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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1678 (Engine Mechanical - 6.6L (LMM) - Repair Instructions - On Vehicle) >> Turbocharger Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: 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.
NOTE: 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. Remove the transmission. Refer to Transmission Replacement .
  2. Remove 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) .
    3. Fig 1: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  3. Loosen the exhaust pipe clamp. Slide the clamp onto the exhaust pipe.
  4. Remove the left exhaust pipe. Refer to Exhaust Pipe Replacement - Left Side .
  5. Remove the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) .
  6. Remove the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side .
  7. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  8. Remove the air conditioning (A/C) suction hose. Refer to Suction Hose Replacement (LY2, LMF, L76 and L92) or Suction Hose Replacement (LMM) .
  9. Reposition the suction hose aside.
    10. NOTE: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
  10. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
    11. Fig 2: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
  11. Remove the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
    12. Fig 3: View Of Turbocharger Outlet Coolant Pipe
    GM1335578Courtesy of GENERAL MOTORS CORP.
    NOTE: Use care not to damage this hose during the procedure.
  12. Reposition the hose clamp and remove the turbocharger outlet coolant hose from the turbocharger.
  13. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
    14. Fig 4: Identifying Upper EGR Cooler Pipe Bolt
    GM1862415Courtesy of GENERAL MOTORS CORP.
  14. Remove the glow plug module and both brackets. Refer to Glow Plug Control Module Replacement .
  15. Remove the EGR cooler pipe bolt.
  16. Remove the Exhaust Gas Recirculation Coolant Hoses/Pipes. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement .
  17. Remove the engine lift hook bracket
    18. Fig 5: View Of Turbocharger Heat Shield & EGR Cooler Pipe (6.6L, LMM)
    GM1862416Courtesy of GENERAL MOTORS CORP.
  18. Reposition the EGR cooler pipe (4) out of the way.
  19. Remove the EGR valve adapter pipe bracket bolts (1).
  20. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
    21. Fig 6: View Of Turbocharger Oil Feed Pipe Banjo Bolt
    GM1335577Courtesy 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.
  21. Remove the turbocharger oil feed pipe banjo bolt and washer.
  22. Reposition the oil feed pipe out of the way.
  23. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
  24. Disconnect the turbocharger vane position sensor electrical connector.
    25. Fig 7: View Of Turbocharger W/Oil Return Pipe
    GM1335579Courtesy of GENERAL MOTORS CORP.
  25. Remove the turbocharger bolts.
  26. Remove the turbocharger (with the oil return pipe).
  27. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.
    28. Fig 8: View Of Oil Feed Pipe Bolt, Washer & Pipe
    GM1335581Courtesy of GENERAL MOTORS CORP.
  28. Remove the turbocharger lower heat shield, if necessary.
  29. Remove the oil feed pipe bolt, washer, and pipe, if necessary.
  30. 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.
    31. Fig 9: View Of Oil Return Pipe Bolts
    GM1336136Courtesy of GENERAL MOTORS CORP.
  31. Remove the turbocharger outlet coolant pipe banjo bolt and washers.
  32. If replacing the turbocharger, remove the oil return pipe bolts, pipe and gasket. Discard the gasket.
  33. Clean all turbocharger to engine gasket mating surfaces.
  34. If required, clean and inspect the turbocharger. Refer to Turbocharger Cleaning and Inspection
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