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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. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
    2. Fig 1: View of Generator Harness, Clip, A/C Refrigerant Switch, Dual Generator Harness Connector & A/C Compressor Clutch
    GM674573Courtesy of GENERAL MOTORS CORP.
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  3. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  4. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74)  or Fan Shroud Replacement - Upper (W/M74) .
  5. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L (LLY).
  6. Disconnect the air conditioning (A/C) compressor clutch electrical connector (5).
  7. Disconnect the A/C cut out switch electrical connector.
  8. Remove the A/C compressor bolts.
  9. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.
    10. Fig 2: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  10. Remove the generator positive cable to generator nut.
  11. Remove the positive cable from the generator.
  12. Remove the clip holding the positive cable to the engine front cover.
  13. Remove the battery positive cable junction block to power steering pump bolt (1).
    14. Fig 3: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  14. Move the generator positive cable and the junction block bracket aside.
  15. Disconnect the generator electrical connector.
  16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    17. Fig 4: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  17. Remove the power steering pump bracket bolts.
  18. Reposition the power steering pump bracket and secure to the side.
    • Do not remove the power steering pump from the bracket.
    • The hoses and battery cables can remain on the power steering pump.
    19. Fig 5: View Of A/C Compressor & Power Steering Pump Bracket
    GM1334867Courtesy of GENERAL MOTORS CORP.
  19. Remove the heater outlet hose bracket bolt from the generator bracket.
  20. Remove the idler pulley.
  21. Remove the generator bracket bolts.
    22. Fig 6: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  22. Remove the generator bracket and position to the side.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
  23. Remove the oil fill tube. Refer to Oil Fill Tube Replacement in Engine Mechanical - 6.6L (LLY).
  24. Remove the water outlet. Refer to Water Outlet Tube Replacement (6.6L (LLY) Engine) .
  25. Reposition the exhaust gas recirculation (EGR) hose clamp at the EGR coolant pipe.
  26. Remove the EGR coolant pipe bolt.
  27. Remove the EGR coolant pipe with O-ring seal from the crossover.
    28. Fig 7: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
    GM1335419Courtesy of GENERAL MOTORS CORP.
  28. Reposition the turbocharger coolant return pipe hose clamp.
  29. Remove the turbocharger coolant return pipe hose.
    30. Fig 8: View Of Turbocharger Coolant Outlet Hose & Clamps
    GM1335429Courtesy of GENERAL MOTORS CORP.
  30. Remove the fuel line bracket bolt at the thermostat housing crossover.
    31. Fig 9: View Of Fuel Pipe Bracket Bolt
    GM1335434Courtesy of GENERAL MOTORS CORP.
  31. Remove the cooling fan pulley. Refer to Cooling Fan Pulley Replacement (6.6L (LLY) Engine) .
  32. Remove the water pump inlet pipe bolts.
    33. Fig 10: View Of Water Pump Inlet Pipe Bolts
    GM1335424Courtesy of GENERAL MOTORS CORP.
  33. Remove the thermostat housing bolts and nuts.
  34. Remove the thermostat housing, with the bypass pipe.
  35. Remove and discard the thermostat bypass pipe to water pump O-ring seal.
  36. Remove and discard the thermostat housing gaskets.
    37. Fig 11: View Of Thermostat Housing
    GM1335441Courtesy of GENERAL MOTORS CORP.
  37. If necessary, perform the following steps:
    1. Remove the thermostat bypass pipe from the thermostat housing.
    2. Remove and discard the thermostat bypass pipe O-ring seal.
    3. Remove the thermostat cover bolts and cover.
    4. Remove the thermostats.
    5. Remove and discard the thermostat seals.
  38. If required, clean and inspect the thermostat housing. Refer to Thermostat Housing Cleaning and Inspection in Engine Mechanical - 6.6L (LLY).
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