PowerMax Diesel Upgrade For Duramax Engines Installation Instructions 2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

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Part Number: 766172-0001

Tools Needed

Description

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Turbocharger PN 765563-1 Exhaust Outlet Kit Exhaust Elbow V-Band Clamp V-band Clamp Nut Heat Shield Bolt, Heat Shield M6x1-10 Exhaust Elbow Bracket Bolt, Bracket M8x1.25-20 12-point Washer, Bracket Bolt M8 PN 765562-1 Turbine Inlet Kit Turbine Inlet Adapter Bolt M10x1.5-25 Turbine Inlet Gasket PN 765565-1 Water line Kit Passenger-side Water Line Driver-side Water Line Bolt, Banjo M14 Crush Washer PN 765564-1 Oil Line Kit Oil Outlet Gasket Oil Outlet Adapter Bolt, Oil Outlet (M8x45) Oil Inlet Adapter Bolt M8x1.25-20 12-point O-ring, Oil Inlet Adapter Oil Inlet Line Crush Washer PN 765561-1 Compressor Inlet Kit Compressor Inlet Adapter Compressor Inlet Gasket Bolt, Compressor Inlet (M6x1-25) Instructions, installation

1 1 1 1 1 1 3 1 1 1 1 1 4 1 1 1 1 2 2 1 2 1 2 1 2 1 1 4 1 1 1 3 1

Safety glasses Catch basin for engine coolant 7/16” deepwell socket 8mm 12-point socket 10mm socket 12mm socket 13mm socket 14mm socket

15mm socket 16mm socket 16mm combination wrench 17mm socket 10mm hex socket Torque wrench Various extensions and adapters

• NOTE: Bolt and fastener sizes may be different from one model year to the next depending on OE specifications. Different tools than those listed above may be required.

Recommended Other Items Item 1

Description

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Turbine Inlet Gasket Exhaust Manifold Pipe Gasket

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Oil Drain Gasket – Block

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Coolant (Gallons)

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IMPORTANT INFORMATION - PLEASE READ CAREFULLY We recommend that this turbo upgrade kit be installed by a qualified automotive technician. If you have any doubts as to your ability to install this turbo upgrade kit, consult with a local automotive repair facility. Please be sure to carefully read all of the attached instructions prior to starting the installation process. If you have any questions about the enclosed parts or the instructions, call the distributor that you purchased the kit from for clarification. Prior to installation, be sure that the vehicle is parked on a level surface and the engine is cool. Engine fluids and components are extremely hot during normal vehicle operation. Avoid direct contact of engine fluids or components with your skin; may cause personal injury.

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

IMPORTANT INFORMATION - PLEASE READ CAREFULLY Return Policy Only unused and complete merchandise will be accepted for return subject to inspection and acceptance by Honeywell Turbo Technologies. No goods will be accepted without prior return authorization from Honeywell Turbo Technologies. No returns are accepted after thirty (30) days from original ship date from Honeywell. All accepted returns are subject to a 20% restocking charge - NO EXCEPTIONS. Damaged Shipments The customer must file a claim with the shipping company if goods arrive in a damaged condition. The customer must also notify the distributor from which the goods were purchased with pertinent information. Refused Shipments Sending a shipment back to The Garrett Garage (or Honeywell) does not automatically give rise to a complete refund or credit. Honeywell Turbo Technologies may, at its sole discretion require different payment means for any shipment refused and then reshipped. It is the customer’s responsibility to make all arrangements with Honeywell Turbo Technologies for disposition of refused shipments. Shortage or Discrepancy Claim Shortage or Discrepancy claims must be reported within forty-eight (48) hours of receipt of goods to the distributor from which the goods were purchased. The Honeywell distributor will determine the best solution on how to address shortages or discrepancies. Limited Warranty Honeywell Turbo Technologies warrants to the original purchaser of its Turbocharger Products that such Turbocharger Products will, for a period of 1 year from date of shipment and subject to the Limitations on Warranty, be free from defects in materials and workmanship. For approved warranty claims Honeywell Turbo Technologies will, at its sole discretion, either credit the original purchaser in an amount equal to the original purchase price, or replace the applicable Turbocharger Product free of charge, within 60 days of Honeywell Turbo Technologies’ approval. This is purchaser’s sole and exclusive remedy and provides the complete financial responsibility of Honeywell Turbo Technologies for a warranty claim. To be eligible for reimbursement, Customer must (a) submit all warranty claims to Honeywell Turbo Technologies within 30 days of the discovery of the alleged Turbocharger Product defect; and (b) complete and return a Returned Material Authorization Form. Consumers are required to work through Honeywell’s distributors in order to process any warranty claims. When Honeywell Turbo Technologies requires the examination of a failed part, Honeywell Turbo Technologies will promptly notify Customer and will await receipt of the failed part before further processing the warranty claim. If Honeywell Turbo Technologies ultimately determines that the failed part is covered under the Limited Warranty, Honeywell Turbo Technologies will reimburse Customer for the actual cost of ground shipment for any part found to be defective.

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

IMPORTANT INFORMATION - PLEASE READ CAREFULLY Limitations on Warranty The Limited Warranty does not apply to any parts: (a) not used in accordance with Honeywell Turbo Technologies’ written instructions (b) for which no fault is found; (c) that have been modified in any manner not specifically approved by Honeywell Turbo Technologies; (d) for which an inspection indicates that reasonable and proper installation and/or preventative care and maintenance has not occurred; (e) that have been subject to damage attributable to or caused by misuse, abuse or vandalism; mishandling, improper shipping or other transit related damage; acts of god or insurrection; foreign object entry; any part not supplied by Honeywell Turbo Technologies; any repair, maintenance or service by anyone other than Honeywell Turbo Technologies; or any other acts that are beyond Honeywell Turbo Technologies’ reasonable control; or (f) attributable to parts not supplied by Honeywell Turbo Technologies. Honeywell Turbo Technologies expressly disclaims any and all warranties relative to the foregoing circumstances. Honeywell Turbo Technologies shall not be liable to Customer under any circumstances for any special, incidental or consequential damages, including without limitation, damage to or loss of property other than for Turbocharger Products; damages incurred in installation, repair or replacement; lost profits, revenue or opportunity; loss of use; losses resulting from or related to downtime of Turbocharger Products; the cost of replacement transportation, power, or compression; the cost of substitute products; or claims of third parties for such damages, howsoever caused, and whether based on warranty, contract, and/or tort (including negligence, strict liability or otherwise). The Limited Warranty is the only warranty made by Honeywell Turbo Technologies for any of its turbochargers and related parts and/or services, and is in lieu of and excludes all other warranties, expressed or implied, including warranties of merchantability or fitness for a particular purpose. Honeywell Turbo Technologies hereby disclaims all other warranties not expressly set forth. Some jurisdictions do not allow for the exclusion of implied warranties, so the above exclusions may not apply to you, however if implied warranties do apply they are limited to the original purchaser and for a period of one (1) year from the date of shipment. Diagnosing Your Vehicle Do not rely on diagnostic software without seeking the advice of an ASE certified mechanic. Diagnostic software should only be used as a general guideline to help you facilitate the repair of your car. If you experience or suspect any malfunction of vital safety equipment, such as your brakes, exhaust, motor, transmission, fuel delivery system, your car’s structural integrity or any other potentially life threatening malfunction, cease driving your vehicle immediately and seek professional help. Always consult your owner’s manual. Vehicle Modification Notice Any modifications to your car are AT YOUR OWN RISK. You should consult the owner’s manual and service manual. You should also contact your car’s manufacturer to determine what effects modifications may have on your safety, warranty, performance, etc. Please also contact your local authorities to determine whether your intended modifications will make your car illegal to drive on public roads. A vehicle modified by the use of competition parts may not meet the legal requirement for use on public roads. It is your responsibility to comply with federal, state, and local laws prior to driving your vehicle on public roads. Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

IMPORTANT INFORMATION - PLEASE READ CAREFULLY OTHER PRECAUTIONS Observe all safety precautions and warnings contained in the installation instructions. Wear eye and ear protection and appropriate protective clothing. When working under or around the vehicle support it securely with jack stands. Use only the proper tools. Exercise extreme caution when working with flammable, corrosive, and hazardous liquids and materials. LEGAL INFORMATION The Garrett turbo kits are for use off the public roadways. Federal law restricts the removal or modification of any part of a federally required emission control system on motor vehicles. Also, many states have enacted laws which prohibit tampering with or modifying emission or noise control systems. Vehicles which are not operated on public roadways may be exempt from certain regulations, however the buyer is strongly urged to check all applicable local and state laws and is ultimately responsible for compliance with the applicable laws and regulations. Contact Information for Questions Please contact the Honeywell distributor from which the equipment was purchased for any questions regarding this Shipping/Returns/Cancellation Policy, for notifications to Honeywell Turbo Technologies, and for instructions on processing damaged shipments and authorized returns.

Honeywell Turbo Technologies Garrett Independent Aftermarket Honeywell International Inc. 3201 W. Lomita Blvd. Torrance, CA 90505 www.TurboByGarrett.com Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 1. Prepare the work area. Since this installation requires handling turbocharger and exhaust components, the vehicle should be cold. A top-side creeper will be a very valuable to ease this job. Alternatively, rolled shop towels can provide some cushion when laying over the engine while working on the turbocharger and exhaust pipes. Have a shop light handy. 2. Raise the hood fully. Locate and disconnect the negative lead from both batteries.

Fig. 1

3. Raise the vehicle as per the manufacturer’s approved procedure. Failure to properly support the vehicle can result in serious injury or death. Remove the right front wheel/tire. Remove the right front fender inner liner. (Fig. 1) Fig. 2 4. Using a 7/16 deep socket, remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe. (Fig. 2)

5. If equipped with an automatic transmission, using a 13mm wrench, remove the transmission fluid fill tube to bell housing nuts. (Fig. 3)

Fig. 3 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 6. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission. 8. Using a 10mm socket, remove the left exhaust pipe heat shield bolts and insulators (4) . (Fig.4, one of four bolts shown)

9. 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.

Fig. 4

Important: Do not bend the exhaust pipe at the expansion area. 10. Using a 12mm 12-point socket, remove the left exhaust pipe to exhaust manifold bolts (3). (Fig. 5) 11. Remove and discard the gasket.

Fig. 5

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions Important: Do not bend the exhaust pipe at the expansion area. 12. Using a 12mm 12-point socket, remove the right exhaust pipe to exhaust manifold bolts (3). Using a 14mm socket, remove the downpipe support bracket bolt. (Fig. 6.) 13. Remove and discard the gasket. Fig. 6

14. Remove the lower bolt for the exhaust outlet shield.

15. Lower the vehicle.

16. Loosen the outlet duct clamp at the upper intake manifold cover. (Fig. 7)

Fig. 7

17. Remove the upper intake manifold cover from the outlet duct. 18. Pull the cover off of the pin at the rear of the the cover and remove upper intake manifold cover. 19. Drain the engine coolant. Refer to Manufacturer’s recommended procedure.

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 20. Loosen the inlet duct clamps at the turbocharger and the mass air flow/intake air temperature sensor (MAF/IAT) sensor. (Fig. 8) 21. Remove the inlet duct from the turbocharger and MAT/IAT sensor. Important: After removing the charge-aircooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of debris.

Fig. 8

22. Loosen both of the charge-air-cooler outlet duct to intake hose clamps. (Fig. 9) Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 23. Remove the hose from the charge-air-cooler duct to the intake manifold tube. 24. Loosen the clamp on the turbocharger compressor discharge hose. (Fig. 10)

Fig. 9

Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 25. Remove the compressor discharge hose from the turbocharger compressor.

Fig. 10

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 26. Disconnect the A/C compressor clutch electrical connector. (Fig. 11) 27. Disconnect the A/C Cut Out switch electrical connector. (Fig. 12) 28. Remove the drive belt as per the manufacturer’s approved procedure. 29. With a 15mm socket, remove the A/C compressor mounting bolts (4).

Fig. 11

30. Move the A/C compressor with the hoses attached to the right side of the engine compartment. 31. Disconnect the turbocharger outlet coolant hose from the coolant bypass valve (Fig. 13). Then remove the hose from the turbocharger water line. It will be reused in step 70.

Fig. 12

32. Disconnect the turbocharger inlet coolant hose from the turbocharger. This hose is located under the wastegate actuator on the passenger-side of the turbo. 33. Disconnect the PCV hose from the tube assembly. (Fig. 14) 34. Position the hose out of the way. Fig. 13

Fig. 14 Doc. 737639-26 (Rev - )

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2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Part Number: 766172-0001

Installation Instructions 35. Using a 10mm socket, remove the wire connector from the intake heater. (Fig. 15) ** For California Emissions Spec vehicle:, Remove wire connector from the elbow assembly pressure transducer (Red Arrow). Using a 14mm socket, loosen and remove two nuts holding the elbow assembly to the intake manifold cross over tube, and lift the elbow off of the studs and move out of the way. 36. If equipped, remove the intake air heater relay module mounting nuts and move the module away from the turbocharger. (Fig. 16)

Fig. 15

37. Using a 10mm socket, remove the 3 bolts holding the heat shield to the turbocharger. (Fig. 17) 36. Remove the turbocharger heat shield. 39. Remove the remaining 2 bolts for the exhaust outlet heat shield. 40. Remove the exhaust outlet heat shield.

Fig. 16

Fig. 17 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions

***Removing the bolts and nuts in the next few steps may be difficult. Use plenty of penetrating oil and be on your best behavior…***

41. Remove the 4 bolts (12mm 12-point socket) and the 2 nuts (17mm socket) for the exhaust outlet. (Fig. 18 & Fig. 19, turbo shown removed for clarity)

Fig. 18

42. Move the exhaust outlet aside in order to access the right exhaust pipe to turbocharger bolts.

43. Remove and discard the exhaust outlet gasket. Fig. 19 44. Using a 12mm 12-point socket, remove the right exhaust pipe to turbocharger bolts (3). (Fig. 20) 45. Separate the right exhaust pipe from the turbine housing, being careful not to bend the pipe at the EGR expansion area, if equipped. 46. Remove and discard the gasket.

Fig. 20 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 47. Move the exhaust outlet to one side in order to access the left exhaust pipe. 48 Remove the left exhaust pipe heat shield from the vehicle 49. Using a 12mm 12-point socket, remove the left exhaust pipe to turbocharger bolts (3). (Fig. 21) 50. Remove the left exhaust pipe. 51. Remove and discard the gasket.

Fig. 21 52. Using a 14mm socket, remove the turbocharger oil supply hose banjo bolt, and washers. (Fig. 22) Discard the used washers but save the banjo bolt as it will be reused in step 83. 53. Move the oil supply hose out of the way.

Fig. 22

54. Using a 12mm socket, remove the turbocharger oil drain pipe nuts at the flywheel housing. (Fig. 23)

Fig. 23 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 55. Using a 17mm socket, remove the three turbocharger mounting bolts. (Fig. 24 & Fig. 25) It is helpful to use a “wobble” extension to get the socket to fit on the bolt head. 56. Remove the turbocharger and oil drain pipe as an assembly. Be careful to not let any dirt or debris drop into the oil drain passage. 57. Remove the exhaust outlet pipe from the top. Fig. 24

Fig. 25 58. Remove the oil feed line from the top of the block by removing the banjo bolt. (Fig 26)

Fig. 26

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 59. Using a 12mm socket, remove the oil drain line bolts and remove the oil drain line from the stock turbocharger (Fig. 27). Clean any gasket material from both oil drain line flanges on the oil drain line. 60. Using a 12mm socket, remove the top clamp plate/pin assembly from the stock turbo, keeping the clamp and bolt. Remove the adjacent clamp plate and bolt, keeping the clamp plate and setting aside the bolt. (Fig. 28)

Fig. 27

61. Set the stock turbo aside, as it will no longer be used. Now comes the preparation of the Garrett PowerMax turbo for installation into the vehicle. Be very careful not to let any foreign objects enter into any of the turbo passageways or foul any blades on the compressor or turbine wheels. 61. Using a 13mm socket, remove the top clamp bolt on the Garrett PowerMax turbo (Fig 29). Using a 12mm socket, install the top clamp/pin assembly and bolt from the stock turbo (Fig 30). Tighten the bolt to 13.5 N.m(120 lb-in). 62. Remove the wastegate actuator assembly from the turbo by removing the hose from the actuator nipple and applying 30psi to the actuator. Remove the circlip and lift the rod end off of the pin. Release pressure slowly to prevent actuator damage. Using a 8mm 12-point socket, remove the two bolts holding the bracket to the turbine housing, and set the actuator aside. It will be reinstalled later in steps 79 and 80.

Fig. 28

Fig. 29

Fig. 30 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions

64. Using a 13mm socket, remove the lower two bolts and clamp plate from the Garrett PowerMax turbo (Fig. 31). Install the single clamp plate removed from the stock turbo onto the Garrett PowerMax turbo as shown and torque to 13.5 N.m(120 lb-in). (Fig. 32) Fig. 31 The other hole will be left open for this application.

65. From the PN 765562-1 Turbine Inlet Kit, find the Turbine Inlet Adapter, Turbine Inlet Gasket, and (4) M10x1.5-25 Bolts. Install the Garrett PowerMax turbo to the Turbine Inlet Adapter using the supplied Turbine Inlet Gasket and (4) M10x1.525 bolts (Fig 36). With a 16mm wrench, tighten all 4 bolts to 75Nm/55ft-lb. **The Powermax Turbine Inlet Adapter has two bosses that have been placed on the casting to allow for installation of a pre-turbo pyrometer for measuring Exhaust Gas Temperature. If you want to use these, simply drill and tap the casting to fit the pyrometer of your choice prior to mounting it to the turbocharger** 66. From the PN 765564-1 Oil Line Kit, find the Oil Inlet Fitting, O-ring, and (2) M8x1.25-20 bolts. With an 8mm 12-point socket, install the Oil Inlet Fitting to the center housing oil inlet flange with the O-ring and Bolts. Ensure that the o-ring is properly seated in the groove on the underside of the fitting. Tighten the bolts to 23Nm(17 lb ft).

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Fig. 32

Fig. 36

Fig. 37

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 67. From the 765564-1 Oil Line Kit, find the Oil Feed Hose and (2) Copper Crush Washers. Install the new oil feed hose to the block. Reuse the existing banjo bolt with the supplied new copper crush washers. With a 14mm socket, tighten the turbocharger oil supply hose banjo bolt to 34 N.m (25 lb ft). (Fig. 38)

Fig. 38

68. From the 765564-1 Oil Line Kit, find the Oil Outlet Adapter,(2) Oil Outlet Gaskets, and (2) M8x1.25-45 bolts. Install the oil drain line to the upgrade turbo using the supplied adapter, 2 gaskets, and bolts. Be sure to use the supplied gaskets between the drain line flange and the adapter, and between the adapter and the turbo oil outlet. With a 13mm socket, tighten the oil drain pipe bolts to 21 N~m (190lb-in). (Fig. 39). Due to the close fit, some trimming of the gasket or grinding of the adapter and oil drain flange may be necessary to keep these parts from contacting the turbocharger backplate.

69. From the 765565-1 Water Line Kit, Find the Driver’s-side Water Line, M14 Banjo Bolt, and (2) Crush Washers. Install the Driver’s-side Water Line Banjo to the center housing, using the supplied Banjo Bolt and 2 Crush Washers. (Fig. 40) Using a 10mm Bolt hex socket, tighten the Banjo Bolt to 40 N.m (30 lb ft).

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Gaskets

Fig. 39 Driver’s side waterline

Crush Washers Fig. 40

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 70. Install the Rubber coolant line removed from the stock turbo in step 31 onto the coolant pipe as shown. (Fig. 40)

Fig. 40 71. From the 765561-1 Compressor Inlet Kit, Find the Compressor Inlet Adapter, Compressor Inlet Adapter Gasket, and (3) M6x1-20 bolts. Install the compressor inlet elbow onto the compressor inlet using the supplied gasket and (3) M6x1-20 bolts. Be sure to orient as shown. Mount the wastegate hose positioning clamp on the top bolt. Using an 8mm socket, tighten bolts to 3.4 N-m (30 lbf-in). (Fig. 41) 72. Clean the following gasket surfaces: All exhaust pipe flanges Both exhaust manifold flanges

Fig. 41

73. Verify that the turbocharger lower heat shield is properly positioned on the engine block. (Fig. 42)

Fig. 42

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions

74. From the 765564-1 Exhaust Outlet Kit, Find the Exhaust Elbow, the Heat Shield, and (3) M6x1-10 Bolts. Install the Exhaust Elbow Heat Shield onto the Exhaust Elbow with the supplied M6x1-10 Bolts. With an 8mm socket, tighten bolts to 3.4 Nm (30 lbf-in). (Fig. 43) 75. From the passenger-side wheel well, slip the Exhaust Elbow assembly into place between the engine and firewall. Leave it loose for now.

75. From the 765565-1 Water Line Kit, Find the Passenger-side Water Line. Insert the Passengerside Water Line into the rubber coolant inlet hose just above the passenger-side valve cover. Do not put clamp into place yet. Rotate the line up to keep it out of the way during turbocharger installation. (Fig. 44)

Fig. 43 Passenger side waterline

Clamp Fig. 44

76. Fit the turbocharger in place on the engine, making sure that the oil drain flange fits over the studs for the mating flange on the back of the block.

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 77. Install the three turbocharger mounting bolts. Using a 17 mm socket, tighten the turbocharger mounting bolts to 108 N-m (80 lb ft ). A wobble extension or socket will be extremely helpful in tightening these bolts. 78. From the 765565-1 Water Line Kit, Find the remaining M18 Banjo Bolt and (2) Crush Washers. Rotate the Passenger-side water line from step 75 down to meet the port on the center housing. Connect the line to the center housing using the supplied M18 Banjo Bolt and Crush Washers. Using a 10mm hex socket, torque the banjo bolt to 40 Nm (30 lb ft). Install the clamp onto the waterline that was left loose in step 75. (Fig. 45)

Fig. 45

79. Re-install the wastegate actuator onto the turbocharger. Note: The turbocharger comes with the actuator pre-calibrated for stock boost level. The actuator can be adjusted to achieve higher boost and each half turn will raise boost by approximately 1.5 psi. Increased boost places additional stress on the entire drivetrain. Excessive boost will lead to overspeed of the turbocharger, which is not covered by any warranty. Refer to spec sheet for maximum boost recommendations.

Fig. 46

Place the rod end over the wastegate lever pin and position the actuator in place. Apply 30-35 psi to the actuator nipple to extend the actuator. Bolt the actuator to the turbine housing using the bolts removed in step 62 and using an 8mm 12-point socket, torque to 23 N-m (17 ft lb). (Fig. 46) 80. Install the retaining clip onto the wastegate lever pin. (Fig. 47). Release pressure on the actuator. Replace the boost hose and clamp. Doc. 737639-26 (Rev - )

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Fig. 47

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 81. Install the oil drain pipe nuts. With a 12mm socket, tighten to 21 N-m (15 ft lb). (Fig. 48)

82. Pre-lube the turbocharger by pouring about 4-5 oz of clean oil into the oil inlet fitting.

Fig. 48

83. From the 765564-1 Oil Line Kit, Find the remaining (2) Crush Washers. Position the Oil Inlet Line over the Oil Inlet Adapter on the turbocharger and install the stock banjo bolt removed in step 52. and new Crush Washers. Using a 14mm socket, tighten the oil inlet banjo bolt to 34 N-m (25 lb ft). (Fig. 49) Be sure to position the line so that it does not rub on any other surface or component. 84. *** For California Emissions Spec vehicles: Using a NEW gasket, install the elbow assembly onto the intake manifold cross over tube studs. Using a 14mm socket, install the nuts and tighten to 10 N-m (89 in lb). Re-install wire connector to the elbow assembly pressure transducer.***

Fig. 49

85. Position the left exhaust pipe. 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. With a 12mm 12-point socket, tighten the left exhaust pipe to turbocharger bolts to 53 N.m (39 lb ft). (Fig. 50) 86. Position the left exhaust pipe heat shield, but do not install the bolts. Fig. 50 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 87. Install the right exhaust pipe, with a 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. Install the right exhaust pipe to turbocharger. With a 12mm 12-point socket, tighten the right exhaust pipe to turbocharger bolts to 53 N m (39 lb ft). (Fig. 51) Fig. 51

88. From the 765563-1 Exhaust Outlet Kit, Find the V-band Clamp and V-band Clamp Nut. Place the Vband Clamp over the exhaust outlet pipe. Install the Exhaust Elbow to the turbocharger, and fit the V-band clamp over the flange. Install the V-band clamp nut and tighten snugly but not fully tight. (Fig. 52) Fig. 52

89. Connect the PCV hose to the tube assembly. (Fig. 53)

Fig. 53

90. Connect the turbocharger inlet coolant hose to the turbocharger coolant bypass valve. (Fig. 54) Fig. 54 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 91. Install the inlet air heater relay. Using a 13mm socket, torque the nuts to 21 N-m (15 ft lb). (Fig. 55)

Fig. 55

92. Connect the wire terminal and the nut to intake air heater. Using a 10mm socket, tighten the intake air heater nut to 4 N.m (35 lb in). Connect the wire connector to the intake manifold pressure sensor. (Fig 56)

Fig. 56 93. Position the A/C compressor. 94. Install the A/C compressor mounting bolts (Fig 57, yellow arrow). With a 15mm socket, tighten the A/C compressor mounting bolts to 50 N.m (37 lb ft). Connect the A/C cut out switch electrical connector and A/C clutch electrical connector. (Fig 57, red arrows) 95. Install the drive belt. Refer to Drive Belt routing diagram on the plastic cowl under the hood.

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Fig. 57

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 96. Install the charge air hose to the compressor discharge. Position the clamp as shown for proper clearance. Using a 7/16” deep socket, tighten the clamp to 6 N m (53 lb in). (Fig. 58) 97. Install the charge air cooler outlet hose to the intake manifold tube. The hose is marked DUCT which connects to the charge air cooler outlet duct. The hose is marked ENG which connects to the Intake manifold. Align the marks on the hose with the alignment marks on the pipe and tube. Position the clamps as shown for proper clearance Using a 7/16” deep socket, tighten the clamps to 6 N m (53 lb in). (Fig. 59)

Fig. 58

Important: The outlet duct must be fully seated against the positive stop feature on the inlet. 99. If using an aftermarket intake system, install it now as per the manufacturers instruction. Skip to step 103.

Fig. 59

100.If using the stock air filter setup, install the air inlet duct to the turbocharger on one end and the MAF/IAT sensor/airbox at the other end. (Fig. 47) Install the upper intake manifold cover over the pin on the turbo and insert the hose connection into the inlet duct. Important: The outlet duct must be fully seated against the MAF/IAT sensor with the edge of the seal in the vertical position.

Fig. 60

Tighten the outlet duct clamps at the turbocharger, MAF/IAT sensor, and cover. Using an 8mm socket, tighten the clamps to 6 N m (53 lb in). (Fig. 60 & 61)

Fig. 61 Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions

101. Raise the vehicle. 102. Install the right exhaust pipe with a NEW gasket to exhaust manifold. Align the tab on the exhaust pipe gasket facing outward. 103. Install the right exhaust pipe bolts. Using a 12mm 12-point socket, tighten the exhaust pipe to exhaust manifold bolts to 53 N m (39 lb ft). (Fig. 62)

Fig. 62

104. Install the left exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the exhaust pipe gasket facing outward. 105. Install the left exhaust pipe bolts. Using a 12mm 12-point socket, tighten the exhaust pipe to exhaust manifold bolts to 53 N.m (39 lb ft). (Fig. 63) 106. Position the left exhaust pipe heat shield.

Fig. 63

107. Install the left exhaust pipe heat shield bolts. Using a 10mm socket, tighten the left exhaust pipe heat shield bolt to 8 N-m (71 lb in). (Fig. 64, 1 of 4 bolts shown)

Fig. 64

Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 108. If equipped position the transmission fluid fill tube. Align the tube to be centered in the relief in the exhaust down pipe. 109. Install the transmission fluid fill tube nuts. Using a 13mm socket, tighten the transmission fluid fill tube nuts to 18 N.m (13 lb in). (Fig. 65)

Fig. 65 110. Install the Exhaust Elbow outlet to exhaust pipe clamp. 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). (Fig. 66)

Fig. 66 111. From the 765563-1 Exhaust Outlet Kit, Find the Exhaust Elbow Bracket, M8x1.25-20 12-point Bolt, and Washer . Install the Exhaust Elbow Bracket between the Exhaust Elbow and exhaust manifold bracket using bolt removed in step 12, and the bolt and washer from the kit. Using a 14mm socket, tighten the manifold bolt to 53Nm (39 lb ft). With an 8mm 12-point socket, tighten the downpipe bolt to 23Nm (17 lb ft). Re-install the plastic fender liner and replace the right front tire/wheel assembly. Torque lug nuts to 190Nm (140 lb ft)

Fig. 67

112. Lower the vehicle. Doc. 737639-26 (Rev - )

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Part Number: 766172-0001

2001-2004 Chevrolet / GMC 6.6 (Silverado/Sierra Duramax LB7 Diesel

Installation Instructions 113. Tighten the turbine housing outlet/downpipe v-band nut to 13 Nm (10 lb ft). (Fig 68)

Fig. 68 114. Fill the cooling system according to the factory service manual. Verify that the engine oil level is correct. 115. Connect both battery negative cables. Refer to the owners manual. 116. Now retrace your steps to verify that everything has been re-installed, re-tightened, or re-connected and that there are no loose wires, hoses, or fasteners. Make sure you have retrieved all rags, tools, etc. from the work area. DO NOT OPERATE the engine without all inlet ducting in place

117. Start the vehicle and allow it to idle until the engine is at operating temperature. Check for leaks or any abnormal noises or operation. 118. Once it is confirmed that there are no issues, you are ready to enjoy your new PowerMax turbocharger upgrade kit!

Honeywell Turbo Technologies Garrett Independent Aftermarket Honeywell International Inc. 3201 W. Lomita Blvd. Torrance, CA 90505 www.TurboByGarrett.com

Doc. 737639-26 (Rev - )

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