GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 Savana 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Turbocharger Replacement

Removal Procedure

    Object Number: 104973 Size: SH
  1. Disconnect the negative battery cable.
    2. • For the front battery, refer to Battery Cable Replacement in Engine Electrical.
    • For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.
  2. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Body and Accessories.
  3. Remove the crankcase depression regulator (CDR) valve.
  4. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
  5. Remove the air cleaner intake duct from the turbocharger.
  6. Remove the transmission oil level indicator and tube from the upper intake manifold.
  7. Remove the upper intake manifold from turbocharger. Refer to Intake Manifold Replacement .

    8. Object Number: 173009 Size: SH
  8. Remove the turbocharger heat shield mounting bolts.
  9. Remove the turbocharger heat shield.

    10. Object Number: 173010 Size: SH
  10. Remove the exhaust pipe clamps from the exhaust pipes that connect the turbocharger to the exhaust manifolds.
  11. Remove the exhaust pipes that connect the turbocharger to the exhaust manifolds.

    12. Object Number: 177900 Size: SH
  12. Remove the turbocharger mounting bolts.
  13. Remove the turbocharger assembly from the engine block.

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

Important: Perform the following steps before installing the turbocharger:

   • Check the intake and exhaust systems leading to and from the turbocharger in order to ensure that there is no debris. Even small debris can cause severe wheel damage if drawn in during high speed operation.
   • Make sure the turbocharger and exhaust manifold flanges are clean and free of any foreign material.
   • Use high temperature anti-seize compound GM P/N 1052771 on all threaded fasteners connected to the turbocharger.
   • Inspect the oil feed and return passages in the engine block and the turbocharger. Make sure these passages are clean and open.
   • Always replace the O-ring between the turbocharger and the engine block.


    Object Number: 177900 Size: SH
  1. Install the turbocharger assembly to the engine block.

    2. 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.

  2. Install the turbocharger mounting bolts.

    3. Tighten
    Tighten the bolts to 65 N·m (48 lb ft).


    Object Number: 173010 Size: SH
  3. Install the exhaust pipes that connect the exhaust manifolds to the turbocharger.
  4. Install the exhaust pipe clamps.

    5. Tighten
    Tighten the clamps to 10 N·m (90 lb in).

  5. Install the vacuum line to the wastegate actuator.

    6. Object Number: 173009 Size: SH
  6. Install the turbocharger heat shield.
  7. Install the turbocharger heat shield mounting bolts and nut.

    8. Tighten

    1. Tighten the bolts (right and top) to 30 N·m (22 lb ft).
    2. Tighten the center bolts to 22 N·m (17 lb ft).
    3. Tighten the heat shield nut to 30 N·m (22 lb ft).
  8. Install the upper intake manifold on the turbocharger. Refer to Intake Manifold Replacement .

    9. Object Number: 104973 Size: SH
  9. install the transmission oil level indicator tube to the upper intake manifold.
  10. Install the air cleaner intake duct to the turbocharger.
  11. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
  12. Install the CDR valve on the valve rocker arm rocker cover.
  13. Connect the battery negative cables to the batteries.
    14. • For the front battery, refer to Battery Cable Replacement in Engine Electrical.
    • For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.

    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.

  14. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Body and Accessories.