Installation 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.

From under the vehicle, position the turbocharger exhaust pipe to rear of the engine Do not install the pipe to the turbocharger.

Fig 1: Positioning Turbocharger Exhaust Pipe (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the right exhaust pipe with NEW gasket to the turbocharger. Align the tabs on the gasket to face inward.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the exhaust pipe to turbocharger bolts (2).
Tighten

Tighten the bolts to 53 N.m (39 lb ft).

Fig 2: Installing Exhaust Pipe, Gasket & Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger exhaust pipe with a NEW gasket to the turbocharger.
Install the turbocharger exhaust pipe bolts/nuts.
Tighten

Tighten the bolts/nuts to 53 N.m (39 lb ft).

Fig 3: Installing Turbocharger Exhaust Pipe Bolt & Nut (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger exhaust pipe heat shield.
Install the upper turbocharger exhaust pipe heat shield bolts (1, 3).
Tighten

Tighten the bolts to 8 N.m (71 lb in).

Fig 4: Installing Upper Turbocharger Exhaust Pipe Heat Shield Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the turbocharger heat shield.
Install the turbocharger heat shield bolts.
Tighten

Tighten the bolts to 9 N.m (80 lb in).

Fig 5: Installing Turbocharger Heat Shield & Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Raise the vehicle.
Install the lower turbocharger exhaust pipe heat shield bolt (2).
Tighten

Tighten the bolt to 8 N.m (71 lb in).

Fig 6: Installing Lower Turbocharger Exhaust Pipe Heat Shield Bolt (6.6L)
Courtesy of GENERAL MOTORS CORP.
If equipped with an automatic transmission, install the transmission fluid fill tube to bell housing nuts.
Tighten

Tighten the nuts 18 N.m (13 lb ft).

Fig 7: Installing Transmission Fluid Fill Tube To Bell Housing Nuts (6.6L)
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Install the right exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward as shown.
Install the right exhaust pipe to exhaust manifold bolts (1).
Tighten

Tighten the bolts to 53 N.m (39 lb ft).

Fig 8: Installing Right Exhaust Pipe, Gasket & Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the exhaust manifold pipe hanger in the insulator.

Fig 9: Installing Exhaust Manifold Pipe Hanger (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the exhaust muffler to the exhaust manifold pipe.
Install the exhaust muffler nuts until snug.

Fig 10: Installing Exhaust Muffler & Nuts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Slide the exhaust pipe clamp down and around the pipe connection.
Tighten the exhaust pipe clamp.
Tighten
- Tighten the clamp to 40 N.m (30 lb ft).
- Tighten the nuts to 40 N.m (30 lb ft).
Lower the vehicle.

Fig 11: Tightening Exhaust Pipe Clamp (6.6L)
Courtesy of GENERAL MOTORS CORP.
Install the upper intake manifold sight shield.
Install the upper intake manifold cover to the outlet duct.
Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten

Tighten the clamp to 6 N.m (53 lb in).

Fig 12: Installing Upper Intake Manifold Cover (6.6L)
Courtesy of GENERAL MOTORS CORP.
Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).
Tighten

Tighten the bolts to 25 N.m (18 lb ft).
Inspect for exhaust leaks.

Fig 13: Moving Hood Hinge Bolts From Service Position (6.6L)
Courtesy of GENERAL MOTORS CORP.