Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Turbocharger

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Removal & Installation



6.5L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Air inlet duct
     
    Oil feed line from the top of the turbocharger
     
    Crankcase Depression Regulator (CDR) valve vent bracket screw
     
    CDR valve and vent tube
     
    Air cleaner assembly
     
    Heat shield
     
    Right front tire assembly and the splash shield
     
    Exhaust pipe-to-turbocharger exhaust outlet elbow V-band clamp
     
    Oil drain tube-to-turbocharger center bearing bolts
     
    Exhaust manifold-to-turbocharger nuts
     
    Turbocharger

    Click image to see an enlarged view

    Fig. Turbocharger mounting-6.5L diesel engine

     

  2.  

To install:


NOTE
Use anti-seize compound on all threaded fasteners connected to the turbocharger

  1. Install or connect the following:
    NOTE
    Use 0.03-0.07 fl. oz. (0.88-2ml) of engine oil to feed the oil feed hole at the top of the turbocharger and hand rotate the compressor wheel/shaft. This will prelube the shaft bearings



    Turbocharger to the exhaust manifold. Torque the nuts to 37 ft. lbs. (50 Nm).
     
    New oil drain tube flange gasket and the oil drain tube. Torque the bolts to 19 ft. lbs. (26 Nm).
     



    Oil feed line. Torque the connection to 13 ft. lbs. (17 Nm).
     
    Exhaust pipe to the turbocharger exhaust elbow V-band clamp. Torque the clamp to 71 inch. lbs. (8 Nm).
     

  2.  
  3. Disengage the injection pump fuel shutdown solenoid connector and crank the engine for no more 15 seconds to prime the oil system. Do not let the engine start.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger



    Right front wheel and splash shield
     
    Heat shield. Apply Loctite® to the bolts and torque to 56 inch lbs. (6 Nm)
     
    Air cleaner assembly
     
    Turbocharger compressor outlet
     
    CDR valve, tube and bracket
     
    Air intake duct
     

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air inlet duct
     
    Oil feed line from the top of the turbocharger
     
    Crankcase Depression Regulator (CDR) valve vent bracket screw
     
    CDR valve and vent tube
     
    Air cleaner assembly

    Click image to see an enlarged view

    Fig. Turbocharger mounting-6.5L engines

     
    Heat shield
     
    Right front tire assembly and the splash shield
     
    Exhaust pipe-to-turbocharger exhaust outlet elbow V-band clamp
     
    Oil drain tube-to-turbocharger center bearing bolts
     
    Exhaust manifold-to-turbocharger nuts
     
    Turbocharger
     

  4.  

To install:


NOTE
Use anti-seize compound on all threaded fasteners connected to the turbocharger

  1. Install or connect the following:
    NOTE
    Use 0.03-0.07 fl. oz. (0.88-2ml) of engine oil to feed the oil feed hole at the top of the turbocharger and hand rotate the compressor wheel/shaft. This will pre-lube the shaft bearings



    Turbocharger to the exhaust manifold. Torque the nuts to 37 ft. lbs. (50 Nm).
     
    New oil drain tube flange gasket and the oil drain tube. Torque the bolts to 19 ft. lbs. (26 Nm).
     



    Oil feed line. Torque the connection to 13 ft. lbs. (17 Nm).
     
    Exhaust pipe to the turbocharger exhaust elbow V-band clamp. Torque the clamp to 71 inch. lbs. (8 Nm).
     

  2.  
  3. Disengage the injection pump fuel shutdown solenoid connector and crank the engine for no more 15 seconds to prime the oil system. Do not let the engine start.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger



    Right front wheel and splash shield
     
    Heat shield. Apply Loctite®or equivalent to the bolts. Torque to 56 inch. lbs. (6 Nm).
     
    Air cleaner assembly
     
    Turbocharger compressor outlet
     
    CDR valve, tube and bracket
     
    Air intake duct
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air inlet duct
     
    Oil feed line from the top of the turbocharger
     
    Crankcase Depression Regulator (CDR) valve vent bracket screw
     
    CDR valve and vent tube
     
    Air cleaner assembly

    Click image to see an enlarged view

    Fig. Turbocharger mounting-diesel engines

     
    Heat shield
     
    Right front tire assembly and the splash shield
     
    Exhaust pipe-to-turbocharger exhaust outlet elbow V-band clamp
     
    Oil drain tube-to-turbocharger center bearing bolts
     
    Exhaust manifold-to-turbocharger nuts
     
    Turbocharger
     

  4.  

To install:


NOTE
Use anti-seize compound on all threaded fasteners connected to the turbocharger

  1. Install or connect the following:
    NOTE
    Use 0.03-0.07 fl. oz. (0.88-2ml) of engine oil to feed the oil feed hole at the top of the turbocharger and hand rotate the compressor wheel/shaft. This will pre-lube the shaft bearings



    Turbocharger to the exhaust manifold. Torque the nuts to 37 ft. lbs. (50 Nm)
     
    New oil drain tube flange gasket and the oil drain tube. Torque the bolts to 19 ft. lbs. (26 Nm)
     



    Oil feed line. Torque the connection to 13 ft. lbs. (17 Nm).
     
    Exhaust pipe to the turbocharger exhaust elbow V-band clamp. Torque the clamp to 71 inch. lbs. (8 Nm).
     

  2.  
  3. Disengage the injection pump fuel shutdown solenoid connector and crank the engine for no more 15 seconds to prime the oil system. Do not let the engine start.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger



    Right front wheel and splash shield
     
    Heat shield. Apply Loctite or equivalent to the bolts. Torque to 56 inch. lbs. (6 Nm)
     
    Air cleaner assembly
     
    Turbocharger compressor outlet
     
    CDR valve, tube and bracket
     
    Air intake duct
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air inlet duct
     
    Oil feed line from the top of the turbocharger
     
    Crankcase Depression Regulator (CDR) valve vent bracket screw
     
    CDR valve and vent tube
     
    Air cleaner assembly

    Click image to see an enlarged view

    Fig. Turbocharger mounting-diesel engines

     
    Heat shield
     
    Right front tire assembly and the splash shield
     
    Exhaust pipe-to-turbocharger exhaust outlet elbow V-band clamp
     
    Oil drain tube-to-turbocharger center bearing bolts
     
    Exhaust manifold-to-turbocharger nuts
     
    Turbocharger
     

  4.  

To install:


NOTE
Use anti-seize compound on all threaded fasteners connected to the turbocharger

  1. Install or connect the following:
    NOTE
    Use 0.03-0.07 fl. oz. (0.88-2ml) of engine oil to feed the oil feed hole at the top of the turbocharger and hand rotate the compressor wheel/shaft. This will pre-lube the shaft bearings



    Turbocharger to the exhaust manifold. Torque the nuts to 37 ft. lbs. (50 Nm)
     
    New oil drain tube flange gasket and the oil drain tube. Torque the bolts to 19 ft. lbs. (26 Nm)
     



    Oil feed line. Torque the connection to 13 ft. lbs. (17 Nm).
     
    Exhaust pipe to the turbocharger exhaust elbow V-band clamp. Torque the clamp to 71 inch. lbs. (8 Nm).
     

  2.  
  3. Disengage the injection pump fuel shutdown solenoid connector and crank the engine for no more 15 seconds to prime the oil system. Do not let the engine start.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger



    Right front wheel and splash shield
     
    Heat shield. Apply Loctite or equivalent to the bolts. Torque to 56 inch. lbs. (6 Nm)
     
    Air cleaner assembly
     
    Turbocharger compressor outlet
     
    CDR valve, tube and bracket
     
    Air intake duct
     

  4.  

6.6L Engine
  1. Disconnect the negative battery cables.
  2.  
  3. Open the hood and move the hinge bolts to the service position.
  4.  
  5. Raise the vehicle.
  6.  
  7. Drain the coolant.
  8.  
  9. Remove or disconnect the following:

    Left and right wheelhouse liners
     
    Exhaust pipe-to-exhaust outlet clamp. Move the clamp onto the exhaust pipe
     
    Transmission fluid fill tube-to-bell housing nuts if equipped with an A/T. Position the tube to the right side of the vehicle; it does not need to be removed from the transmission
     
    3 nuts and left exhaust heat shield from the front of the lower dash panel
     
    Left exhaust pipe heat shield bolts
     

  10.  
  11. Position the left exhaust pipe heat shield to access the left exhaust pipe-to-manifold bolts. Do not remove the heat shield from the vehicle at this time.
    NOTE
    Do not bend the exhaust pipe at the expansion area.



    Left, then the right exhaust pipe-to-exhaust manifold bolts
     
    Gaskets and discard
     
    Lower bolt for the exhaust outlet shield
     

  12.  
  13. Lower the vehicle.

    Upper intake manifold sight shield front retaining bolt
     
    Sight shield
     
    Air cleaner outlet duct from the air cleaner and turbocharger. Cover the openings to prevent debris from entering
     
    Charged air cooler outlet duct-to-intake hose clamps (loosen only)
     
    Hose from the charged air cooler duct-to-intake manifold tube
     
    A/C compressor clutch electrical connector
     
    A/C cut-out switch connector
     
    Drive belt
     
    A/C compressor mounting bolts; position the compressor aside with the lines attached
     
    Turbocharger inlet coolant hose from the bypass valve
     
    Turbocharger outlet coolant hose from the turbocharger
     
    Crankcase hose from the left valve cover and position aside
     
    Wire connector from the intake heater
     
    Intake air heater relay, if equipped
     
    Heat shield-to-turbocharger bolts and heat shield
     
    Remaining 2 bolts from the exhaust outlet heat shield
     
    Exhaust outlet heat shield
     
    4 bolts and 2 nuts from the exhaust outlet. You do not have to remove the outlet for turbocharger removal
     

  14.  
  15. Move the exhaust outlet to one side in order to access the right exhaust pipe-to-turbocharger bolts.

    Exhaust outlet gasket and discard
     
    Right exhaust pipe-to-turbocharger bolts
     
    Right exhaust pipe and gasket
     

  16.  
  17. Move the exhaust outlet to one side for access to the left pipe.

    Left exhaust pipe heat shield
     
    Left exhaust pipe-to-turbocharger bolts
     
    Left exhaust pipe and gasket
     
    Turbocharger oil supply hose eye bolt and washers. Move the hose aside
     
    Turbocharger oil drain pipe nuts from the flywheel housing
     
    Turbocharger mounting bolts
     
    Turbocharger with the oil drain pipe
     

  18.  
  19. If replacing the turbocharger, remove the oil drain pipe and coolant hose.
  20.  

To install:

  1. Thoroughly clean the gasket surfaces.
  2.  
  3. Install or connect the following:

    Turbocharger oil drain pipe and new gasket. Tighten the bolts to 16 ft. lbs. (21 Nm).
     
    Turbocharger inlet coolant hose
     
    Turbocharger oil supply hose to the engine block
     
    Turbocharger oil supply hose eye bolt and washers and tighten to 31 ft. lbs. (42 Nm)
     
    Turbocharger lower heat shield
     
    Turbocharger. Tighten the 3 mounting bolts to 80 ft. lbs. (108 Nm).
     
    New gasket for oil drain pipe
     
    Oil drain pipe nuts and tighten to 15 ft. lbs. (20 Nm)
     

  4.  
  5. If installing a new turbocharger, pour 4-5 oz. of clean engine oil into the turbocharger supply hose opening, while rotating the impeller.

    Oil supply hose, using new washers. Tighten the eye bolt to 31 ft. lbs. (42 Nm).
     

  6.  
  7. Install the remaining components in the reverse order of removal, noting the following important points:

    When installing the exhaust pipe, use new gaskets and align the tabs and make sure the proper pipe flange is towards the turbocharger, as they are different. Tighten the exhaust pipe-to-turbocharger bolts to 39 ft. lbs. (53 Nm).
     
    Tighten the turbocharger heat shield bolts to 80 inch lbs. (9 Nm)
     
    Tighten the A/C compressor bolts to 37 ft. lbs. (50 Nm)
     
    Tighten the exhaust pipe clamp to 30 ft. lbs. (40 Nm)
     

  8.  
  9. Fill the cooling system and connect the negative battery cables.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger

  10.  

  1. Disconnect the negative battery cables.
  2.  
  3. Open the hood and move the hinge bolts to the service position.
  4.  
  5. Raise the vehicle.
  6.  
  7. Drain the coolant.
  8.  
  9. Remove or disconnect the following:

    Exhaust pipe-to-exhaust outlet clamp. Move the clamp onto the exhaust pipe
     
    Transmission fluid fill tube-to-bell housing nuts if equipped with an A/T. Position the tube to the right side of the vehicle; it does not need to be removed from the transmission
     
    3 nuts and left exhaust heat shield from the front of the lower dash panel
     
    Left exhaust pipe heat shield bolts
     

  10.  
  11. Positoin the left exhaust pipe heat shield to access the left exhaust pipe-to-manifold bolts. Do not remove the heat shield from the vehicle at this time.
    NOTE
    Do not bend the exhaust pipe at the expansion area.






    Left, then the right exhaust pipe-to-exhaust manifold bolts
     
    Gaskets and discard
     
    Lower bolt for the exhaust outlet shield
     

  12.  
  13. Lower the vehicle.

    Upper intake manifold sight shield front retaining bolt
     
    Sight shield by lifting up on the front of the shield, then lifting it off the rear bracket
     
    Air cleaner outlet duct front he air cleaner and turbocharger. Cover the openings to prevent debris from entering
     
    Loosen the charged air cooler outlet duct-to-intake hose clamps
     
    Hose from the charged air cooler duct-to-intake manifold tube by twisting it
     
    A/C compressor clutch electrical connector
     
    A/C cut-out switch connector
     
    Drive belt
     
    A/C compressor mounting bolts, then position the compressor aside with the lines attached
     
    Turbocharger inlet coolant hose from the bypass valve
     
    Turbocharger outlet coolant hose from the turbocharger
     
    PCV hose from the left valve cover and position aside
     
    Wire connector from the intake heater
     
    Intake air heater relay, if equipped
     
    Heat shield-to-turbocharger bolts and heat shield
     
    Remaining 2 bolts from the exhaust outlet heat shield
     
    Exhaust outlet heat shield
     
    4 bolts and 2 nuts from the exhaust outlet. You do not have to remove the outlet for turbocharger removal
     

  14.  
  15. Move the exhaust outlet to one side in order to access the right exhaust pipe-to-turbocharger bolts.

    Exhaust outlet gasket and discard
     
    Right exhaust pipe-to-turbocharger bolts
     
    Right exhaust pipe and gasket
     

  16.  
  17. Move the exhaust outlet to one side for access to the left pipe.

    Left exhaust pipe heat shield
     
    Left exhaust pipe-to-turbocharger bolts
     
    Left exhaust pipe and gasket
     
    Turbocharger oil supply hose eye bolt and washers. Move the hose aside
     
    Turbocharger oil drain pipe nuts from the flywheel housing
     
    Turbocharger mounting bolts
     
    Turbocharger with the oil drain pipe.
     

  18.  
  19. If replacing the turbocharger, remove the oil drain pipe and coolant hose.
  20.  

To install:

  1. Thoroughly clean the gasket surfaces.
  2.  
  3. Install or connect the following:

    Turbocharger oil drain pipe and new gasket. Tighten the bolts to 16 ft. lbs. (21 Nm)
     
    Turbocharger inlet coolant hose
     
    Turbocharger oil supply hose to the engine block
     
    Turbocharger oil supply hose eye bolt and washers. Tighten to 31 ft. lbs. (42 Nm)
     
    Turbocharger lower heat shield
     
    Turbocharger. Tighten the 3 mounting bolts to 80 ft. lbs. (108 Nm)
     
    New gasket for oil drain pipe
     
    Oil drain pipe nuts and tighten to 15 ft. lbs. (20 Nm)
     

  4.  
  5. If installing a new turbocharger, pour 4-5 oz. of clean engine oil into the turbocharger supply hose opening, while rotating the impeller.

    Oil supply hose, using new washers. Tighten the eye bolt to 31 ft. lbs. (42 Nm).
     

  6.  
  7. Install the remaining components in the reverse order of removal, noting the following important points:

    When installing the exhaust pipe, use new gaskets and align the tabs and make sure the proper pipe flange is towards the turbocharger, as they are different. Tighten the exhaust pipe-to-turbocharger bolts to 39 ft. lbs. (53 Nm).
     
    Tighten the turbocharger heat shield bolts to 80 inch lbs. (9 Nm)
     
    Tighten the A/C compressor bolts to 37 ft. lbs. (50 Nm)
     
    Tighten the exhaust pipe clamp to 30 ft. lbs.
     

  8.  
  9. Fill the cooling system and connect the negative battery cables.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger

  10.  

  1. Disconnect the negative battery cables.
  2.  
  3. Open the hood and move the hinge bolts to the service position.
  4.  
  5. Raise the vehicle.
  6.  
  7. Drain the coolant.
  8.  
  9. Remove or disconnect the following:
    NOTE
    If necessary, the entire transmission can be removed to gain additional clearance



    Left and right wheelhouse liners
     
    Exhaust pipe-to-exhaust outlet clamp. Move the clamp onto the exhaust pipe
     
    Transmission fluid fill tube-to-bell housing nuts if equipped with an A/T. Position the tube to the right side of the vehicle; it does not need to be removed from the transmission.
     



    3 nuts and left exhaust heat shield from the front of the lower dash panel
     
    Left exhaust pipe heat shield bolts
     

  10.  
  11. Position the left exhaust pipe heat shield to access the left exhaust pipe-to-manifold bolts. Do not remove the heat shield from the vehicle at this time.
    NOTE
    Do not bend the exhaust pipe at the expansion area.



    Left, then the right exhaust pipe-to-exhaust manifold bolts
     
    Gaskets and discard
     
    Lower bolt for the exhaust outlet shield
     

  12.  
  13. Lower the vehicle.

    Upper intake manifold sight shield front retaining bolt
     
    Sight shield
     
    Air cleaner outlet duct from the air cleaner and turbocharger. Cover the openings to prevent debris from entering
     
    Charged air cooler outlet duct-to-intake hose clamps (loosen only)
     
    Hose from the charged air cooler duct-to-intake manifold tube
     
    A/C compressor clutch electrical connector
     
    A/C cut-out switch connector
     
    Drive belt
     
    A/C compressor mounting bolts; position the compressor aside with the lines attached
     
    Turbocharger inlet coolant hose from the bypass valve
     
    Turbocharger outlet coolant hose from the turbocharger
     
    Crankcase hose from the left valve cover and position aside
     
    Wire connector from the intake heater
     
    Intake air heater relay, if equipped
     
    Heat shield-to-turbocharger bolts and heat shield
     
    Remaining 2 bolts from the exhaust outlet heat shield
     
    Exhaust outlet heat shield
     
    4 bolts and 2 nuts from the exhaust outlet. You do not have to remove the outlet for turbocharger removal
     

  14.  
  15. Move the exhaust outlet to one side in order to access the right exhaust pipe-to-turbocharger bolts.

    Exhaust outlet gasket and discard
     
    Right exhaust pipe-to-turbocharger bolts
     
    Right exhaust pipe and gasket
     

  16.  
  17. Move the exhaust outlet to one side for access to the left pipe.

    Left exhaust pipe heat shield
     
    Left exhaust pipe-to-turbocharger bolts
     
    Left exhaust pipe and gasket
     
    Turbocharger oil supply hose eye bolt and washers. Move the hose aside
     
    Turbocharger oil drain pipe nuts from the flywheel housing
     
    Turbocharger mounting bolts
     
    Turbocharger with the oil drain pipe
     

  18.  
  19. If replacing the turbocharger, remove the oil drain pipe and coolant hose.
  20.  

To install:

  1. Thoroughly clean the gasket surfaces.
  2.  
  3. Install or connect the following:

    Turbocharger oil drain pipe and new gasket. Tighten the bolts to 15 ft. lbs. (21 Nm).
     
    Turbocharger inlet coolant hose
     
    Turbocharger oil supply hose to the engine block
     
    Turbocharger oil supply hose eye bolt and washers and tighten to 31 ft. lbs. (42 Nm) except on 2007 models. On 2007 models, tighten to 25 ft. lbs. (34 Nm)
     
    Turbocharger lower heat shield
     
    Turbocharger. Tighten the 3 mounting bolts to 80 ft. lbs. (108 Nm).
     
    New gasket for oil drain pipe
     
    Oil drain pipe nuts and tighten to 15 ft. lbs. (20 Nm) except on 2007 models. On 2007 models, tighten to 18 ft. lbs. (25 Nm)
     

  4.  
  5. If installing a new turbocharger, pour 4-5 oz. of clean engine oil into the turbocharger supply hose opening, while rotating the impeller.

    Oil supply hose, using new washers. Tighten the eye bolt to 31 ft. lbs. (42 Nm) except on 2007 models. On 2007 models, tighten to 25 ft. lbs. (34 Nm)
     

  6.  
  7. Install the remaining components in the reverse order of removal, noting the following important points:

    When installing the exhaust pipe, use new gaskets and align the tabs and make sure the proper pipe flange is toward the turbocharger, as they are different. Tighten the exhaust pipe-to-turbocharger bolts to 39 ft. lbs. (53 Nm).
     
    Tighten the turbocharger heat shield bolts to 80 inch lbs. (9 Nm)
     
    Tighten the A/C compressor bolts to 37 ft. lbs. (50 Nm)
     
    Tighten the exhaust pipe clamp to 30 ft. lbs. (40 Nm)
     

  8.  
  9. Fill the cooling system and connect the negative battery cables.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger

  10.  

  1. Disconnect the negative battery cables.
  2.  
  3. Open the hood and move the hinge bolts to the service position.
  4.  
  5. Raise the vehicle.
  6.  
  7. Drain the coolant.
  8.  
  9. Remove or disconnect the following:
    NOTE
    If necessary, the entire transmission can be removed to gain additional clearance



    Left and right wheelhouse liners
     
    Exhaust pipe-to-exhaust outlet clamp. Move the clamp onto the exhaust pipe
     
    Transmission fluid fill tube-to-bell housing nuts if equipped with an A/T. Position the tube to the right side of the vehicle; it does not need to be removed from the transmission.
     



    3 nuts and left exhaust heat shield from the front of the lower dash panel
     
    Left exhaust pipe heat shield bolts
     

  10.  
  11. Position the left exhaust pipe heat shield to access the left exhaust pipe-to-manifold bolts. Do not remove the heat shield from the vehicle at this time.
    NOTE
    Do not bend the exhaust pipe at the expansion area.



    Left, then the right exhaust pipe-to-exhaust manifold bolts
     
    Gaskets and discard
     
    Lower bolt for the exhaust outlet shield
     

  12.  
  13. Lower the vehicle.

    Upper intake manifold sight shield front retaining bolt
     
    Sight shield
     
    Air cleaner outlet duct from the air cleaner and turbocharger. Cover the openings to prevent debris from entering
     
    Charged air cooler outlet duct-to-intake hose clamps (loosen only)
     
    Hose from the charged air cooler duct-to-intake manifold tube
     
    A/C compressor clutch electrical connector
     
    A/C cut-out switch connector
     
    Drive belt
     
    A/C compressor mounting bolts; position the compressor aside with the lines attached
     
    Turbocharger inlet coolant hose from the bypass valve
     
    Turbocharger outlet coolant hose from the turbocharger
     
    Crankcase hose from the left valve cover and position aside
     
    Wire connector from the intake heater
     
    Intake air heater relay, if equipped
     
    Heat shield-to-turbocharger bolts and heat shield
     
    Remaining 2 bolts from the exhaust outlet heat shield
     
    Exhaust outlet heat shield
     
    4 bolts and 2 nuts from the exhaust outlet. You do not have to remove the outlet for turbocharger removal
     

  14.  
  15. Move the exhaust outlet to one side in order to access the right exhaust pipe-to-turbocharger bolts.

    Exhaust outlet gasket and discard
     
    Right exhaust pipe-to-turbocharger bolts
     
    Right exhaust pipe and gasket
     

  16.  
  17. Move the exhaust outlet to one side for access to the left pipe.

    Left exhaust pipe heat shield
     
    Left exhaust pipe-to-turbocharger bolts
     
    Left exhaust pipe and gasket
     
    Turbocharger oil supply hose eye bolt and washers. Move the hose aside
     
    Turbocharger oil drain pipe nuts from the flywheel housing
     
    Turbocharger mounting bolts
     
    Turbocharger with the oil drain pipe
     

  18.  
  19. If replacing the turbocharger, remove the oil drain pipe and coolant hose.
  20.  

To install:

  1. Thoroughly clean the gasket surfaces.
  2.  
  3. Install or connect the following:

    Turbocharger oil drain pipe and new gasket. Tighten the bolts to 15 ft. lbs. (21 Nm).
     
    Turbocharger inlet coolant hose
     
    Turbocharger oil supply hose to the engine block
     
    Turbocharger oil supply hose eye bolt and washers and tighten to 31 ft. lbs. (42 Nm) except on 2007 models. On 2007 models, tighten to 25 ft. lbs. (34 Nm)
     
    Turbocharger lower heat shield
     
    Turbocharger. Tighten the 3 mounting bolts to 80 ft. lbs. (108 Nm).
     
    New gasket for oil drain pipe
     
    Oil drain pipe nuts and tighten to 15 ft. lbs. (20 Nm) except on 2007 models. On 2007 models, tighten to 18 ft. lbs. (25 Nm)
     

  4.  
  5. If installing a new turbocharger, pour 4-5 oz. of clean engine oil into the turbocharger supply hose opening, while rotating the impeller.

    Oil supply hose, using new washers. Tighten the eye bolt to 31 ft. lbs. (42 Nm) except on 2007 models. On 2007 models, tighten to 25 ft. lbs. (34 Nm)
     

  6.  
  7. Install the remaining components in the reverse order of removal, noting the following important points:

    When installing the exhaust pipe, use new gaskets and align the tabs and make sure the proper pipe flange is towards the turbocharger, as they are different. Tighten the exhaust pipe-to-turbocharger bolts to 39 ft. lbs. (53 Nm).
     
    Tighten the turbocharger heat shield bolts to 80 inch lbs. (9 Nm)
     
    Tighten the A/C compressor bolts to 37 ft. lbs. (50 Nm)
     
    Tighten the exhaust pipe clamp to 30 ft. lbs. (40 Nm)
     

  8.  
  9. Fill the cooling system and connect the negative battery cables.
    NOTE
    Operate the engine at idle for at least 3 minutes after installing the turbocharger

  10.  

 
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