GM Service Manual Online
For 1990-2009 cars only

Turbocharger Coolant Hoses/Pipes Replacement Inlet

Removal Procedure

  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  2. Remove the engine cover. Refer to Engine Cover Replacement.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling.

  4. Object Number: 1728255  Size: SH
  5. Compress the clamp (1) and disconnect the turbocharger inlet cooling hose/pipe (2) from the thermostat housing.

  6. Object Number: 1862415  Size: SH
  7. Remove the EGR cooler pipe bolt.

  8. Object Number: 1862416  Size: SH
  9. Reposition the EGR cooler pipe (4) out of the way.
  10. Remove the EGR valve adapter pipe bracket bolts (1).
  11. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).

  12. Object Number: 1728393  Size: SH

    Note: Steps 6 and 7 are to allow for movement of the fuel lines and glow plug bracket to gain access to the turbocharger inlet cooling hose/pipe bolt.

  13. Remove the left bank fuel return line bracket bolt (1) and the 2 glow plug module bracket bolts (2).

  14. Object Number: 1728447  Size: SH
  15. Remove the left bank fuel line bracket bolt.

  16. Object Number: 1728525  Size: SH
  17. Remove the turbocharger inlet cooling hose/pipe bolt and remove the inlet hose/pipe.

Installation Procedure

  1. Position the turbocharger inlet cooling hose/pipe to the vehicle.
  2. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1728525  Size: SH
  3. Using new brass seals, install the turbocharger inlet cooling hose/pipe bolt and tighten to 25 N·m (18 lb ft).

  4. Object Number: 1728447  Size: SH
  5. Position the left bank fuel line and install the bracket bolt then tighten to 25 N·m (18 lb ft).

  6. Object Number: 1728393  Size: SH
  7. Position the glow module bracket to the valve cover, install the 2 bolts (2) and the remaining left bank fuel line bracket bolt (1).
  8. • Tighten the glow plug module bracket bolts to 10 N·m (89 lb in).
    • Tighten the fuel line bracket bolt to 25 N·m (18 lb ft).

    Object Number: 1862416  Size: SH
  9. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
  10. Install the EGR valve adapter pipe bracket bolts (1) and tighten to 9 N·m (80 lb in).
  11. Position the EGR cooler pipe (4).

  12. Object Number: 1862415  Size: SH
  13. Install the EGR cooler pipe bolt and tighten to 9 N·m (80 lb in).

  14. Object Number: 1728255  Size: SH
  15. Position the turbocharger inlet cooling hose/pipe (2) to the thermostat housing and position the compression clamp (1) to secure.
  16. Fill the cooling system. Refer to Cooling System Draining and Filling.
  17. Install the engine cover. Refer to Engine Cover Replacement.
  18. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.

Turbocharger Coolant Hoses/Pipes Replacement Outlet

Removal Procedure

  1. Remove the engine cover. Refer to Engine Cover Replacement.

  2. Object Number: 1862415  Size: SH
  3. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
  4. Remove the EGR cooler pipe bolt.

  5. Object Number: 1862416  Size: SH
  6. Reposition the EGR cooler pipe (4) out of the way.
  7. Remove the EGR valve adapter pipe bracket bolts (1).
  8. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
  9. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement.
  10. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
  11. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.

  12. Object Number: 1730036  Size: SH
  13. Remove the turbocharger outlet cooling hose/pipe bolt from the valve cover.

  14. Object Number: 1729993  Size: SH
  15. Remove the turbocharger outlet cooling hose/pipe bolt.
  16. Compress the clamp and disconnect the turbocharger cooling hose/pipe from the thermostat bypass pipe.

  17. Object Number: 1730090  Size: SH
  18. Remove the turbocharger outlet cooler pipe to turbocharger nut.

  19. Object Number: 1728393  Size: SH

    Note: Steps 11 and 12 are to allow movement of the fuel lines and glow plug bracket to gain access to the turbocharger inlet cooling hose/pipe bolt.

  20. Remove the left bank fuel return line bracket bolt (1) and the two glow plug module bracket bolts (2).

  21. Object Number: 1728447  Size: SH
  22. Remove the left bank fuel line bracket bolt.

  23. Object Number: 1730130  Size: SH
  24. Remove the turbocharger outlet cooling hose/pipe to turbocharger bolt and remove the inlet hose/pipe.

Installation Procedure

  1. Position the turbocharger inlet cooling hose/pipe to the vehicle.
  2. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1730130  Size: SH
  3. Using new brass seals, install the turbocharger inlet cooling hose/pipe bolt and tighten to 25 N·m (18 lb ft).

  4. Object Number: 1728447  Size: SH
  5. Position the left bank fuel line and install the bracket bolt and tighten to 25 N·m (18 lb ft).

  6. Object Number: 1728393  Size: SH
  7. Position the glow module bracket to the valve cover, install the two bolts (2) and the remaining left bank fuel line bracket bolt (1).
  8. 4.1. Tighten the glow plug module bracket bolts to 10 N·m (89 lb in).
    4.2. Tighten the fuel line bracket bolt to 25 N·m (18 lb ft).

    Object Number: 1862416  Size: SH
  9. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
  10. Install the EGR valve adapter pipe bracket bolts (1) and tighten to 9 N·m (80 lb in).
  11. Position the EGR cooler pipe (4).

  12. Object Number: 1862415  Size: SH
  13. Install the EGR cooler pipe bolt and tighten to 9 N·m (80 lb in).

  14. Object Number: 1730090  Size: SH
  15. Install the turbocharger outlet cooler pipe to the turbocharger nut and tighten to 9 N·m (80 lb in).

  16. Object Number: 1729993  Size: SH
  17. Compress the clamp and connect the turbocharger cooling hose/pipe to the thermostat bypass pipe.

  18. Object Number: 1730036  Size: SH
  19. Install the turbocharger outlet cooling hose/pipe to the valve cover and tighten turbocharger outlet pipe bolt to 9 N·m (80 lb in).
  20. Install the turbocharger outlet cooling hose/pipe bolt and tighten to 9 N·m (80 lb in).
  21. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
  22. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
  23. Install the EGR cooler tube replacement. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
  24. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement.
  25. Install the engine cover. Refer to Engine Cover Replacement.
  26. Perform the turbocharger learn procedure. Refer to Turbocharger Learn.