GM Full Size Vans 1987-1997 Repair Guide

Turbocharger

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Exploded view of the turbocharger components - 1996-97 models shown

  1. Disconnect the negative battery and remove the engine cover.
  2.  
  3. Remove the CDR valve.
  4.  
  5. Remove the air cleaner assembly and air duct.
  6.  
  7. Remove the heat shield from the turbocharger.
  8.  
  9. Remove the center intake manifold.
  10.  
  11. Tag and remove the vacuum hose from the wastegate actuator.
  12.  
  13. Disconnect the exhaust pipe, exhaust clamps and retaining bolts from the turbocharger.
  14.  
  15. Remove the turbocharger from the engine.
  16.  

To install:
  1. Before installing the turbocharger, perform the following checks.
    1. Check the intake and exhaust systems leading to and from the turbocharger for dirt and debris. Even small pieces of dirt can cause severe damage.
    2.  
    3. Ensure the exhaust manifold-to-turbocharger mating surfaces and clean.
    4.  
    5. Make sure the oil feed and return passages in the block and turbocharger are free of clean and open.
    6.  

  2.  
  3. Install the turbocharger on the engine.
  4.  
  5. Coat the turbocharger retaining bolts with a high temperature anti-seize compound, install the bolts and tighten them to 48 ft. lbs. (65 Nm).
  6.  

Replace the O-rings between the turbocharger and the intake manifold and between the turbocharger and the engine block.

  1. Connect the exhaust pipes to the turbocharger and tighten the clamps to 90 inch lbs. (10 Nm).
  2.  
  3. Connect the vacuum hose to the wastegate actuator and install the heat shield.
  4.  
  5. Install the air cleaner assembly and air intake duct.
  6.  
  7. Install the CDR valve and the center intake manifold.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and let it idle for two minutes after finishing the installation. Check for oil leaks.
  12.  

 
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