Engine Mechanical - 6.6l (5 of 5) Chevrolet Cab & Chassis Silverado 3500 HD

Intake Manifold Crossover Installation

1. Install the intake manifold crossover gaskets.
2. Install the intake manifold crossover.
3. Install the intake manifold crossover nuts and bolts in sequence. Tighten the intake manifold crossover nuts and bolts to 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Lower Left Side

1. Install NEW valve rocker arm cover grommets and use NEW valve rocker arm cover bolts if they are serviced with the grommet.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover bolts. Tighten the lower valve rocker arm cover bolts in the proper sequence to 10 N.m (89 lb in) . Retighten the lower valve rocker arm cover bolts in the proper sequence to the same torque, 10 N.m (89 lb in) .

Valve Rocker Arm Cover Installation - Lower Right Side

1. Install NEW valve rocker arm cover grommets and use NEW valve rocker arm cover bolts if they are serviced with the grommet.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover bolts. Tighten the lower valve rocker arm cover bolts in the proper sequence to 10 N.m (89 lb in) . Retighten the lower valve rocker arm cover bolts in the proper sequence to the same torque, 10 N.m (89 lb in) .

Valve Rocker Arm Cover Installation - Upper Left Side

1. Install NEW valve rocker arm cover grommets and use NEW valve rocker arm cover bolts if they are serviced with the grommet.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts. Tighten the upper valve rocker arm cover bolts to 8 N.m (71 lb in).

Valve Rocker Arm Cover Installation - Upper Right Side

1. Install NEW valve rocker arm cover grommets and use NEW valve rocker arm cover bolts if they are serviced with the grommet.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts. Tighten the upper valve rocker arm cover bolts in the proper sequence to 8 N.m (71 lb in).

Fuel Injector Installation

1. Install a new O-ring onto the fuel injector.
2. Lubricate the O-ring with engine oil.
3. Install a new copper washer into the fuel injector bore in the cylinder head.
4. Install the fuel injector right bracket pin.
5. Install the fuel injector left bracket pin.
6. Install the right fuel injector with fuel injector bracket.
7. Install the left fuel injector with fuel injector bracket.
8. Install the right fuel injector bracket bolts and tighten to 30 N.m (22 lb ft).
9. Install the left fuel injector bracket bolts and tighten to 30 N.m (22 lb ft).

Fuel Feed Pipe and Fuel Rail Installation

1. Install the right fuel rail.
2. Install the right fuel rail mounting bolts and tighten to 25 N.m (18 lb ft).
3. Install the left fuel rail.
4. Install the left fuel rail mounting bolts and tighten to 25 N.m (18 lb ft).
5. Install the injection pipes to the right bank and tighten to 41 N.m (30 lb ft).
6. Install the injection pipes to the left bank and tighten to 41 N.m (30 lb ft).
7. Install the exhaust gas recirculation (EGR) mounting brackets.
8. Install the EGR mounting bracket bolts and tighten to 20 N.m (15 lb ft).
9. Install the left fuel rail to pump pipe and tighten to 41 N.m (30 lb ft).
10. Install the coolant pipe.
11. Install the coolant pipe bolt and nut and tighten to 25 N.m (18 lb ft).
12. Install the distribution block and fuel line assembly.
13. Install the distribution block and fuel line assembly bolts. Tighten the fuel line assembly bolts to 25 N.m (18 lb ft).
14. Connect the fuel hoses to the fuel injector pump.
15. Install the right fuel return hose.
16. Install the left fuel return hose.
17. Install the fuel rail balance pipe.
18. Install the fuel rail balance pipe bolts and tighten to 21 N.m (15 lb ft).
19. Connect the fuel rail balance pipe to the fuel rails. Tighten the fuel rail balance pipe nuts to 41 N.m (30 lb ft).
20. Install the fuel feed pipe.
21. Install the fuel feed pipe attaching nuts and bolts. Tighten the fuel feed pipe bolts and nut to 25 N.m (18 lb ft).

Turbocharger Installation

1. Install the turbocharger oil supply line to the engine block.
2. Install the turbocharger oil supply line eye bolt and washers. Tighten the turbocharger oil supply line eye bolt to 26 N.m (19 lb ft).
3. Install the turbocharger lower heat shield to the engine block.
4. Install the turbocharger assembly with the oil return pipe.
5. Install the turbocharger mounting bolts and tighten to 108 N.m (80 lb ft).
6. Install the turbocharger cooling outlet hose and tighten hose clamp.
7. Install the cooling outlet hose eye bolts.
8. Install the oil supply line eye bolt and washers to the turbocharger. Lubricate the washers with diesel fuel before installing. Tighten the oil supply hose eye bolt to 26 N.m (19 lb ft).
9. Install the turbocharger heat shield.
10. Install the turbocharger upper heat shield bolts and tighten to 10 N.m (89 lb in).

Exhaust Gas Recirculation Valve and Cooler Installation

1. Install the intake manifold tube.
2. Install the exhaust gas recirculation (EGR) cooler bracket.
3. Install the EGR cooler bracket bolts and tighten to 25 N.m (18 lb ft).
4. Install the EGR and cooler.
5. Install the EGR mount bolt and tighten to 50 N.m (37 lb ft).
6. Install the top EGR cooler bolts and tighten to 25 N.m (18 lb ft).
7. Install the air inlet tube.
8. Install the air inlet tube nuts and tighten to 25 N.m (18 lb ft).
9. Install the air inlet tube to intake manifold tube bolt and nut. Tighten the air inlet tube to intake manifold tube bolt and nut to 25 N.m (18 lb ft).

Engine Wiring Harness Assembly Installation

1. Install the engine wiring harness assembly.
2. Install the right glow plugs and tighten to 18 N.m (13 lb ft).
3. Install the left glow plugs tighten to 18 N.m (13 lb ft).
4. Install the glow plug nuts and tighten to 2 N.m (18 lb in).
5. Install the glow plug controller.
6. Install the glow plug controller bolts and tighten to 10 N.m (89 lb in).
7. Install the oil level sensor harness bolt and tighten to 40 N.m (29 lb ft).
8. Connect the oil pressure sensor electrical connector.
9. Connect the fuel rail pressure sensor.
10. Connect the turbocharger vane control solenoid valve.
11. Connect the fuel injector electrical connections.
12. Connect and install the turbocharger vane position sensor. Tighten the turbocharger vane position sensor to 23 N.m (16 lb ft).
13. Connect the glow plug controller electrical connector.
14. Connect the fuel temperature sensor connector.
15. Connect the oil level sensor electrical harness connector.
16. Connect the fuel pressure control valve electrical connector.
17. Install the tie strap to the electrical harness.
18. Connect the crankshaft position sensor electrical connector.
19. Install the two ground bolts and tighten to 41 N.m (30 lb ft).
20. Connect the EGR valve electrical connector.
21. Install the positive crankcase ventilation (PCV) pipe.
22. Install the left PCV pipe bolt and tighten to 25 N.m (18 lb ft).
23. Install the right PCV pipe bolt and tighten to 25 N.m (18 lb ft).
24. Connect the PCV hose clamp.
25. Install the right glow plug harness bracket bolts and tighten to 10 N.m (89 lb in).
26. Install the left glow plug harness bracket bolts and tighten to 10 N.m (89 lb in).

Engine Coolant Thermostat Housing Installation

1. Install the thermostat housing.
2. Install the thermostat housing bolts and nuts. Tighten: Tighten the thermostat housing bolts and nuts to 25 N.m (18 lb ft).
3. Install the fuel pipe bracket bolt. Tighten: Tighten the fuel pipe bracket bolt to 25 N.m (18 lb ft).
4. Install the water pump inlet pipe.
5. Install the turbocharger coolant outlet hose and clamps.
6. Install the water pump inlet pipe bolts. Tighten: Tighten the water pump inlet pipe bolts to 25 N.m (18 lb ft).
7. Install the EGR coolant pipe.
8. Install the EGR coolant pipe bolts. Tighten: Tighten the EGR coolant pipe bolts to 25 N.m (18 lb ft).
9. Connect the coolant temperature sensor.
10. Install the oil fill tube.
11. Install the oil fill tube bolts. Tighten: Tighten the oil fill tube bolts to 25 N.m (18 lb ft).
12. Install the water outlet.
13. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).
14. Install the electrical harness bracket.
15. Install the electrical harness bracket bolt. Tighten: Tighten the electrical harness bracket bolt to 10 N.m (89 lb in).
16. Connect the turbocharger coolant inlet hose.
17. Install the main electrical harness bracket.
18. Install the main electrical harness bracket bolts. Tighten: Tighten the main electrical harness bracket bolts to 10 N.m (89 lb in).
19. Connect and install the turbocharger vane position sensor.
20. Connect and install the barometric sensor.
21. Install the main engine electrical harness connector hold down bolts. Tighten: Tighten the main electrical harness connector hold down bolts to 10 N.m (89 lb in).

Generator and Drive Belt Tensioner Bracket Installation

1. Install the drive belt tensioner and generator mounting bracket.
2. Install the drive belt tensioner and generator mounting bracket bolts. Tighten the drive belt tensioner and generator mounting bracket bolts to 50 N.m (37 lb ft).
3. Install the drive belt tensioner.
4. Install the drive belt tensioner bolt and tighten to 50 N.m (37 lb ft).
5. Install the electrical harness clip bolts and tighten to 10 N.m (89 lb in).

Fuel Filter Assembly Installation

1. Install the fuel filter assembly.
2. Install the fuel filter bracket bolts. Tighten: Tighten the fuel filter bracket bolts to 21 N.m (15 lb ft).
3. Connect the fuel filter assembly connectors.
4. Install the fuel hoses.

Power Steering Pump Mounting Bracket Installation

1. Install the power steering pump mounting bracket.
2. Install the power steering pump mounting bracket bolts and tighten to 46 N.m (34 lb ft).

Fan Pulley Installation

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the camshaft position sensor.
3. Install the camshaft position sensor retaining bolt and tighten to 10 N.m (89 lb in).
4. Install the cooling fan pulley.
5. Install the cooling fan pulley bolts and nuts and tighten to 41 N.m (30 lb ft).
6. Connect the camshaft position sensor connector.

Tools Required

J 36857 Engine Lift Bracket. See Special Tools .

Removal Procedure

1. Bolt J 36857 to the ends of the cylinder heads. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-1-of-5) .
2. Lift the engine and the engine stand with a suitable hoist.
3. Remove the engine stand from the engine adapter.
4. Lower the engine to the floor. Support the engine with blocks.
5. Remove the engine adapter.

Flywheel Housing Installation

1. Install the oil cooler adapter with gaskets to the oil cooler.
2. Install the oil cooler adapter to oil cooler bolts and tighten to 21 N.m (15 lb ft).
3. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant to the engine block mating surface.
4. Install the flywheel housing to the cylinder block.
5. Install the flywheel housing bolts and tighten to 80 N.m (60 lb ft).
6. Install a new gasket to the turbocharger oil return pipe.
7. Install the turbocharger oil return pipe to flywheel housing studs. Tighten the turbocharger oil return pipe to flywheel housing studs to 10 N.m (89 lb in).
8. Install the turbocharger oil return pipe nuts and tighten to 25 N.m (18 lb ft).

Upper Oil Pan Installation

1. Apply a 2-3 mm wide by 0.5-1.5 mm bead of GM P/N 12378521 (Canadian P/N 88901148) sealant to the upper oil pan mating surfaces.
2. Install the upper oil pan to the engine block.
3. Install the upper oil pan bolts. Tighten the upper oil pan bolts in sequence to 20 N.m (15 lb ft).
4. Install the two flywheel housing to upper oil pan bolts and tighten to 50 N.m (37 lb ft).
5. Install the oil level indicator tube.
6. Install the oil level indicator tube bracket bolt and tighten to 21 N.m (15 lb ft).

Lower Oil Pan Installation

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant to the lower oil pan mating surface.
2. Install the lower oil pan.
3. Install the lower oil pan bolts and nuts and tighten to 10 N.m (89 lb in).
4. Connect the oil level sensor.

Exhaust Pipe Installation - Left Side

1. Install the exhaust pipe with gaskets.
2. Install the exhaust pipe to turbocharger bolts.
3. Install the exhaust pipe to exhaust manifold bolts. Tighten the exhaust pipe bolts to 53 N.m (39 lb ft) in the proper sequence.
4. Install the exhaust pipe heat shield.
5. Install the exhaust pipe heat shield bolts and tighten to 10 N.m (89 lb in).

Exhaust Pipe Installation - Right Side

1. Install the exhaust pipe with gaskets.
2. Install the exhaust outlet bracket.
3. Install the exhaust pipe to turbocharger bolts.
4. Install the exhaust pipe to exhaust manifold bolts in sequence. Tighten: Tighten the exhaust pipe bolts to 53 N.m (39 lb ft) in sequence. Tighten: Tighten the exhaust pipe to EGR cooler nuts to 26 N.m (19 lb ft).

Exhaust Outlet Installation

1. Install the exhaust outlet.
2. Install the exhaust outlet clamp and tighten to 15 N.m (11 lb ft).
3. Install the exhaust outlet to right exhaust pipe bracket bolt and tighten to 34 N.m (25 lb ft).
4. Install the exhaust outlet heat shield.
5. Install the exhaust outlet heat shield bolts and tighten to 10 N.m (89 lb in).

J 44642 Crankshaft Rear Oil Seal Installer. See Special Tools .

Installation Procedure

1. Place the crankshaft rear oil seal onto the crankshaft.
2. Install the J 44642 to the crankshaft. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-1-of-5) .
3. Press the crankshaft rear oil seal into position using the J 44642 . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-1-of-5) . The J 44642 will bottom out when the seal reaches the proper depth. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-1-of-5) .
4. Remove the J 44642 . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-1-of-5) .

Special Tools

1. J 44643: Flywheel Hold Tool
2. J 45059: Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Install the flywheel to the crankshaft.
2. Install the flywheel washer to the flywheel with the beveled side facing the engine.
3. Install NEW flywheel bolts.
4. Install the J 44643: tool to lock the flywheel.
5. Tighten the flywheel bolts in the proper sequence. 1st step 79 N.m (59 lb ft) . 2nd step 60 degrees using J 45059: meter . 3rd step 60 degrees using J 45059: meter .

1. J 44643: Flywheel Hold Tool
2. J 45059: Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Install the pilot bearing.
2. Install the flywheel.
3. Loosely install NEW flywheel bolts.
4. Install J 44643: tool to hold the flywheel from rotating.
5. Use the following steps and the proper sequence to tighten the flywheel bolts: Tighten the flywheel bolts to 79 N.m (59 lb ft) . Tighten the flywheel bolts to 60 degrees using the J 45059: meter . Tighten the flywheel bolts again to 60 degrees using the J 45059: meter .
6. Remove J 44643: tool.

J 44643 Flywheel Hold Tool. See Special Tools .

1. Lightly lubricate the crankshaft balancer internal hub with engine oil.
2. Install the crankshaft balancer to the crankshaft.
3. Lightly lubricate the crankshaft balancer bolt with engine oil.
4. Install the crankshaft balancer bolt and washer. Tighten: Tighten the bolt to 100 N.m (74 lb ft) on the first pass. Tighten the bolt an additional 105 degrees.
5. Remove the J 44643 . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-1-of-5) .

Starter Installation

1. Install the starter motor to the flywheel housing.
2. Install the starter motor bolts. Tighten: Tighten the starter bolts to 78 N.m (58 lb ft).

J 45299: Engine Preluber

For equivalent regional tools, refer to Special Tools .

Prelubing Procedure

1. Remove the engine oil filter, fill with clean engine oil, and reinstall. Tighten the oil filter to 24 N.m (18 lb ft).
2. Remove the oil pressure sensor.
3. Install the M16 x 1.5 adapter P/N 509375.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299: preluber to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the oil pressure sensor and tighten to 41 N.m (30 lb ft).
8. Top off the engine oil to the proper level.

See also:
• Fastener Caution
• Special Tools