GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Boost Sensor Replacement

Removal Procedure
  1. Turn OFF the ignition.
  2. Remove the air cleaner layer. Refer to Air Cleaner Replacement .

    3. Object Number: 740438 Size: SH
  3. Disconnect the electrical connector (2) from the boost pressure sensor (3).
  4. Remove the nut (4) retaining the boost pressure sensor bracket and the coolant tube.
  5. Lift the coolant tube (1) off of the stud and move it out of the way.

    6. Object Number: 740442 Size: SH
  6. Remove the boost pressure sensor (2) and the bracket (1) from the intake manifold.
  7. Remove the bracket from the sensor.
  8. Inspect the boost pressure sensor seal for damage and replace as necessary.

Installation Procedure

    Object Number: 740442 Size: SH
  1. Position the bracket (1) over the sensor (2).
  2. Install the boost pressure sensor into the intake manifold and guide the bracket over the stud.

    3. Object Number: 740438 Size: SH
  3. Position the coolant tube (1) over the stud.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the retaining bolt (4).

    5. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  5. Connect the electrical connector (2) to the boost pressure sensor (3).
  6. Install the air cleaner layer. Refer to Air Cleaner Replacement .