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.

Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
Loosen the exhaust manifold pipe clamp.
Slide the exhaust pipe clamp up onto the exhaust pipe.

Fig 1: Loosening Exhaust Manifold Pipe Clamp (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the exhaust muffler nuts.

Fig 2: Removing Exhaust Muffler Nuts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Slide the exhaust manifold pipe hanger from the insulator.
Remove the exhaust manifold pipe from the vehicle.

Fig 3: Removing Exhaust Manifold Pipe (6.6L)
Courtesy of GENERAL MOTORS CORP.
If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.

Fig 4: Removing Transmission Fluid Fill Tube To Bellhousing Nuts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the right exhaust pipe to exhaust manifold (1) bolts.

Fig 5: Removing Right Exhaust Pipe To Exhaust Manifold Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the lower bolt (2) retaining the heat shield to the exhaust outlet.
Lower the vehicle.

Fig 6: Removing Heat Shield To Exhaust Outlet Lower Bolt (6.6L)
Courtesy of GENERAL MOTORS CORP.
Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).

Fig 7: Moving Hood Hinge Bolts To Service Position (6.6L)
Courtesy of GENERAL MOTORS CORP.
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.

Fig 8: Removing Upper Intake Manifold Cover (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the heat shield to turbocharger bolts.
Remove the turbocharger heat shield.

Fig 9: Removing Turbocharger Heat Shield & Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the remaining bolts (1, 3) for the exhaust outlet heat shield.
Remove the exhaust outlet heat shield.

Fig 10: Removing Exhaust Outlet Heat Shield Remaining Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the turbocharger exhaust pipe bolts/nuts.
Remove the turbocharger exhaust pipe and gasket from the turbocharger.
Position the turbocharger exhaust pipe to the side in order to access the right exhaust pipe to turbocharger bolts.
The turbocharger exhaust pipe cannot be removed until the right exhaust pipe is removed.

Fig 11: Removing Turbocharger Exhaust Pipe Bolt & Nut (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the right exhaust pipe to turbocharger bolts (2).
Remove the right exhaust pipe and gaskets.

Fig 12: Removing Right Exhaust Pipe, Gasket & Bolts (6.6L)
Courtesy of GENERAL MOTORS CORP.
Remove the turbocharger exhaust pipe out the bottom of the vehicle.

Fig 13: Removing Turbocharger Exhaust Pipe (6.6L)
Courtesy of GENERAL MOTORS CORP.