GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Crew) C4/C5 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Turbocharger Replacement

Removal Procedure

    Object Number: 668379 Size: SH

    Notice: If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.

    Important: If a turbocharger failure is thought to be caused due to lack of oil, the camshaft bearing should be inspected. The number 4 camshaft bearing bore feeds the turbocharger oil supply (feed) pipe. If this camshaft bearing spins in the bore, the turbocharger will be starved for oil. This will cause a failure of the turbocharger. Failure to diagnosis this condition will result in repeat turbocharger failures.

  1. Disconnect both battery negative cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    2. Raise the vehicle if required. Refer to Lifting and Jacking the Vehicle in General Information.

  2. Remove the air cleaner layer. Refer to Air Cleaner Replacement in Engine Controls.
  3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  4. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
  5. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.

    6. Object Number: 668426 Size: SH
  6. Remove the left exhaust pipe heat shield bolts.
  7. Position the left exhaust pipe heat shield in order to access the left exhaust pipe to exhaust manifold bolts. Do not remove the heat shield from the vehicle at this time.

    8. Object Number: 654524 Size: SH

    Important: Do not bend the exhaust pipe at the expansion area.

  8. Remove the left exhaust pipe to exhaust manifold bolts (2).
  9. Remove and discard the gasket.

    10. Object Number: 654525 Size: SH

    Important: Do not bend the exhaust pipe at the expansion area.

  10. Remove the right exhaust pipe to exhaust manifold bolts (1).
  11. Remove and discard the gasket.

    12. Object Number: 668425 Size: SH
  12. Remove the lower bolt (2) for the exhaust outlet shield.
  13. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.

    14. Object Number: 664851 Size: SH
  14. Loosen both of the charged air cooler outlet duct to intake hose clamps.

    15. Important: Do not use a screw driver or other tool to pry the hose loose. Loosen the hose by twisting.

  15. Remove the hose from the charged air cooler duct to the intake manifold tube.

    16. Object Number: 664853 Size: SH
  16. Loosen the charged air cooler inlet duct to turbocharger cool air outlet clamp.

    17. Important: Do not use a screw driver or other tool to pry the hose loose. Loosen the hose by twisting.

  17. Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.

    18. Object Number: 652573 Size: SH
  18. Disconnect the A/C compressor clutch electrical connector.
  19. Disconnect the A/C cut out switch electrical connector.
  20. Remove the drive belt. Refer to Drive Belt Replacement .
  21. Remove the A/C compressor mounting bolts.
  22. Move the A/C compressor with the hoses attached to the right side of the engine compartment.

    23. Object Number: 668427 Size: SH
  23. Disconnect the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.

    24. Object Number: 668428 Size: SH
  24. Disconnect the turbocharger outlet coolant hose from the turbocharger.

    25. Object Number: 687021 Size: SH
  25. Disconnect the positive crankcase ventilation (PCV) hose from the left valve rocker arm cover.
  26. Position the hose out of the way.
  27. Remove the wire connector from the intake heater.
  28. If equipped, remove the intake air heater relay. Refer to Intake Air Heater Relay Replacement in Engine Controls - 6.6L.

    29. Object Number: 660382 Size: SH
  29. Remove the 3 bolts holding the heat shield to the turbocharger.
  30. Remove the turbocharger heat shield.

    31. Object Number: 668425 Size: SH
  31. Remove the remaining 2 bolts (1, 3) for the exhaust outlet heat shield.
  32. Remove the exhaust outlet heat shield.

    33. Object Number: 654540 Size: SH
  33. Remove the 4 bolts and the 2 nuts for the exhaust outlet.

    34. Important: The exhaust outlet does not require removal in order to remove the turbocharger.

  34. Move the exhaust outlet to one side in order to access the right exhaust pipe to turbocharger bolts.
  35. Remove and discard the exhaust outlet gasket.

    36. Object Number: 654525 Size: SH
  36. Remove the right exhaust pipe to turbocharger bolts (2).
  37. Remove the right exhaust pipe.
  38. Remove and discard the gasket.

    39. Object Number: 654524 Size: SH
  39. Move the exhaust outlet to one side in order to access the left exhaust pipe.
  40. Remove the left exhaust pipe heat shield from the vehicle.
  41. Remove the left exhaust pipe to turbocharger bolts (1).
  42. Remove the left exhaust pipe.
  43. Remove and discard the gasket.

    44. Object Number: 660383 Size: SH

    Notice: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

  44. Remove the turbocharger oil feed pipe eye bolt, and washers.
  45. Move the oil feed pipe out of the way.

    46. Object Number: 668429 Size: SH
  46. Remove the turbocharger oil drain pipe nuts at the flywheel housing.

    47. Object Number: 660388 Size: SH
  47. Remove the turbocharger 3 mounting bolts.
  48. Remove the turbocharger with the turbocharger oil drain pipe.

    49. Object Number: 697717 Size: SH
  49. If replacing the turbocharger remove the following items:
    50. • Oil drain pipe
    • Coolant hose
  50. Clean the following gasket surfaces:
    51. • Oil drain pipe to turbocharger
    • Oil drain pipe to flywheel housing
    • Air intake tube
    • Both exhaust pipe flanges
    • Both exhaust manifold flanges
    • Exhaust outlet
    • Turbocharger, exhaust outlet
    • Turbocharger, both exhaust pipe

Installation Procedure

    Object Number: 697717 Size: SH
  1. Install the turbocharger oil drain pipe and NEW gasket to the turbocharger.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the turbocharger oil drain pipe bolts.

    3. Tighten
    Tighten the oil drain pipe bolts to 21 N·m (16 lb ft).

  3. Install the turbocharger inlet coolant hose to the turbocharger.

    4. Object Number: 660418 Size: SH

    Notice: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

  4. Install the turbocharger oil feed pipe to the engine block.
  5. Install the turbocharger oil feed pipe eye bolt and washers.

    6. Tighten
    Tighten the turbocharger oil feed pipe eye bolt to 34 N·m (31 lb ft).

  6. Install the turbocharger lower heat shield to the engine block.

    7. Object Number: 660388 Size: SH
  7. Install the turbocharger to the engine.
  8. Install the turbocharger 3 mounting bolts.

    9. Tighten
    Tighten the turbocharger mounting bolts to 108 N·m (80 lb ft).


    Object Number: 668429 Size: SH
  9. Install a NEW gasket for the oil drain pipe.
  10. Install the turbocharger oil drain pipe nuts.

    11. Tighten
    Tighten the turbocharger drain pipe nuts to 21 N·m (15 lb ft).


    Object Number: 660383 Size: SH
  11. If installing a new turbocharger, pour about 120-150 cc (4-5 oz) of clean engine oil in the turbocharger oil feed pipe opening while rotating the impeller.
  12. Using NEW sealing washers, install the oil feed pipe and bolt to the turbocharger.

    13. Tighten
    Tighten the oil feed pipe eye bolt to 42 N·m (31 lb ft).


    Object Number: 654524 Size: SH
  13. Position the left exhaust pipe. The pipe flanges are different. Ensure the proper pipe flange is towards the turbocharger.
  14. Install the left exhaust pipe to the turbocharger with NEW gasket. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.

    15. Tighten
    Tighten the left exhaust pipe to turbocharger bolts (1) to 53 N·m (39 lb ft).

  15. Position the left exhaust pipe heat shield, but do not install the bolts.

    16. Object Number: 654525 Size: SH
  16. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the gasket at the turbocharger with the tab on the gasket facing inward. To aid in installing the pipe to the turbocharger temporarily install one of the pipe to manifold bolts.
  17. Install the right exhaust pipe to turbocharger bolts (2).

    18. Tighten
    Tighten the right exhaust pipe to turbocharger bolts to 53 N·m (39 lb ft).


    Object Number: 654540 Size: SH
  18. Install the exhaust outlet with a NEW gasket to the turbocharger.
  19. Install the exhaust outlet bolts and nuts.

    20. Tighten
    Tighten the exhaust outlet bolts and nuts to 53 N·m (39 lb ft).


    Object Number: 668425 Size: SH
  20. Install the exhaust outlet heat shield.
  21. Install the upper 2 exhaust outlet heat shield bolts (1, 3).

    22. Tighten
    Tighten the exhaust outlet heat shield bolts to 8 N·m (71 lb in).


    Object Number: 660382 Size: SH
  22. Install the turbocharger heat shield.
  23. Install the turbocharger heat shield bolts.

    24. Tighten
    Tighten the turbocharger heat shield bolts to 9 N·m (80 lb in).


    Object Number: 687021 Size: SH
  24. Connect the PCV hose to the upper left valve rocker arm cover.

    25. Object Number: 668428 Size: SH
  25. Connect the turbocharger outlet coolant hose to the turbocharger.

    26. Object Number: 668427 Size: SH
  26. Connect the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
  27. Install the inlet air heater relay. Refer to Intake Air Heater Relay Replacement in Engine Controls - 6.6L.

    28. Notice: Refer to Fastener Notice in the Preface section.

  28. Connect the wire terminal and the nut to intake air heater.

    29. Tighten
    Tighten the intake air heater nut to 4 N·m (35 lb in).


    Object Number: 652573 Size: SH
  29. Position the A/C compressor.
  30. Install the A/C compressor mounting bolts.

    31. Tighten
    Tighten the A/C compressor mounting bolts to 50 N·m (37 lb ft).

  31. Install the drive belt. Refer to Drive Belt Replacement .
  32. Connect the A/C cut out switch electrical connector.
  33. Connect the A/C clutch electrical connector.

    34. Object Number: 664853 Size: SH
  34. Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.
  35. Position the clamp as shown for proper clearance.

    36. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 664851 Size: SH
  36. Install the hose to the charged air cooler outlet duct to intake manifold tube.

    37. The hose is marked DUCT which connects to the charged air cooler outlet duct.

    The hose is marked ENG which connects to the turbocharger.

    Align the marks on the hose with the alignment marks on the pipe and tube.

  37. Position the clamps as shown for proper clearance.

    38. Tighten
    Tighten the clamps to 6 N·m (53 lb in).


    Object Number: 668425 Size: SH
  38. Install the lower bolt (2) for the exhaust outlet heat shield.

    39. Tighten
    Tighten the exhaust outlet heat shield bolt to 8 N·m (71 lb in).


    Object Number: 654525 Size: SH
  39. Install the right exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
  40. Install the right exhaust pipe bolts (2).

    41. Tighten
    Tighten the exhaust pipe to exhaust manifold bolts to 53 N·m (39 lb ft).


    Object Number: 654524 Size: SH
  41. Install the left exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward.
  42. Install the left exhaust pipe bolts (1).

    43. Tighten
    Tighten the exhaust pipe to exhaust manifold bolts to 53 N·m (39 lb ft).


    Object Number: 668426 Size: SH
  43. Position the left exhaust pipe heat shield.
  44. Install the left exhaust pipe heat shield bolts.

    45. Tighten
    Tighten the left exhaust pipe heat shield bolts to 8 N·m (71 lb in).


    Object Number: 668379 Size: SH
  45. Install the exhaust outlet to exhaust pipe clamp.

    46. To assist in positioning the clamp on the flanges use a suitable screw jack to hold the exhaust pipe in position.

    Tighten
    Tighten the exhaust pipe clamp to 40 N·m (30 lb ft).

  46. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  47. Connect both battery negative cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  48. Install the air cleaner layer. Refer to Air Cleaner Replacement in Engine Controls - 6.6L.
  49. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  50. Road test the vehicle for normal operation.
  51. Inspect for coolant, oil, or exhaust leaks.