Installation Procedure

WARNING: This page is about a different variant/trim than selected.

NOTE: Refer to Fastener Notice .

Fig 1: View Of Oil Return Pipe Bolts

Courtesy of GENERAL MOTORS CORP.

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).

IMPORTANT: Lubricate the washer with diesel fuel prior to installing.

Fig 2: View Of Oil Feed Pipe Bolt, Washer & Pipe

Courtesy of GENERAL MOTORS CORP.

Install the oil feed pipe, washer, and bolt, if necessary.
Tighten: Tighten the bolt to 34 N.m (25 lb ft).
Install the turbocharger lower heat shield, if necessary.
Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
Install the turbocharger (with the oil return pipe).

Fig 3: View Of Turbocharger W/Oil Return Pipe
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger bolts.
Tighten: Tighten the bolts to 108 N.m (80 lb ft).
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).
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.
Position the oil feed pipe to the turbocharger.
Install a NEW turbocharger oil feed pipe washer and the banjo bolt.

Fig 4: View Of Turbocharger Oil Feed Pipe Banjo Bolt
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolt to 34 N.m (25 lb ft).
Install the left exhaust pipe and a NEW gasket.

Fig 5: View Of Left Exhaust Pipe
Courtesy of GENERAL MOTORS CORP.
Install the left exhaust pipe to turbocharger bolts.
Tighten: Tighten the bolt to 53 N.m (39 lb ft).
Install the right exhaust pipe and a NEW gasket.

Fig 6: View Of Right Exhaust Pipe
Courtesy of GENERAL MOTORS CORP.
Install the right exhaust pipe to turbocharger bolts.
Tighten: Tighten the bolt to 53 N.m (39 lb ft).
Install the exhaust outlet.

Fig 7: View Of Exhaust Outlet
Courtesy of GENERAL MOTORS CORP.
Tighten the exhaust outlet clamp.

Fig 8: View Of Exhaust Outlet Clamp
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the clamp to 15 N.m (11 lb ft).
Install the exhaust outlet heat shield.

Fig 9: View Of Exhaust Outlet Shield
Courtesy of GENERAL MOTORS CORP.
Install the remaining exhaust outlet heat shield bolts.
Tighten: Tighten the bolt to 8 N.m (71 lb in).
Install the PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
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.

Fig 10: Identifying Cooling Outlet Hose Eye Bolts
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger outlet coolant pipe banjo bolt and washers.
Tighten: Tighten the bolt to 26 N.m (19 lb ft).
Install the turbocharger outlet coolant hose to the turbocharger and position the hose clamp.

Fig 11: View Of Turbocharger Outlet Coolant Pipe
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.

Fig 12: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger upper heat shield.

Fig 13: View Of Turbocharger Upper Heat Shield
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger upper heat shield bolts.
Tighten: Tighten the bolt to 9 N.m (80 lb in).
Remove the tape from the turbocharger openings.
IMPORTANT: Lubricate the end of the duct prior to installation.
Install the charged air cooler inlet duct connector (4) to the turbocharger.

Fig 14: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
Courtesy of GENERAL MOTORS CORP.
Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
Tighten: Tighten the clamp to 6 N.m (53 lb in).
Install a NEW quick connect fitting clip to the charged air cooler duct.
Install the charged air cooler outlet duct to the intake.

Fig 15: Charged Air Cooler Outlet Duct
Courtesy of GENERAL MOTORS CORP.
Fill the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) or Draining and Filling Cooling System (w/o RPO HP2) .
Install the lower bolt for the exhaust outlet shield.

Fig 16: View Of Exhaust Outlet Shield
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolt to 8 N.m (71 lb in).
Install a NEW exhaust manifold gasket.
Install the right exhaust pipe to exhaust manifold bolts.

Fig 17: View Of Right Exhaust Pipe
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolts to 53 N.m (39 lb ft).
Install a NEW exhaust manifold gasket.
Install the left exhaust pipe to exhaust manifold bolts.

Fig 18: View Of Left Exhaust Pipe
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolts to 53 N.m (39 lb ft).
Install the heat shield.

Fig 19: View Of Left Exhaust Pipe Heat Shield & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the left exhaust pipe heat shield bolts.
Tighten: Tighten the bolts to 8 N.m (71 lb in).
If equipped with an automatic transmission, position the fill tube to the studs.

Fig 20: View Of Fill Tube To Bellhousing Nuts
Courtesy of GENERAL MOTORS CORP.
Install the transmission fill tube to bellhousing nuts.
Tighten: Tighten the nuts to 18 N.m (13 lb ft).
Slide the clamp onto the exhaust pipe. Tighten the exhaust pipe clamp.

Fig 21: View Of Turbocharger Exhaust Pipe & Clamp
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the clamp to 40 N.m (30 lb ft).
Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
If a NEW turbocharger was installed, perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure .
Road test the vehicle for normal operation.
Inspect for coolant, oil, or exhaust leaks. Correct as necessary.
Perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure .