Removal Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
- Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
- Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
- Loosen the charged air cooler outlet duct clamp (1).IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
- Remove the charged air cooler outlet duct.
- Loosen the charged air cooler inlet duct to turbocharger clamp (1).IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
- Remove the charged air cooler inlet duct from the turbocharger.
- Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
- Remove the glow plug relay. Refer to Glow Plug Relay Replacement (Federal Emissions) or Glow Plug Relay Replacement (California Emissions) .
- Remove the fuel rail feed pipe from junction block.
- Remove the fuel rail feed pipe from right fuel rail.