Removal Procedure
- Disconnect the battery negative cables from the batteries. Refer to Battery Replacement in Engine Electrical.
- Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
- Remove the CDR valve from the right valve rocker arm cover.
- Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
- Remove the heater hoses from the heater core.
- Remove the engine wiring harness from the upper intake manifold.
- Secure engine wiring harness out of the way.
- Remove the upper intake manifold from the turbocharger. Refer to Intake Manifold Replacement .
- Raise the vehicle.
- Remove the exhaust pipe from the turbocharger. Refer to Front Pipe Replacement in Engine Exhaust.
- Remove the transfer case from the transmission. Refer to Transfer Case Replacement in Driveline/Axle.
- Remove the transmission from the engine assembly. Refer to Transmission Replacement in Transmission/Transaxle.
- Lower the vehicle.
- Remove the engine assembly from the vehicle. Refer to Engine Replacement .
- Remove the exhaust pipes between the turbocharger and the exhaust manifolds.
- Remove the turbocharger mounting bolts.
- Remove the turbocharger from the vehicle.
Important: Usually some quantity of oil will exist inside the vent system. The crankcase vapor consists of vaporized oil that condenses within the vent and intake system. The inside of the air intake duct and compressor wheel housing can be quite oily due to the venting of the crankcase vapors.
Installation Procedure
- Make sure the turbocharger and exhaust manifold flanges are clean and free of any foreign material.
- Inspect the oil feed and return passages in the engine block and the turbocharger. Make sure these passages are clean and open.
- Install the turbocharger on the engine block.
- Apply high temperature anti-seize compound GM P/N 1052771 on all threaded fasteners connected to the turbocharger.
- Install the turbocharger mounting bolts.
- Install the exhaust pipes between the turbocharger and the exhaust manifolds.
- Install the exhaust pipe clamps.
- Install the turbocharger heat shield mounting bolts and nut.
- Tighten the bolts (right and top) to 30 N·m (22 lb ft).
- Tighten the center bolts to 22 N·m (17 lb ft).
- Tighten the heat shield nut to 30 N·m (22 lb ft).
- Install the engine assembly in the vehicle. Refer to Engine Replacement .
- Install the exhaust pipe to the turbocharger. Refer to Front Pipe Replacement in Engine Exhaust.
- Install the transmission to the engine assembly. Refer to Transmission Replacement in Transmission/Transaxle.
- Install the transfer case to the transmission assembly. Refer to Transfer Case Replacement in Driveline/Axle.
- Lower the vehicle.
- Install the heater hoses to the heater core.
- Install the upper intake manifold to the turbocharger. Refer to Intake Manifold Replacement .
- Install the engine wiring harness to the upper intake manifold.
- Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
- Install the CDR valve from the right valve rocker arm cover.
- Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
- Connect the battery negative cables to the batteries. Refer to Battery Replacement in Engine Electrical.
Important: Always replace the O-ring between the turbocharger and the engine block.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the turbocharger mounting bolts to 65 N·m (48 lb ft).
Tighten
Tighten the clamps to 10 N·m (90 lb in).
Tighten
Important: Run the engine at an idle for at least 2 minutes after completing the installation of the turbocharger. This will allow the oil to lubricate the bearing inside the turbocharger. While running the engine, check for any leaks.
