Chevrolet / GMC Silverado Diesel 6.6 2001-2004 PowerMax Diesel Upgrade For Duramax Engines PDF Manual

1. Prepare the work area. Since this installation requires handling turbocharger and exhaust components, the vehicle should be cold. A top-side
creeper will be a very valuable to ease this job. Alternatively, rolled shop towels can provide some cushion when laying over the engine while working on the turbocharger and exhaust pipes. Have a shop light handy.
2. Raise the hood fully. Locate and disconnect the negative lead from both batteries.
3. Raise the vehicle as per the manufacturer’s approved procedure. Failure to properly support the vehicle can result in serious injury or death. Remove the right front wheel/tire. Remove the right front fender inner liner. (Fig. 1)
4. Using a 7/16 deep socket, remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
5. If equipped with an automatic transmission, using a 13mm wrench, remove the transmission fluid fill tube to bell housing nuts. (Fig. 3)
6. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
8. Using a 10mm socket, remove the left exhaust pipe heat shield bolts and insulators (4) . (Fig.4, one of four bolts shown)
9. Position the left exhaust pipe heat shield in order to access the left exhaust pipe to exhaust manifold bolts. Do not remove the heat shield from the vehicle at this time. Important: Do not bend the exhaust pipe at the expansion area.
10. Using a 12mm 12-point socket, remove the left exhaust pipe to exhaust manifold bolts (3). (Fig. 5)
11. Remove and discard the gasket. Important: Do not bend the exhaust pipe at the expansion area.
12. Using a 12mm 12-point socket, remove the right exhaust pipe to exhaust manifold bolts (3). Using a 14mm socket, remove the downpipe support bracket bolt. (Fig. 6.)
13. Remove and discard the gasket.
14. Remove the lower bolt for the exhaust outlet shield.
15. Lower the vehicle.
16. Loosen the outlet duct clamp at the upper intake manifold cover. (Fig. 7)
17. Remove the upper intake manifold cover from the outlet duct.
18. Pull the cover off of the pin at the rear of the the cover and remove upper intake manifold cover.
19. Drain the engine coolant. Refer to Manufacturer’s recommended procedure.
20. Loosen the inlet duct clamps at the turbocharger and the mass air flow/intake air temperature sensor (MAF/IAT) sensor. (Fig.
21. Remove the inlet duct from the turbocharger and MAT/IAT sensor.
Important: After removing the charge-air-cooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of debris.
22. Loosen both of the charge-air-cooler outlet duct to intake hose clamps. (Fig. 9)
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
23. Remove the hose from the charge-air-cooler duct to the intake manifold tube.
24. Loosen the clamp on the turbocharger compressor discharge hose. (Fig. 10) Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
25. Remove the compressor discharge hose from the turbocharger compressor.
26. Disconnect the A/C compressor clutch electrical connector. (Fig. 11)
27. Disconnect the A/C Cut Out switch electrical connector. (Fig. 12)
28. Remove the drive belt as per the manufacturer’s approved procedure.
29. With a 15mm socket, remove the A/C compressor mounting bolts (4).
30. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
31. Disconnect the turbocharger outlet coolant hose from the coolant bypass valve (Fig. 13). Then remove the hose from the turbocharger water line. It will be reused in step 70.
32. Disconnect the turbocharger inlet coolant hose from the turbocharger. This hose is located under the wastegate actuator on the passenger-side of the turbo.
33. Disconnect the PCV hose from the tube assembly. (Fig. 14)
34. Position the hose out of the way.