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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1028 (Engine Exhaust System) >> Repair Instructions >> Turbocharger Exhaust Pipe Replacement (6.6L (LLY) Engine) >> Removal Procedure

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.
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Loosen the exhaust manifold pipe clamp.
    Fig 1: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  3. Slide the exhaust pipe clamp up onto the exhaust pipe.
    4. Fig 2: Exhaust Muffler Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM694338Courtesy of GENERAL MOTORS CORP.
  4. Remove the exhaust muffler nuts.
    5. Fig 3: Exhaust Manifold Pipe Hanger And Insulator (6.0L, 6.6L, and 8.1L Engines)
    GM694896Courtesy of GENERAL MOTORS CORP.
  5. Slide the exhaust manifold pipe hanger out from the insulator.
  6. Remove the exhaust manifold pipe.
    7. Fig 4: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  7. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
  8. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  9. Lower the vehicle.
    10. Fig 5: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  10. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
  11. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
    12. Fig 6: Turbocharger Upper Heat Shield (6.6L (LLY) Engine)
    GM1335576Courtesy of GENERAL MOTORS CORP.
  12. Remove the turbocharger upper heat shield bolts.
  13. Remove the turbocharger upper heat shield.
    14. Fig 7: Exhaust Outlet Heat Shield (6.6L (LLY) Engine)
    GM1334821Courtesy of GENERAL MOTORS CORP.
  14. Remove the exhaust outlet heat shield bolts.
  15. Remove the exhaust outlet heat shield.
  16. Remove the exhaust outlet to right exhaust pipe bracket bolt.
    17. Fig 8: Exhaust Outlet Pipe Clamp (6.6L (LLY) Engine)
    GM1334826Courtesy of GENERAL MOTORS CORP.
  17. Loosen the exhaust outlet pipe clamp.
    18. Fig 9: Exhaust Outlet Pipe (6.6L (LLY) Engine)
    GM1341232Courtesy of GENERAL MOTORS CORP.
  18. Remove the exhaust outlet pipe.
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