GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Crew) C4/C5 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Positive Crankcase Ventilation Hose/Pipe/Tube Replacement

Removal Procedure

    Object Number: 664851 Size: SH
  1. Remove the air cleaner layer. Refer to Air Cleaner Replacement in Engine Controls.

    2. In order to access the right side, loosen both charged air cooler outlet duct to intake manifold duct hose clamps.

    Important: Do not use a screw driver or other tool to pry the hose loose. Loosen the hose by twisting.

  2. Remove the charged air cooler outlet duct to intake hose.

    3. Object Number: 664853 Size: SH
  3. In order to access the left side, loosen the charged air cooler inlet duct to turbocharger clamp.

    4. Important: Do not use a screw driver or other tool to pry the hose loose. Loosen the hose by twisting.

  4. Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.

    5. Object Number: 687021 Size: SH
  5. Disconnect both of the positive crankcase ventilation (PCV) hoses from the valve rocker arm covers.

    6. Object Number: 687093 Size: SH
  6. Disconnect the oil separator oil drain hose form the engine block.
  7. Remove the oil separator and hoses.
  8. Inspect the all of the PCV hoses for damage.
  9. Inspect the oil separator for cracks or damage.
  10. Replace any parts found with damage.

Installation Procedure

    Object Number: 687093 Size: SH
  1. Connect the oil separator oil drain hose to the engine block.

    2. Object Number: 687021 Size: SH
  2. Connect both of the PCV hoses to the valve rocker arm covers.

    3. Object Number: 664853 Size: SH
  3. Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Position the clamp as shown for proper clearance.

    5. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 664851 Size: SH
  5. Install the charged air cooler outlet duct to intake manifold duct hose.

    6. The hose is marked DUCT which connects to the charged air cooler outlet duct.

    The hose is marked ENG which connects to the intake manifold duct.

    Align the marks on the hose with the alignment marks on the pipe and duct.

  6. Position the clamps as shown for proper clearance.

    7. Tighten
    Tighten the clamps to 6 N·m (53 lb in).

  7. Install the air cleaner assembly. Refer to Air Cleaner Replacement in Engine Controls.