Turbocharger Installation G

1. Install the seal onto the engine block.
2. Install the turbocharger.

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.

3. Install the turbocharger mounting bolts.

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

4. Install the wastegate actuator bracket mounting bolts.

Tighten
Tighten the wastegate actuator bracket mounting bolts to 65 N·m (48 lb ft).

Important: In order to ensure heat shield clearance, locate the exhaust pipe clamps as shown.

5. Slide the exhaust clamps over the exhaust manifold and turbocharger.



6. Install the right hand side exhaust pipe.

Important: Tighten the clamps at the exhaust manifold end first.

7. Place the clamps in the correct position.

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




8. Install the left hand side exhaust pipe.

Important: Tighten the clamps at the exhaust manifold end first.

9. Place the clamps in the correct position.

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

Turbocharger Installation C3500HD

1. Install the turbocharger on the exhaust manifold and the studs.

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 nuts to the exhaust manifold.

Tighten
Tighten the exhaust manifold mounting nuts to 58 N·m (43 lb ft).




3. Install the gasket on the oil return pipe.



4. Install the oil return pipe to the bottom of the turbocharger.

Tighten
Tighten the oil return pipe bolts to 26 N·m (19 lb ft).

Important: Fill the oil feed hole at the top of the turbocharger with a small amount of the engine oil while rotating the compressor wheel by hand. This action will lubricate the turbocharger shaft bearings.

5. Install the oil feed hose at the turbocharger and the block.

Tighten
Tighten the oil feed hose fittings to 28 N·m (21 lb ft).




6. Install the oil return pipe with the hose and the clamps at the block.

Important: Apply the silicone sealant GM P/N United States 12346240, GM P/N Canada 10953493, or the equivalent to the turbocharger outlet hose before installing onto turbocharger.

7. Install the outlet hose and the clamp on the turbocharger.

Tighten
Tighten the connector hose clamps to 6 N·m (50 lb in).

8. Install the long and the short turbocharger braces.

Tighten

•	Tighten the long turbocharger brace nut to 34 N·m (26 lb ft).

•	Tighten the long turbocharger brace bolt to 50 N·m (37 lb ft).

•	Tighten the short turbocharger brace bolts to 25 N·m (19 lb ft).




9. Install the grommet (4) in the valve rocker arm cover.
10. Install the CDR (Crankcase Depression Regulator) assembly (1) in the valve rocker arm cover.