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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. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  3. Remove the radiator inlet hose from the water outlet tube.
    4. Fig 1: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  4. Open the clip and remove the wiring harness branch from the bracket.
  5. Remove the bolt and wiring harness bracket at the thermostat housing.
    6. Fig 2: View Of Wiring Harness Bracket At Thermostat Housing
    GM1335388Courtesy of GENERAL MOTORS CORP.
  6. Remove the main engine electrical harness connector bolts.
    7. Fig 3: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the barometric sensor electrical connector.
    8. Fig 4: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the turbocharger vane position sensor electrical connector.
    9. Fig 5: View Of Turbocharger Vane Position Sensor And Electrical Connector
    GM1334926Courtesy of GENERAL MOTORS CORP.
  9. Remove the main electrical harness bracket bolts.
  10. Remove the main electrical harness bracket.
    11. Fig 6: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.
    12. Fig 7: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
  12. Remove the water outlet bolts.
    13. Fig 8: View Of Water Outlet & Bolt
    GM1335391Courtesy of GENERAL MOTORS CORP.
  13. Remove the water outlet.
    14. Fig 9: View Of Water Outlet Removed
    GM1335393Courtesy of GENERAL MOTORS CORP.
  14. Remove and discard the O-ring seal.
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