Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Loosen the outlet duct clamp at the upper intake manifold cover.
Remove the upper intake manifold cover from the outlet duct.
Remove the upper intake manifold cover.
Drain the cooling system. Refer to Draining and Filling Cooling System .

Fig 1: Remove Upper Intake Manifold Cover
Courtesy of GENERAL MOTORS CORP.
Remove the radiator inlet hose from the water outlet tube.

Fig 2: Remove Radiator Inlet Hose
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Remove the bolt and wiring harness bracket at the thermostat housing.

Fig 3: Remove Bolt & Wiring Harness Bracket
Courtesy of GENERAL MOTORS CORP.
Disconnect the turbocharger coolant return hose from the turbocharger bypass valve.

Fig 4: Disconnect Turbocharger Coolant Return Hose
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Remove the turbocharger bypass valve and sealing washer from the water outlet tube.

Fig 5: Remove Turbocharger Bypass Valve & Sealing Washer
Courtesy of GENERAL MOTORS CORP.
Remove the water outlet bolts.
Remove the water outlet.
Remove and discard the O-ring seal.

Fig 6: Remove Water Outlet, Bolts & O-Ring Seal
Courtesy of GENERAL MOTORS CORP.