Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 380 (ENGINE CONTROLS - 6.6L (LB7) (INTRODUCTION))REPAIR INSTRUCTIONSAIR CLEANER OUTLET DUCT REPLACEMENTINSTALLATION PROCEDURE

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: The outlet duct must be fully seated against the positive stop feature on the turbocharger inlet.

Install the outlet duct to the turbocharger.
Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).

Fig 1: Outlet Duct Alignment Indicator & Turbocharger Alignment Indicator

Courtesy of GENERAL MOTORS CORP.

Install the outlet duct to the MAF/IAT sensor.
NOTE: Refer to Fastener Notice in Cautions and Notices.
Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.
Tighten: Tighten the clamp to 6 N.m (53 lb in).

Fig 2: View Of Outlet Duct

Courtesy of GENERAL MOTORS CORP.

Install the upper intake manifold cover.
Install the upper intake manifold cover to the outlet duct.
Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten: Tighten the clamp to 6 N.m (53 lb in).

Fig 3: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp

Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.