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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1401 (Engine Mechanical - 6.6L (2 Of 5)) >> Repair Instructions - On Vehicle >> Turbocharger Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Oil Return Pipe Bolts
    GM1336136Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  1. If the turbocharger was replaced, install the oil return pipe, bolts, and a NEW gasket.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

  2. Install the turbocharger outlet coolant pipe banjo bolt and washers.

    Tighten:  Tighten the bolt to 26 N.m (19 lb ft).

    3. Fig 2: View Of Oil Feed Pipe Bolt, Washer & Pipe
    GM1335581Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.
    NOTE: Lubricate the washer with diesel fuel prior to installing.
  3. Install the oil feed pipe, washer, and bolt, if necessary.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

  4. Install the turbocharger lower heat shield, if necessary.
    5. Fig 3: View Of Turbocharger W/Oil Return Pipe
    GM1335579Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
  6. Install the turbocharger (with the oil return pipe).
  7. Install the turbocharger bolts.

    Tighten:  Tighten the bolts to 108 N.m (80 lb ft).

  8. Install the turbocharger oil return pipe nuts at the top of the flywheel housing.

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

  9. Connect the turbocharger vane position sensor electrical connector.
    10. Fig 4: View Of Turbocharger Oil Feed Pipe Banjo Bolt
    GM1335577Courtesy of GENERAL MOTORS CORP.
  10. If installing a NEW turbocharger, add about 120-150 cc (4-5 oz.) of clean engine oil in the turbocharger oil feed pipe opening while rotating the impeller.
  11. Position the oil feed pipe to the turbocharger.
  12. Install a NEW turbocharger oil feed pipe washer and the banjo bolt.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

    13. Fig 5: View Of Cooling Outlet Hose Eye Bolts
    GM1457469Courtesy of GENERAL MOTORS CORP.
  13. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
  14. If the cooling outlet hose eye bolts were removed, install the longer bolt (1) with 2 holes, in the top location. Install the shorter bolt (2) in the lower location.
    15. Fig 6: View Of Turbocharger Outlet Coolant Pipe
    GM1335578Courtesy of GENERAL MOTORS CORP.
  15. Install the turbocharger outlet coolant hose to the turbocharger and position the hose clamp.
    16. Fig 7: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
  16. Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
    17. Fig 8: View Of Turbocharger Heat Shield & EGR Cooler Pipe (6.6L, LMM)
    GM1862416Courtesy of GENERAL MOTORS CORP.
  17. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
  18. Install the EGR valve adapter pipe bracket bolts (1).

    Tighten:  Tighten the bolts to 9 N.m (80 lb in).

  19. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  20. Install the glow plug module and both brackets. Refer to Glow Plug Control Module Replacement .
    21. Fig 9: Identifying Upper EGR Cooler Pipe Bolt
    GM1862415Courtesy of GENERAL MOTORS CORP.
  21. Install the EGR cooler pipe bolt.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  22. Remove the tape from the turbocharger openings.
    NOTE: Lubricate the end of the duct prior to installation.

    Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .

  23. Install the A/C suction hose. Refer to Suction Hose Replacement (LMM) .
  24. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
  25. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
    26. Fig 10: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  26. Install the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side .
  27. Install the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) .
  28. Install the left exhaust pipe. Refer to Exhaust Pipe Replacement - Left Side .
  29. Slide the clamp onto the exhaust pipe. Tighten the exhaust pipe clamp.

    Tighten:  Tighten the clamp to 40 N.m (30 lb ft).

  30. Install the left and right wheelhouse liners. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) or Front Wheelhouse Liner Replacement - Right Side (GMC) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) or Front Wheelhouse Liner Replacement - Left Side (GMC) .
  31. Install the transmission. Refer to Transmission Replacement .
  32. Install NEW engine oil and a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement .
  33. If a NEW turbocharger was installed, perform the turbocharger learn procedure. Refer to Turbocharger Learn .
  34. Road test the vehicle for normal operation.
  35. Inspect for coolant, oil, or exhaust leaks. Correct as necessary.
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