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 .
Disconnect the negative battery cables. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) or BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY) .

Fig 1: Remove Upper Intake Manifold Cover
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: After removing the turbocharger air ducts, cover the openings with tape to prevent entry of objects.
Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
Remove the outlet duct.

Fig 2: Remove Outlet Duct
Courtesy of GENERAL MOTORS CORP.
Loosen the charged air cooler outlet duct to intake hose clamp (1).
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
Remove the charged air cooler duct from the intake.

Fig 3: Remove Charged Air Cooler Duct
Courtesy of GENERAL MOTORS CORP.
Remove the generator positive cable nut.
Remove the positive cable from the generator.

Fig 4: Remove Positive Cable & Nut
Courtesy of GENERAL MOTORS CORP.
Disconnect the generator electrical connector (1).

Fig 5: Disconnect Generator Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Remove the ribbed idler pulley from the generator bracket.
Remove the generator bracket and position to the side.
- The generator does not require removal.
- The drive belt tensioner does not require removal.
Fig 6: Remove Ribbed Idler Pulley
Courtesy of GENERAL MOTORS CORP.
Disconnect the fuel injection control module electrical connectors (2).

Fig 7: Disconnect Fuel Injection Control Module Electrical Connectors
Courtesy of GENERAL MOTORS CORP.
Remove the fuel line bolts.
Remove the fuel lines (2) from the fuel injection control module.

Fig 8: Remove Fuel Lines
Courtesy of GENERAL MOTORS CORP.
Using J 43181, disconnect the inlet heater hose from the heater core inlet.
Remove the fuel injection control module wiring harness conduit from the heater pipe.

Fig 9: Disconnect Inlet Heater Hose Using J 43181
Courtesy of GENERAL MOTORS CORP.
Remove the heater inlet pipe to fuel filter bolt.
Remove the heater inlet pipe to thermostat housing bolt.
Remove the heater inlet pipe with O-ring seal from the thermostat housing.

Fig 10: Remove Heater Inlet Pipe To Thermostat Housing Bolt
Courtesy of GENERAL MOTORS CORP.
Remove the turbocharger coolant feed pipe bracket bolts.
Remove the turbocharger coolant return hose clamps and hose.

Fig 11: Remove Turbocharger Coolant Feed Pipe Bracket Bolts, Return Hose Clamps & Hose
Courtesy of GENERAL MOTORS CORP.
Disconnect the turbocharger coolant feed hose from the turbocharger.

Fig 12: Disconnect Turbocharger Coolant Feed Hose
Courtesy of GENERAL MOTORS CORP.
Remove the turbocharger coolant feed pipe nut.
Remove the coolant feed pipe.

Fig 13: Remove Turbocharger Coolant Feed Pipe & Nut
Courtesy of GENERAL MOTORS CORP.
Disconnect the turbocharger coolant return hose from the turbocharger coolant bypass valve.
Disconnect the turbocharger coolant return hose from the turbocharger.

Fig 14: Disconnect Turbocharger Coolant Return Hose
Courtesy of GENERAL MOTORS CORP.