GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2001 🢒 GMC C Sierra - 2WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Air Cleaner Outlet Duct Replacement

Removal Procedure

    Object Number: 658266 Size: SH
  1. Remove the upper intake manifold sight shield using the following procedure:
    2. 1.1. Remove the retaining bolt in the front of the shield.
    1.2. Lift-up on the front of the shield.
    1.3. Lift the shield off the rear bracket.

    Object Number: 664844 Size: SH

    Important: After removing the turbocharger air duct hoses, cover the turbocharger, the air inlet duct, and the charged air cooler openings with tape to prevent entry of objects.

  2. Remove the air cleaner intake duct from the air cleaner and the turbocharger. Refer to Air Cleaner Inlet Duct Replacement .
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

    4. Object Number: 664851 Size: SH
  4. Loosen both air outlet duct to intake manifold tube hose clamps.

    5. 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.

  5. Remove the hose from the air outlet duct to intake manifold tube.

    6. Object Number: 664860 Size: SH
  6. Working through the right front fender wheelhouse opening loosen the clamp for the air outlet duct to charged air cooler.
  7. Remove the charged air cooler outlet hose and pipe assembly from the vehicle.
  8. Disassemble the hose and pipe assembly as required.

    9. Object Number: 664853 Size: SH
  9. Loosen the air inlet duct to turbocharger clamp.

    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.

  10. Remove the air outlet duct to turbocharger air outlet hose from the turbocharger.

    11. Object Number: 664856 Size: SH
  11. Loosen the air inlet duct to charged air cooler clamp.
  12. Remove the air cooler inlet hose and pipe assembly from the vehicle. The assembly can be removed as one piece with the left front fender wheelhouse inner panel removed.
  13. Disassemble the hose and pipe assembly as required.
  14. Inspect the hoses for cuts or tears.
  15. Inspect the pipes for damage.
  16. Replace the hose or pipe if damage is found.

Installation Procedure

    Object Number: 664856 Size: SH
  1. Install the air inlet hose to the pipe. The hose is marked for correct installation.
  2. Install the hose clamps on the air inlet hose but do not tighten.
  3. Install the air inlet hose to the charged air cooler aligning the marks on the hoses.

    4. Object Number: 664853 Size: SH
  4. Install the upper hose on the charged air cooler inlet pipe.
  5. Install the clamps on the hose assembly but do not tighten.
  6. Install the air inlet duct to turbocharger cool air outlet hose to the turbocharger.

    7. 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.

  7. Position all of the clamps as shown for proper clearance.

    8. Tighten
    Tighten the charged air cooler hose clamps to 6 N·m (53 lb in).


    Object Number: 664860 Size: SH
  8. Install the lower hose on the charged air cooler outlet pipe. The hose is marked for correct installation.
  9. Install the clamps on the outlet hose but do not tighten.

    10. Object Number: 664851 Size: SH
  10. Install the air outlet duct to intake manifold tube hose.

    11. The hose is marked DUCT which connects to the air outlet duct.

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

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

  11. Position all of the clamps as shown for proper clearance.

    12. Tighten
    Tighten the air duct hose clamps to 6 N·m (53 lb in).

  12. Inspect the routing of the air ducts to ensure they are not contacting anything. Adjust the ducts if necessary.
  13. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

    14. Object Number: 664844 Size: SH
  14. Install the air cleaner inlet duct to the air cleaner.

    15. Object Number: 664847 Size: SH
  15. Install the air cleaner inlet duct to turbocharger. Align the duct to the air cleaner.

    16. Tighten
    Tighten the air inlet duct clamps to 6 N·m (53 lb in).


    Object Number: 658266 Size: SH
  16. Install the upper intake manifold sight shield.

    17. Tighten
    Tighten the upper intake manifold shield bolt to 9 N·m (80 lb in).