1999 GM 6.5L V8 – Turbocharger Replacement – Removal Procedure

1. Remove the engine cover from the upper intake manifold.

2. Remove the CDR valve from the right valve rocker arm cover.

3. Disconnect both the battery negative cables from the batteries. Refer to Battery Cable in Engine Electrical.

4. Remove the braces from the turbo charger and the upper and lower intake manifold.

Important: Some quantity of oil will exist inside the vent system. The crankcase vapor consist of vaporized oil that condenses within the vent and intake system .
The inside of the air duct and compressor wheel housing will have some oil due to the venting of the crankcase vapors.

5. Loosen the clamps on the hose between the air cleaner assembly and the turbo charger.
Important: Silicone sealant is used on the hose between the upper intake manifold and the turbo charger.

6. Remove the hose between the upper intake manifold and the turbo charger assembly .

6.1. Use a small flat bladed screw driver to break the seal on the hose between the upper intake manifold and the turbo charger.

6.2. Slide the hose and the clamps toward the upper intake manifold.

7. Remove the oil feed line from the turbo charger and position to the side.

8. Partially rise the vehicle.

9. Remove the right front tire from the vehicle.

10. Remove the exhaust pipe from the turbo charger

11. Remove the oil return line from the turbo charger.

12. Remove the turbo charger from the right exhaust manifold.

13. Clean the all mounting bolts for the turbo charger.

14. Clean and inspect the sealing surface of the exhaust manifold. Refer to Exhaust Manifold Clean and Inspect.

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