GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Positive Crankcase Ventilation Hose/Pipe/Tube Replacement

Removal Procedure

    Object Number: 813243 Size: SH
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.

    4. Object Number: 813244 Size: SH

    Important: After removing the turbocharger air ducts, cover the turbocharger openings with tape to prevent entry of objects.

  4. If removing the right side hose, loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
  5. Remove the outlet duct.

    6. Object Number: 877275 Size: SH
  6. If removing the right side hose, loosen the charged air cooler outlet duct to intake hose clamp (1).

    7. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  7. Remove the charged air cooler outlet duct from the intake.

    8. Object Number: 877281 Size: SH
  8. If removing the left side hose, loosen the charged air cooler inlet duct to turbocharger clamp (1).

    9. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  9. Remove the charged air cooler inlet duct from the turbocharger.

    10. Object Number: 665386 Size: SH
  10. In order to access the right side hose, remove the heater outlet hose nut (1) and bolt (2).
  11. Position the heater outlet hose out of the way.

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

    13. Object Number: 687093 Size: SH
  13. Disconnect the PCV oil separator drain hose from the engine block.
  14. Disconnect the hose from the oil separator.
  15. Remove the oil separator and hoses.
  16. Inspect the all of the PCV hoses for damage.
  17. Inspect the oil separator for cracks or damage.
  18. 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. Connect the hose to the oil separator.

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

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


    Object Number: 665386 Size: SH
  4. Position the heater outlet hose.
  5. Install the heater outlet hose nut (1) and bolt (2).

    6. Tighten

        • Tighten the nut to 9 N·m (80 lb in).
        • Tighten the bolt to 25 N·m (18 lb ft).

    Object Number: 877281 Size: SH
  6. Remove the tape from the turbocharger openings.
  7. Install the charged air cooler inlet duct to the turbocharger.
  8. Align the mark on the duct (2) with the mark on the turbocharger.
  9. Position the clamp (1) as shown for proper clearance.

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


    Object Number: 877275 Size: SH
  10. Install the charged air cooler outlet duct to the intake.

    11. Align the mark on the duct (3) with the mark on the intake.

  11. Position the clamp (1) as shown for proper clearance.

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


    Object Number: 813246 Size: SH
  12. Install the outlet duct to the turbocharger.
  13. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).

    14. Object Number: 813244 Size: SH

    Important: The outlet duct must be fully seated against the MAT/IAT sensor with the edge of the seal in the vertical position.

  14. Install the outlet duct to the MAT/IAT sensor.
  15. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.

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


    Object Number: 813243 Size: SH
  16. Install the upper intake manifold cover.
  17. Install the upper intake manifold cover to the outlet duct.
  18. Tighten the outlet duct clamp at the upper intake manifold cover.

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