2008 6.6L Duramax – TURBOCHARGER REPLACEMENT – Installation Procedure

1. 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.
2. Install the oil feed pipe, washer, and bolt, if necessary.
Tighten: Tighten the bolt to 34 N.m (25 lb ft).
3. Install the turbocharger lower heat shield, if necessary.

4. Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
5. Install the turbocharger (with the oil return pipe).
6. Install the turbocharger bolts.

Tighten: Tighten the bolts to 108 N.m (80 lb ft).
7. Install the turbocharger oil return pipe nuts at the top o f the flywheel housing.
Tighten: Tighten the nuts to 25 N.m (18 lb ft).

8 . If installing a N EW turbocharger, add about 120-150 cc (4-5 oz) o f clean engine oil in the turbocharger oil feed           pipe opening while rotating the impeller.
9. Position the oil feed pipe to the turbocharger.

10. Install a NEW turbocharger oil feed pipe washer and the banjo bolt.
Tighten: Tighten the bolt to 34 N.m (25 lb ft).

11. Install the left exhaust pipe and a NEW gasket.
12. Install the left exhaust pipe to turbocharger bolts.
Tighten: Tighten the bolt to 53 N.m (39 lb ft).

13. Install the right exhaust pipe and a NEW gasket.
14. Install the right exhaust pipe to turbocharger bolts.
Tighten: Tighten the bolt to 53 N.m (39 lb ft).

15. Install the exhaust outlet.

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

17. Install the exhaust outlet heat shield.
18. Install the remaining exhaust outlet heat shield bolts.
Tighten: Tighten the bolt to 8 N.m (71 lb in).
19. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.

21. Install the turbocharger outlet coolant pipe banjo bolt and washers.
Tighten: Tighten the bolt to 26 N.m (19 lb ft).
22. Install the turbocharger outlet coolant hose to the turbocharger and position the hose clamp.

24. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
25. Install the EGR valve adapter pipe bracket bolts (1).
Tighten: Tighten the bolts to 9 N.m (80 lb in).

26. Position the EGR cooler pipe (4).

27. Install the EGR cooler pipe bolt.
Tighten: Tighten the bolt to 9 N.m (80 lb in).

28. Remove the tape from the turbocharger openings.
29. Install the charged air cooler inlet duct connector (4) to the turbocharger.
30. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
Tighten: Tighten the clamp to 6 N.m (53 lb in).

31. Install the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe Replacement.
32. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining              and Filling (Static Fill).

33. Install the lower bolt for the exhaust outlet shield.
Tighten: Tighten the bolt to 8 N.m (71 lb in).

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

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

38. Install the heat shield.
39. Install the left exhaust pipe heat shield bolts.
Tighten: Tighten the bolts to 8 N.m (71 lb in).

40. If equipped with an automatic transmission, position the fill tube to the studs.
41. Install the transmission fill tube to bellhousing nuts.
Tighten: Tighten the nuts to 18 N.m (13 lb ft).

42. Slide the clamp onto the exhaust pipe. Tighten the exhaust pipe clamp.
Tighten: Tighten the clamp to 40 N.m (30 lb ft).

43. Install the left and right wheelhouse liners. Refer to Front Wheelhouse Liner Replacement – Right Side (GMC) or         Front Wheelhouse Liner Replacement – Right Side (Chevrolet) and Front Wheelhouse Liner Replacement – Left           Side (Chevrolet) or Front Wheelhouse Liner Replacement – Left Side (GMC) .
44. Install the transmission. Refer to Transmission Replacement.
45. If a NEW turbocharger was installed, perform the turbocharger learn procedure. Refer to Turbocharger Learn .
46. Road test the vehicle for normal operation.
47. Inspect for coolant, oil, or exhaust leaks. Correct as necessary.