caused due to lack of oil, the camshaft bearing should be checked. The number 4 camshaft bearing bore feeds the turbocharger oil supply (feed) pipe. If this camshaft bearing spins in the bore, the turbocharger will be starved for oil. This will cause a failure of the turbocharger. Failure to diagnosis this condition will result in repeat turbocharger failures.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  2. Raise the hood to the service position and perform the following:
    1. Remove the hood hinge bolts (1).
    2. Raise the hood until vertical.
    3. Install the hood hinge bolts until snug, in the service position (2).
    3. Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  3. Remove the left and right wheelhouse liners. Refer to Wheelhouse Panel Replacement in Body Front End.
  4. Loosen the exhaust pipe clamp. Slide the clamp onto the exhaust pipe.
    5. Fig 2: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  5. If equipped with an automatic transmission, remove the transmission fill tube to bellhousing nuts.
  6. Lift the fill tube up from the studs and reposition the tube to the right side of the vehicle. The tube does not require removal from the transmission.
    7. Fig 3: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  7. Remove the left exhaust pipe heat shield bolts.
  8. Remove the heat shield.
    9. Fig 4: View Of Left Exhaust Pipe Heat Shield
    GM660364Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not bend the exhaust pipe at the expansion area.
  9. Remove the left exhaust pipe to exhaust manifold bolts.
  10. Remove and discard the exhaust manifold gasket.
    11. Fig 5: View Of Left Exhaust Pipe
    GM1334832Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not bend the exhaust pipe at the expansion area.
  11. Remove the right exhaust pipe to exhaust manifold bolts.
  12. Remove and discard the exhaust manifold gasket.
    13. Fig 6: View Of Right Exhaust Pipe
    GM1334842Courtesy of GENERAL MOTORS CORP.
  13. Remove the lower bolt for the exhaust outlet shield.
    14. Fig 7: View Of Exhaust Outlet Shield
    GM1334821Courtesy of GENERAL MOTORS CORP.
  14. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  15. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 6.6L (LLY).
  16. Loosen the charged air cooler outlet duct to intake hose clamp.
    17. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  17. Remove the charged air cooler outlet duct from the intake.
    18. Fig 8: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
  18. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
    19. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  19. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
    20. Fig 9: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  20. Remove the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
    21. Fig 10: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use care not to damage this hose during the procedure.
  21. Reposition the hose clamp and remove the turbocharger outlet coolant hose from the turbocharger.
  22. Remove the turbocharger outlet coolant pipe banjo bolt and washers.
    23. Fig 11: View Of Turbocharger Outlet Coolant Pipe
    GM1335578Courtesy of GENERAL MOTORS CORP.
  23. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  24. Remove the turbocharger upper heat shield bolts.
  25. Remove the turbocharger upper heat shield.
    26. Fig 12: View Of Turbocharger Upper Heat Shield
    GM1335576Courtesy of GENERAL MOTORS CORP.
  26. Remove the remaining exhaust outlet heat shield bolts.
  27. Remove the exhaust outlet heat shield.
    28. Fig 13: View Of Exhaust Outlet Shield
    GM1334821Courtesy of GENERAL MOTORS CORP.
  28. Loosen the exhaust outlet clamp.
    29. Fig 14: View Of Exhaust Outlet Clamp
    GM1334826Courtesy of GENERAL MOTORS CORP.
  29. Remove the exhaust outlet.
    30. Fig 15: View Of Exhaust Outlet
    GM1341232Courtesy of GENERAL MOTORS CORP.
  30. Remove the right exhaust pipe to turbocharger bolts.
  31. Remove the right exhaust pipe.
    32. Fig 16: View Of Right Exhaust Pipe
    GM1334842Courtesy of GENERAL MOTORS CORP.
  32. Remove and discard the gasket.
  33. Remove the left exhaust pipe to turbocharger bolts.
  34. Remove the left exhaust pipe.
    35. Fig 17: View Of Left Exhaust Pipe
    GM1334832Courtesy of GENERAL MOTORS CORP.
  35. Remove and discard the gasket.
  36. Remove the turbocharger oil feed pipe banjo bolt and washer.
    37. Fig 18: View Of Turbocharger Oil Feed Pipe Banjo Bolt
    GM1335577Courtesy of GENERAL MOTORS CORP.
  37. Reposition the oil feed pipe out of the way.
  38. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
  39. Remove the turbocharger bolts.
  40. Remove the turbocharger (with the oil return pipe).
    41. Fig 19: View Of Turbocharger W/Oil Return Pipe
    GM1335579Courtesy of GENERAL MOTORS CORP.
  41. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.
  42. Remove the turbocharger lower heat shield, if necessary.
  43. Remove the oil feed pipe bolt, washer, and pipe, if necessary.
    44. Fig 20: View Of Oil Feed Pipe Bolt, Washer & Pipe
    GM1335581Courtesy of GENERAL MOTORS CORP.
  44. If the turbocharger has failed, perform the following steps the verify the condition of the number 4 camshaft bearing before installing a new turbocharger.
    1. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole through the turbocharger oil supply hole in the block.
    2. Turn the engine over by hand 1/2 turn and inspect for camshaft bearing movement, indicating a spun camshaft bearing.
    3. If the bearing is spun the engine MUST be replaced.
  45. If replacing the turbocharger, remove the oil return pipe bolts, pipe and gasket. Discard the gasket.
    46. Fig 21: View Of Oil Return Pipe Bolts
    GM1336136Courtesy of GENERAL MOTORS CORP.
  46. Clean all turbocharger to engine gasket mating surfaces.
  47. If required, clean and inspect the turbocharger. Refer to Turbocharger Cleaning and Inspection 
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