GM/Detroit 6.5L TURBOCHARGER – TURBOCHARGER REPLACEMENT

The turbocharger assembly consists of the turbo­ charger housing, internal components, the waste-gate actuator, exhaust elbow, and heat shield.

Remove or Disconnect (Figures 2, 9, 10 and 11)
1. Negative battery cables. Refer to SECTION OA.
2. Upper intake manifold cover.
3. Self tapping screw holding CDR valve tube on top of turbocharger.
4. CDR valve and tube assembly from the air cleaner extension and right rocker cover. Refer to SECTION 6A6.

Important
• Usually some quantity of oil will exist inside the vent system. The crankcase vapor consists of vaporized oil that condenses within the ventand intake system. The inside of the air intakeduct (rubber inlet elbow) and compressor wheel housing can be quite oily due to the venting of the crankcase vapors.
5. Air cleaner extension (rubber elbow) from air clean­er and compressor inlet.

6. Two bolts retaining the air cleaner to the wheel well and lift the air cleaner assembly off the front air intake duct.
• This will allow easier access to the turbocharger flange nuts and exhaust clamp.

NOTICE: The right front wheel and inner splash shield can be removed for easier a ccess to the turbocharger back flange nut. Refer to SECTION 3E.
7. Vacuum hose to the waste-gate actuator.
8. Long and short turbocharger braces (figure 2).
9. Hose clamps at intake extension/turbocharger com­pressor connector hose.

NOTICE: Silicone sealant is used between the connector hose, the in take extension, and turbocharger compressor outlet.

•Use a thin flat blade screwdriver to break the seal between the connector hose, turbocharger compressor outlet, and the intake extension.
• Slide connector hose over intake extension.
10. Exhaust clamp at turbocharger (figure 9).
11. Oil feed hose.
12. Oil return pipe (figure 11).
13. Turbocharger flange nuts (figure 10).

14. Turbocharger assembly from exhaust manifold.
Instal l or Connect (Figures 9, 10, 11, and 12)

Important

Before the turbocharger is installed, perform the fol­lowing steps:
A. Check the intake and exhaust systems leading to and from the turbocharger to ensure that there is no foreign debris. Even small debris can cause severe wheel damage if inducted during high speed operation.
B. Make sure the turbocharger and exhaust mani­fold flanges are clean and free of any foreign material. Use a high temperature anti-seize compound (GM P/N 1052771) or equivalent on ail threaded fasteners connected to the turbo­charger (figure 9).
1. Turbocharger assembly to the exhaust manifold (figure 10).
2. Nuts to exhaust manifold.

Tighten
• Exhaust manifold mounting nuts to 58 N-m (43 Ibs. ft.).
3. Gasket on oil return pipe. Then the oil return pipe to the bottom of the turbocharger (figure 11).

Tighten
• Oil drain tube bolts to 26 N-m (19 I bs. ft.).

Important
• Fill the oil feed hole at the top of the turbo­ charger with a small amount of engine oil (1 to 2 cc) while hand rotating the compressor wheel.
This action will lubricate the turbocharger shaft bearings.
4. Oil feed hose to top of turbocharger.

Tighten
• Oil feed hose fitting to 17 N-m (13 Ibs. ft.).
5. Exhaust pipe to turbocharger with clamp (figure 12).

Tighten
• Exhaust pipe clamp to 8 N.m (71 lbs. in.).

Important
.• When starting the engine, allow it to idle for two minutes so oil can flow into the oil feed hose.
6. Inner splash shield and right front wheel (if removed).
7. Clean surfaces of turbocharger compressor outlet and intake inlet extension housing where the con­nector hose is fastened.

Important
• Apply silicone sealant (GM P/N 9985943) or equiv­alent to turbocharger compressor outlet hose (not
the turbocharger or inlet extension) before installa­tion to prevent oil leakage from the closed breather system.
8. Slide the connector hose over the compressor out­let and then slide the inlet extension into the other end of connector hose. Make sure the connector hose is centered between the compressor outlet and the inlet extension housing.

Tighten .
• Connector hose clamps to N-m 5.6 (50 Ibs. in.).

9. Long turbocharger brace by guiding the flat end of the brace under the heater inlet.
10. Nut onto the stud.
11. Bolt into the bent end of the brace.

Tighten
• Long turbocharger brace nut to 34 N m (26 Ibs. ft.).
• Long turbocharger brace bolt to 50 N m (37 Ibs. ft.).
12. Short turbocharger brace to extension and com­pressor housing.
13. Short turbocharger brace bolts.

Tighten
• Short turbocharger brace bolts to 25 N-m (19 Ibs. ft.).
14. Vacuum hose to waste-gate actuator.
15. Sl ide air cleaner onto the front air inlet duct and attach it to the fenderwell.
16. Large diameter air cleaner bolt.
17. Short diameter air cleaner bol t.

Tighten
• Larger diameter air cleaner bolt to 30 N.m (22 Ibs. ft.).
• Smaller diameter air cleaner bolt to 5 N m (45Ibs. in.).
18. Air cleaner extension (rubber elbow) onto air clean­er and compressor inlet.

Tighten
• Extension clamps to 1.7 N.m (15 Ibs. in.).
19. CDR valve and tube assembly on right rocker cov­er and extension.
• Start self-tapping screw through CDR tube bracket and thread into bracket on turbocharger housing.
20. Upper intake manifold cover.
21. Intake manifold cover bolts.

Tighten
• Intake manifold cover bolts to 11 N m (90 Ibs. in.).
22. Negative battery cable.

Important
• Run engine at idle for at least 2 minutes after com­pleting the installation of the turbocharger. While running the engine, check for any oil leaks at the oil supply and return hoses.

 

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