Engine Controls and Fuel - 6.6l - Introduction (1 of 2) Chevrolet Cab & Chassis Silverado 3500 HD

Temperature Versus Resistance (ECT Sensors)

Temperature Versus Resistance (EGR Temperature Sensors)

EGR Temperature Sensors 1 and 2

Temperature Versus Resistance (EGT Sensors)

EGT 1 and 2 Sensors

Temperature Versus Resistance (Fuel Temperature Sensor)

Temperature Versus Resistance (IAT Sensor 1)

Temperature Versus Resistance (IAT Sensor 2)

Altitude Versus Barometric Pressure

Fastener Tightening Specifications

What Fuel to Use in the United States

In the United States, for best results use Number 2-D diesel fuel year-round, above and below freezing conditions, as oil companies blend Number 2-D fuel to address climate differences. Number 1-D diesel fuel may be used in very cold temperatures when the temperature stays below -18°C (0°F). However, the fuel will produce a power and fuel economy loss. The use of Number 1-D diesel fuel in warm or hot climates may result in stalling, poor starting when the engine is hot and may damage the fuel injection system.

It is acceptable to use diesel fuel containing up to 5 percent biodiesel (B5), but the final blended fuel must meet the same specification, ASTM D 975 (Grades No. 2-D or No. 1-D S15 commonly known as Ultra Low Sulfur diesel), as the other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage could not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier.

Because of the cleansing properties of biodiesel, switching from straight diesel to a biodiesel blend can prematurely restrict the fuel filter with normal deposits in the fuel system. A fuel filter replacement might be required sooner than the recommended interval.

Diesel fuel may foam when filling the tank. This can cause the automatic pump nozzle to shut OFF, even though the tank is not full. If this happens, just wait for the foaming to stop and then continue to fill the tank.

What Fuel to Use in Canada

Canadian fuels are blended for seasonal changes. Diesel Type A fuel is blended for better cold weather starting, when it stays below -18°C (0°F). However, the fuel will produce a power and fuel economy loss. The use of Type A diesel fuel in warmer climates may result in stalling, poor starting. Diesel Type B fuel is blended for temperatures above -18°C (0°F). The emission control system requires the use of diesel fuel with ultra low sulfur, 15 ppm, content. Both low and higher sulfur fuels will be available in Canada. Only ultra low sulfur diesel fuels are available in the United States. Diesel-powered trucks must be refueled with ultra low sulfur fuel only. Use of fuels with higher-sulfur content will affect the function of the emission components and may cause reduced performance, excessive smoke and unpleasant odor.

It is acceptable to use diesel fuel containing up to 5 percent biodiesel (B5), but the final blended fuel must meet the same specification, CAN/CGSB-3.517 (ULS) in Canada, as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier.

Very Cold Weather Operation

If the vehicle is driven in very cold temperatures and can not get a winterized Number 2-D that has been adapted to cold weather or a Number 1-D, use one gallon of kerosene for every 2 gallons of diesel fuel. Once you add kerosene, run the engine for several minutes to mix the fuels. Only add kerosene when the temperature falls below -18°C (0°F), because the fuel economy and lubricating qualities of kerosene is not as good as that of diesel fuel.

In cold weather, the fuel filter may become clogged (waxed). To unclog the filter, move the vehicle to a warm garage area and warm the filter to a temperature between 0-10°C (32-50°F). Replacing the filter is not necessary.

Fuel Specific Gravity Testing

Use a J 38641-B Diesel Fuel Quality Tester to measure the fuel specific gravity (API Rating). See Special Tools . Follow the instructions on the tool to obtain the proper temperature-adjusted value. This information must be accurate for the proper diagnosis of the fuel system.

Fuel Injector Return Flow and Fuel Pressures

The fuel return from the fuel injectors to the tank will vary based on the API value of the fuel. Measure the Fuel API with the Diesel Fuel Quality Tester. For this reason the Fuel System Diagnosis - High Pressure Side values will vary for identifying a fuel injector or fuel pump concern. Use the following tables when referred to by the diagnostic. The first table is to be used during the initial diagnosis to identify the worst fuel injectors. After the fuel injectors that fail the first part of the test are capped off, the return flow from each uncapped fuel injector must be measured again. This is because the fuel system is returning less fuel to the tank, and thus the fuel pressure is higher during the retest. Failure to use the correct table may result in the replacement of good fuel injectors.

Initial Fuel Injector Return Flow Values

Retesting Fuel Injector Return Flow Values

Water in Fuel

Sometimes, water can be pumped into the fuel tank along with diesel fuel. This can happen if the service station does not regularly inspect and clean their fuel tanks, or the fuel gets contaminated for the service stations suppliers.

If water is pumped into the fuel tank, a water in fuel light will illuminate. If the water in fuel light illuminates, the excess water must be drained from the fuel system on the vehicle.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

Engine Control Module Replacement

Note. Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References .

Removal Procedure

1. Using a scan tool, capture the ECM data.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
3. Disconnect the ECM electrical connectors (2).
4. Release the ECM upper retaining tabs.
5. Remove the ECM from the bracket.

Installation Procedure

1. Place the bottom edge of the ECM into the bracket lower retainers.
2. Push the ECM towards the bracket until the upper edge of the ECM snaps into place.
3. Connect the ECM electrical connectors (2).
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
5. If a NEW ECM was installed, program the ECM. Refer to «Control Module References»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

Before Programming a Control Module

Ensure the following conditions are met before programming a control module

1. Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. Turn OFF or disable any system that may put a load on the vehicle's battery. Twilight sentinel Interior lights Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. HVAC systems Engine cooling fans, etc.
2. The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.
3. All tool connections are secure. The connection at the data link connector (DLC) Voltage supply circuits
4. DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur.

High Idle Switch Programming

1. Using the Tech 2, select Module Setup/PTO Options
2. Use soft keys to select desired settings.
3. When setting selections are complete, select Reprogram.
4. Turn OFF the ignition until communication with the ECM is lost, as indicated on the scan tool.
5. Start the vehicle and confirm the new settings by operating the high idle switch.

Circuit/System Description

The control functions for the fuel injection system are integrated in the engine control module (ECM). Each injector's flow rate information and cylinder position are stored in the memory of both the glow plug control module (GPCM) and the ECM. The fuel injector flow rate programming must be done when any of the following procedures are performed

1. The ECM is replaced
2. The GPCM is replaced
3. Any fuel injectors are replaced

If the ECM does not communicate, the flow rate information can be retrieved from the GPCM. If both control modules fail to communicate, the fuel injector flow rate information, or injection quantity adjustment (IQA) flow rate numbers, will need to be retrieved from each individual injector.

Ensure the following conditions are met before programming a control module

1. Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. Battery voltage is between 12-16 volts. The battery must be charged before programming the control module if the battery voltage is low. A battery charger is NOT connected to the vehicle battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. Turn OFF or disable any of the following systems that may put a load on the vehicle battery: Twilight sentinel Interior lights Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. HVAC systems Engine cooling fans, etc.
2. The ignition switch is in the proper position-The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.
3. All of the following tool connections are secure: The connection at the data link connector (DLC) The voltage supply circuits
4. DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur.

Circuit/System Verification

Review the Display ECM & GPCM Inj. Flow Rates parameter with a scan tool. All cylinders should be programmed with a flow rate number. Both the GPCM and the ECM should be programmed with the same flow rate numbers for the corresponding cylinders.

Circuit/System Testing

Scheme 13

1. With a scan tool installed, enter the vehicle information and select the following options: Engine Control Module Module Setup Injector Flow Rate Programming Display ECM & GPCM Inj. Flow Rates
2. Record all flow rate numbers with the corresponding cylinders from the control modules. IMPORTANT: When installing a new fuel injector, ensure that the IQA data number from the yellow IQA Data Tag, shipped with the new injector, is programmed to the correct cylinder If any injectors are replaced, go to Reprogram Injector Flow Rates parameter and enter the flow rate number of the new injector to the corresponding cylinder. The flow rate numbers will automatically update both control modules. If the ECM was replaced, go to Copy GPCM Inj. Flow Rates to ECM parameter and reprogram the ECM. This will update the ECM with the GPCM flow rate numbers. If the GPCM was replaced or the flow rate numbers are not the same for both modules, go to Copy ECM Inj. Flow Rates to GPCM parameter and reprogram the GPCM. This will update the GPCM with the ECM flow rate numbers. If both control modules were replaced, go to Reprogram Injector Flow Rates parameter and enter the previously recorded flow rate numbers or the numbers retrieved from each individual injector, to the corresponding cylinders.

Repair Procedures

1. Install any components or connectors that have been removed or replaced during diagnosis.
2. Perform any adjustment, programming or setup procedures that are required when a component or module is removed or replaced.
3. Turn ON the ignition, with the engine OFF, and clear the DTCs.
4. Disconnect the scan tool and turn OFF the ignition for 2 minutes.
5. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-trouble-code-dtc-list) and perform the appropriate diagnostic procedure. OR If the repair was symptom related, duplicate the conditions under which the customer concern occurred to verify the repair. If the customer concern reoccurs, return to «Symptoms - Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#vehicle-diagnostic-information) and perform the appropriate symptom diagnostic.

Diesel Particulate Filter (DPF) Service Regeneration

Note. If you were not referred to this document from another diagnostic, DO NOT perform this procedure.

Conditions for Running

The following conditions must be met in order to enable DPF Service Regeneration

1. DTCs P2463 or P244B are the only active DTCs displayed.
2. The battery voltage is greater than 10 volts.
3. The engine speed is between 600-1,250 RPM.
4. The exhaust gas temperature (EGT) sensors 1 and 2 are less than 400°C (752°F).
5. The engine coolant temperature (ECT) sensor 1 is between 70-115°C (158-239°F).
6. The brake pedal and accelerator pedal are in the released position.
7. The transmission is in Park or Neutral.

Test Procedure

1. Clear all DTCs with a scan tool before proceeding with DPF Service Regeneration.
2. Observe the scan tool DPF Regenerations Completed parameter and record the value.
3. Check the following fluid levels before and after this procedure: Engine oil Engine coolant Power steering Transmission Fuel level should be over 15 percent to ensure a successful regeneration.
4. Park the vehicle outside the facility, away from any obstacles, place the transmission in Park and apply the parking brake.
5. Ensure the hood is open.
6. Select DPF Service Regeneration in the Output Controls menu and follow the instruction on the scan tool.
7. Command the DPF Service Regeneration ON with a scan tool. If the service regeneration failed to start, repair the vehicle for the condition indicated by the scan tool DPF Regen. Inhibit Reason parameter. Refer to the «Service Regeneration Successful»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. The DPF Service Regeneration will take approximately 35 minutes consisting of the following: 8 minutes for the exhaust system to warm up, with the engine speed slowly increasing to 1,600 RPM, then 2,200 RPM and finally 2,500 RPM 20 minutes for the DPF to regenerate at an engine speed between 2,200-2,500 RPM 3 minutes for the exhaust system to cool down with the engine speed will slowly returning to 1,400 RPM 3 minutes at 800 RPM, then idle speed of 680 RPM
9. The DPF Service Regeneration will be terminated if any of the following actions are performed: Applying the brake pedal Applying the accelerator pedal Selecting Drive or Reverse Commanding DPF Service Regeneration OFF using the scan tool or disconnecting the scan tool from the vehicle
10. After the service regeneration completes, clear all DTCs and turn the ignition OFF for 90 seconds. If the service regeneration did not complete or aborted, replace the Exhaust Particulate Filter.
11. Engine running, perform the following within 10 minutes of a successful service regeneration. Operate the vehicle within the following Conditions for Running DTC P2002. Refer to «DTC P2002»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-dtc-p1448-to-dtc-p2510) . If DTC P2002 or P244B sets, replace the Exhaust Particulate Filter.
12. Verify that the scan tool DPF Regenerations Completed parameter has increased by one. If the value has not increased by one, refer to «Service Regeneration Successful»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

Service Regeneration Successful

Service Regeneration Unsuccessful

The scan tool DPF Regeneration Inhibit reason parameter will display a reason for not enabling or aborting the DPF service regeneration. Refer to the reasons that are displayed and the corrective action for each reason.

Service Regeneration Unsuccessful

Diesel Particulate Filter (DPF) Regeneration Enable

1. Ignition ON, clear all DTCs with a scan tool.
2. Select DPF Regeneration Enable within the Special Function menu.
3. Select ON. The selection can be confirmed by the DPF Regeneration Reason parameter indicating Device Control.
4. Exit the Special Function Menu. The scan tool can now be removed.

The vehicle will perform an active Regeneration as soon as the engine running conditions are met.

1. Drain the cooling system to a level below the engine coolant temperature (ECT) sensors. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the engine wiring harness electrical connector (1) from the appropriate ECT sensor.
3. Remove the appropriate ECT sensor (1).

1. If installing the old sensor(s), coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
2. Install the appropriate ECT sensor (1). Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the engine wiring harness electrical connector (1) to the appropriate ECT sensor.
4. Fill the cooling system, as necessary. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor.
2. Remove the MAF/IAT sensor TORX® screws.
3. Remove the MAF/IAT sensor.

1. Install the MAF/IAT sensor.
2. Install the MAF/IAT sensor TORX® screws. Tighten: Tighten the screws to 8 N.m (70 lb in).
3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor.

1. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Disconnect the engine wiring harness electrical connector (1) from the intake air temperature (IAT) sensor pigtail.
3. Remove the IAT sensor (2) from the center intake manifold.

1. Install the IAT sensor (2) to the center intake manifold. Tighten: Tighten the sensor to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the IAT sensor pigtail.
3. Install the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Disconnect the engine wiring harness electrical connector (2) from the intake air valve.
4. Remove the upper intake manifold brace bolts and brace.
5. Remove the intake air valve bolts (1), nuts (2) and valve.

1. Position the intake air valve to the intake pipe and install the intake air valve bolts (1) and nuts (2). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
2. Install the upper intake manifold brace and bolts. Tighten: Tighten the bolts to 24 N.m (18 lb ft).
3. Connect the engine wiring harness electrical connector (2) to the intake air valve.
4. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the exhaust gas recirculation (EGR) valve motor. Refer to «Exhaust Gas Recirculation Valve Motor Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Remove the upper intake manifold brace bolts and brace.
5. Remove the engine wiring harness clip (1) from the intake manifold tube.
6. Remove the engine wiring harness clip bolt (2) from the intake manifold tube.
7. Disconnect the engine wiring harness electrical connector (1) from the intake air heater (IAH).
8. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
9. Reposition the engine wiring harness branches out of the way.
10. Open the IAH harness lead cover (2).
11. Remove the engine wiring harness lead nut (1) from the IAH stud.
12. Remove the engine wiring harness lead (3) from the IAH stud.
13. Remove the IAH bolts (1) and nuts (2).
14. Remove the intake manifold front tube and IAH from the intake manifold rear tube.
15. Remove the IAH (3) from the intake manifold front tube studs.
16. Remove and discard the IAH gasket.

1. Install a NEW IAH gasket.
2. Install the IAH (3) to the intake manifold front tube studs.
3. Install the intake manifold front tube and IAH to the intake manifold rear tube.
4. Install the IAH bolts (1) and nuts (2). Tighten: Tighten the bolts/nuts to 20 N.m (15 lb ft).
5. Install the engine wiring harness lead (3) to the IAH stud.
6. Install the engine wiring harness lead nut (1) to the IAH stud. Tighten: Tighten the nut to 10 N.m (89 lb in).
7. Close the IAH harness lead cover (2).
8. Position the engine wiring harness branches.
9. Connect the engine wiring harness electrical connector (2) to the MAP sensor.
10. Connect the engine wiring harness electrical connector (1) to the IAH.
11. Install the engine wiring harness clip (1) to the intake manifold tube.
12. Install the engine wiring harness clip bolt (2) to the intake manifold tube. Tighten: Tighten the bolt to 4 N.m (35 lb in).
13. Install the upper intake manifold brace and bolts. Tighten: Tighten the bolts to 24 N.m (18 lb ft).
14. Install the EGR valve motor. Refer to «Exhaust Gas Recirculation Valve Motor Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
15. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
16. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .

1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
2. Remove the MAP sensor bolt.
3. Remove the MAP sensor bracket and sensor.

1. Install the MAP sensor and bracket.
2. Install the MAP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (2) to the MAP sensor.

1. Remove the connector position assurance (CPA) retainer.
2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1).
3. Remove the accelerator pedal bolts.
4. Remove the accelerator pedal.

1. Position the accelerator pedal to the accelerator pedal bracket.
2. Install the accelerator pedal bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Connect the APP sensor electrical connector (1).
4. Install the CPA retainer.
5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range.
6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
7. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
8. Inspect the carpet fit under the accelerator pedal.

Special Tools

1. J 44581 Fuel Line Disconnect Tool. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. J 43178 Fuel Line Disconnect Tool
3. J 41769 Fuel Disconnect Tool

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the fuel fill cap.
3. Remove the retainers from the fuel feed and return pipe quick connect fittings.
4. Using compressed air, blow any dirt or debris from around the fitting.
5. Using the correct end of J 44581 for the size of the fitting. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) . Insert J 44581 into the female connector, then push inward in order to release the locking tabs. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect fittings at the sending unit.
7. If disconnecting the fuel return line, it may be necessary to use J 41769 in order to release the quick connect fitting.
8. Pull the connection apart.
9. Use a clean shop towel in order to wipe off the male end. CAUTION: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.
10. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the fittings together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the connections in order to make sure the connection is secure.
4. Install the retainers to the fuel feed/return pipes.
5. Install the fuel fill cap.
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .

Disconnect Procedure

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Using compressed air, blow any dirt or debris from around the connection.
3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs.
4. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting.
6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction.
7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow.
8. Pull the connection apart.

Connect Procedure

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.
4. Install the fuel fill cap.
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .

Fuel System Priming

1. Prior to priming the fuel system, ensure that the following has been completed: There is fuel in the fuel tank. The fuel filter has been installed and properly tightened. The fuel lines are properly connected. The fuel filter is cool to the touch. Any dirt or debris has been removed from the fuel filter adapter and vent valve screw.
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Open the vent valve screw (1) by turning the screw counterclockwise several full turns.
4. Operate the priming pump (1) until a small amount of fuel seeps from the vent valve. Allow the pump to fully return upward between pumps. When fuel is present, the filter is full of fuel and the system is primed.
5. Close the vent valve screw.
6. Clean any fuel which accumulated on the fuel filter adapter.
7. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Start the engine and allow the engine to idle for a few minutes.
9. Check the fuel system for leaks.

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__water-in-fuel-draining) .
2. Remove the right front wheelhouse liner rear bolts/retainers as required to reposition the rear half of the wheelhouse liner (1) in order to access the fuel filter.
3. Disconnect the water-in-fuel sensor wiring pigtail (2) from the engine wiring harness electrical connector.
4. Remove the fuel filter from the fuel filter adapter.
5. Remove the water-in-fuel sensor from the fuel filter.

1. Install the water-in-fuel sensor to the NEW fuel filter, and tighten 1/2 turn after the seal contacts the filter.
2. Install the NEW fuel filter to the fuel filter adapter, and tighten 1/4 turn after the seal contacts the filter adapter.
3. Connect the water-in-fuel sensor wiring pigtail (2) to the engine wiring harness electrical connector.
4. Position the rear half of the wheelhouse liner (1) and install the rear bolts/retainers as required. Tighten: Tighten the bolts, if required to 2.5 N.m (22 lb in).
5. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
6. Start the engine. If the engine stalls, repeat the above step.
7. Once the engine starts, inspect for fuel leaks.

Fuel Filter Life Reset

This message will appear when a reset is performed either by using the steering wheel controls or following manual procedure.

1. Reset the fuel filter monitor.
2. For vehicles with steering wheel controls, press and hold the select button for 5 seconds while the FUEL FILTER LIFE message is displayed. This message will appear on the driver information center (DIC) for ten seconds.
3. For vehicles without steering wheel controls, do the following: Without pressing the pedals, turn the ignition key to the ON position without starting the engine. Wait 5 seconds. Completely press the brake and the accelerator pedals simultaneously and hold for 10 seconds. The system is now reset. Turn the ignition key OFF.
4. The next time the engine is started, the message will no longer be displayed. ALWAYS reset the FUEL FILTER LIFE system after a fuel filter change.

Scheme 14

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__water-in-fuel-draining) .
2. Remove the right front wheelhouse liner rear bolts/retainers as required to reposition the rear half of the wheelhouse liner (1) in order to access the water in fuel sensor.
3. Disconnect the water in fuel sensor wiring pigtail (2) from the engine wiring harness electrical connector.
4. Remove the water in fuel sensor (1) from the fuel filter.

1. Install the water in fuel sensor (1) to the fuel filter, and tighten 1/2 turn after the seal contacts the filter.
2. Connect the water in fuel sensor wiring pigtail (2) to the engine wiring harness electrical connector.
3. Position the rear half of the wheelhouse liner (1) and install the rear bolts/retainers as required. Tighten: Tighten the bolts, if required to 2.5 N.m (22 lb in).
4. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
5. Start the engine. If the engine stalls, repeat the above step.
6. Once the engine starts, inspect for fuel leaks.

Water-in-Fuel Draining

1. Attach a small piece of hose to the drain onto the water in fuel sensor.
2. Place the other end of the piece of hose into an approved fuel-resistant container.
3. Open the drain 3 or 4 turns or until the water contaminated fuel seeps from the drain.
4. Operate the priming pump (1) until only diesel fuel is visible. Allow the pump to fully return upward between pushes.
5. Tighten the drain.
6. Remove the container and hose.

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__water-in-fuel-draining) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the heater inlet hose bracket nut (4) from the fuel filter adapter stud (1).
4. Remove the heater inlet hose bracket from the stud and position the hose out of the way.
5. Reposition the fuel filter hose clamps (1 and 2).
6. Remove the fuel filter hoses from the fuel filter adapter.
7. Disconnect the fuel filter heater wiring pigtail (1) from the engine wiring harness electrical connector.
8. Disconnect the water in fuel sensor wiring pigtail (2) from the engine wiring harness electrical connector.
9. Remove the fuel filter bracket bolts (1).
10. Remove the fuel filter and bracket assembly.

1. Position the fuel filter and bracket assembly to the upper valve rocker arm cover.
2. Install the fuel filter bracket bolts (1). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Connect the fuel filter heater wiring pigtail (1) to the engine wiring harness electrical connector.
4. Connect the water in fuel sensor wiring pigtail (2) to the engine wiring harness electrical connector.
5. Install the fuel filter hoses to the fuel filter adapter.
6. Position the fuel filter hose clamps (1 and 2).
7. Position the heater inlet hose and install the heater inlet hose bracket to the stud.
8. Install the heater inlet hose bracket nut (4) to the fuel filter adapter stud (1). Tighten: Tighten the nut to 9 N.m (80 lb in).
9. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
10. Start the engine. If the engine stalls, repeat the above step.
11. Once the engine starts, inspect for fuel leaks.

Tools Required

J 45004 Fuel Tank Siphon Hose

Fuel Tank Draining Procedure

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the fuel fill cap.
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
4. Loosen the fuel fill pipe clamp (2).
5. Remove the fuel fill pipe from the fuel tank.
6. Insert the J 45004 hose into the tank.
7. Attach the J 45004 hose to the hose used with the hand or air operated pump devise.
8. Using a hand or air operated pump drain as much fuel from the tank as possible.

1. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the fuel tank filler housing to body screws (1), and retainer (2).
3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.
5. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
7. Remove the fuel tank ground strap bolt (1).
8. Reposition the fuel tank ground strap (3).
9. Loosen the fill pipe vent hose clamp (1) at the fuel tank.
10. Remove the fill pipe vent hose from the fuel tank.
11. Remove the fill pipe.
12. Remove the fuel system cooler. Refer to «Fuel Cooler Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Cooler Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
13. If equipped, remove the fuel tank shield bolts.
14. If equipped, remove the fuel tank shield.
15. Disconnect the fuel feed and return lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
16. Cap the fuel lines in order to prevent possible fuel system contamination.
17. Place a suitable adjustable jack under the fuel tank.
18. Remove the fuel tank strap bolts.
19. Remove the fuel tank straps.
20. Lower the fuel tank until the sending unit electrical connector is accessible.
21. Disconnect the sending unit electrical connector.
22. Completely lower the fuel tank.
23. With the aid of an assistant, place the fuel tank in a suitable work area.
24. If necessary, disconnect and remove the fuel feed (1) and return (2) lines from the sending unit and retaining clips. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
25. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Install and connect the fuel feed (1) and return (2) lines to the sending unit and retaining clips. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank until the sending unit electrical connection can be made.
5. Connect the sending unit electrical connector.
6. Install the fuel tank.
7. Install the fuel tank straps. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
8. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
9. Remove the jack from under the fuel tank.
10. Remove the caps from the fuel lines.
11. Connect the fuel feed and return lines to the fuel tank. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
12. If necessary, install the fuel tank shield.
13. If necessary, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
14. Install the fuel system cooler. Refer to «Fuel Cooler Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Cooler Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
15. Install the fuel tank fill pipe and vent hose to the fuel tank.
16. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
17. Tighten the fuel tank vent hose clamp (1) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
18. Position the fuel tank ground strap (3).
19. Install the fuel tank ground strap bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
20. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
21. Lower the vehicle.
22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
24. Install the fuel tank filler housing to body screws (1), and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
25. Fill the fuel tank.
26. Install the fuel fill cap.
27. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
28. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
29. Start the engine. If the engine stalls, repeat the above step.
30. Once the engine starts, inspect for fuel leaks.

1. Disconnect the fuel feed and pressure balance rear lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Loosen the fuel fill and vent hose clamps (1, 2) at the fuel tank.
3. Remove the fuel fill pipe and vent hose from the tank.
4. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Disconnect the sending unit electrical connectors (1).
6. Disconnect the fuel feed and return lines from the fuel tank. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
8. If necessary, remove the fuel tank shield bolts.
9. If necessary, remove the fuel tank shield.
10. Place a suitable adjustable jack under the fuel tank.
11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps.
13. Lower the fuel tank.
14. With the aid of an assistant, place the fuel tank in a suitable work area.
15. Cap the fuel lines on the vehicle in order to prevent possible fuel system contamination.
16. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the caps from the fuel lines.
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank.
5. Install the fuel tank straps. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
6. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
7. Remove the jack from under the fuel tank.
8. If necessary, install the fuel tank shield.
9. If necessary, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
10. Lower the vehicle.
11. Connect the fuel feed and return lines at the fuel tank. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
12. Connect the sending unit electrical connectors (1).
13. Install the fuel fill pipe and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) at the fuel tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
15. Connect the fuel feed and pressure balance rear lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
16. Fill the fuel tank.
17. Install the fuel fill cap.
18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
19. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.

1. Loosen the fuel fill and vent hose clamps (1, 2) at the tank.
2. Remove the fuel fill and vent hose from the tank.
3. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Disconnect the sending unit electrical connector.
5. Disconnect the fuel feed and return lines from the sending unit. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
7. If equipped, remove the fuel tank shield bolts.
8. If equipped, remove the fuel tank shield.
9. Remove the fuel tank strap bolts.
10. Remove the fuel tank straps.
11. Lower the fuel tank.
12. With the aid of an assistant, place the fuel tank in a suitable work area.
13. Cap the fuel lines in order to prevent possible fuel system contamination.
14. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the caps from the fuel lines.
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank.
5. Install the fuel tank straps. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
6. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
7. Remove the jack from under the fuel tank.
8. If equipped, install the fuel tank cover.
9. If equipped, install the fuel tank cover bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
10. Lower the vehicle.
11. Connect the fuel feed and return lines to the sending unit. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
12. Connect the sending unit electrical connector.
13. Install the fuel fill and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) at the tank. Tighten: Tighten the hose clamps to 2.5 N.m (22 lb in).
15. Fill the fuel tank.
16. Install the fuel fill cap.
17. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
18. Using a scan tool, command the fuel transfer pump on.
19. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (With CH-48027)»(ref-317159-S17834571372009060900000) or «Fuel Pressure Relief (Without CH-48027)»(ref-317159-S24779321712009060900000) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2__fuel-tank-draining) .
4. Remove the fuel tank shield bolts (1) and the fuel tank shield (2).
5. Loosen the fuel fill (1) and vent pipe (2) hose clamps.
6. Disconnect the hoses.
7. With the aid of an assistant, support the fuel tank.
8. Disconnect the evaporative emissions lines and the fuel lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) and «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2)
9. Disconnect the electrical connectors.
10. Remove the fuel tank strap bolts (1) and the auxiliary fuel tank (2).
11. Remove the fuel pump module from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) .
12. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

1. Install the fuel pump module to the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) or «Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) .
2. Remove the caps from the fuel and EVAP pipes.
3. With the aid of an assistant, support and partially raise the fuel tank.
4. Connect the electrical connectors.
5. Connect the evaporative emissions lines and the fuel lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2) and «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-60l-62l-introduction-1-of-2)
6. With the aid of an assistant, support the auxiliary fuel tank.
7. Install the auxiliary fuel tank (1).
8. Install the fuel tank strap attaching bolts (2) and tighten to 40 N.m (30 lb ft).
9. Connect and tighten the fuel fill (1) and vent pipe (2) hose clamps to 4 N.m (35 lb in).
10. Install the fuel tank shield (2) and the fuel tank shield bolts (1) and tighten to 18 N.m (13 lb ft).
11. Refill the fuel tank.
12. Install the fuel filler cap.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) in Engine Electrical.
14. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Disconnect the fuel level sensor electrical connector (1).
3. Remove the sensor retaining clip (3).
4. Squeeze the locking tangs (2) and remove the fuel level sensor.

1. Install the fuel level sensor.
2. Install the sensor retaining clip (3).
3. Connect the sensor electrical connector (1).
4. Install the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Loosen the fuel fill cap to relieve the fuel system pressure.
2. Disconnect the balance pump electrical connector.
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
4. Clean the fuel line connections and surrounding areas at the pump before disconnecting to avoid possible fuel system contamination.
5. Disconnect the fuel lines from the pump.
6. Slide the pump out of the bracket.
7. Cap the fuel lines.

1. Remove the caps from the fuel lines.
2. Install the NEW fuel line O-rings.
3. Position the new balance pump into the bracket.
4. Connect the fuel lines to the balance pump. Use a backup wrench to prevent the pump from turning. Tighten: Tighten the fittings to 30 N.m (22 lb ft).
5. Lower the vehicle.
6. Connect the balance pump electrical connector.
7. Tighten the fuel fill cap.
8. Using a scan tool, command the fuel transfer pump on.
9. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
10. Start the engine. If the engine stalls, repeat the above step.
11. Once the engine starts, inspect for fuel leaks.

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Disconnect the fuel lines from the sending unit. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
4. Remove the sending unit and seal. Discard the seal.
5. Clean the sending unit sealing surfaces.
6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the sending unit and a NEW seal.
2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
3. Connect the fuel lines to the sending unit. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Reposition the fuel filter hose clamp(s) (1 or 2) at the fuel filter adapter.
2. Reposition the fuel filter hose clamp(s) (1 or 2) at the fuel injection fuel feed manifold and/or the fuel feed pipe.
3. Remove the fuel hose retainer (3) from the appropriate fuel filter hose.
4. Remove the fuel filter hose (1) from the fuel filter adapter and the fuel injection fuel feed manifold, if required.
5. Remove the fuel filter hose (2) from the fuel filter adapter and the fuel feed pipe, if required.

1. Install the fuel filter hose (1) to the fuel filter adapter and the fuel injection fuel feed manifold, if required.
2. Install the fuel filter hose (2) from the fuel filter adapter and the fuel feed pipe, if required.
3. Install the fuel hose retainer (3) to the fuel filter hose(s).
4. Position the fuel filter hose clamp(s) (1 or 2) at the fuel injection fuel feed manifold and/or the fuel feed pipe.
5. Position the fuel filter hose clamp(s) (1 or 2) at the fuel filter adapter.
6. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Reposition the fuel hose clamp (1) at the fuel return pipe.
4. Reposition the fuel hose clamp (2) at the fuel injection pump.
5. Remove the fuel hose (1) from the return pipe and injection pump.

1. Install the fuel hose (1) to the return pipe and injection pump.
2. Position the fuel hose clamp (2) at the fuel injection pump.
3. Position the fuel hose clamp (1) at the fuel return pipe.
4. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Install the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.
4. Reposition the fuel hose clamp (3) at the fuel injection pump.
5. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump.

1. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump.
2. Position the fuel hose clamp (3) at the fuel injection pump.
3. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
4. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Install the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. Disconnect the fuel feed and return lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the fuel line bracket nut.
3. Remove the fuel line bracket from the stud.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
5. Remove the fuel bundle clips (2) from the transmission brackets (1).
6. Disconnect the chassis harness from the retaining clips.
7. Remove the fuel system cooler, if necessary. Refer to «Fuel Cooler Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Cooler Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
9. Remove the fuel bundle nuts from the chassis.
10. Loosen the electronic brake control module (EBCM) bracket bolts (4).
11. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
12. Remove the fuel bundle using the following procedure: Guide the fuel bundle pipes towards the rear of the vehicle to clear the engine. Lower the fuel bundle while moving it forward and out.

1. Install the fuel pipe bundle using the following procedure: Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
2. Install the fuel bundle nuts to the chassis. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
3. Connect the fuel feed and return lines to the fuel tank lines. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Install the fuel system cooler, if necessary. Refer to «Fuel Cooler Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Cooler Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Connect the fuel bundle clips (2) to the transmission brackets (1).
6. Tighten the EBCM bracket bolts (4). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Lower the vehicle.
8. Install the fuel line bracket to the stud.
9. Install the fuel line bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
10. Connect the fuel feed and return lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
11. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

1. Disconnect the fuel feed and return lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the fuel line bracket nut.
3. Remove the fuel line bracket from the stud.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
5. Remove the fuel bundle clips (2) from the transmission brackets (1).
6. Disconnect the chassis harness from the retaining clips.
7. Remove the fuel system cooler, if necessary. Refer to «Fuel Cooler Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Cooler Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
9. Remove the fuel bundle nuts from the chassis.
10. Loosen the electronic brake control module (EBCM) bracket bolts (4).
11. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
12. Remove the fuel bundle using the following procedure: Guide the fuel bundle pipes towards the rear of vehicle to clear the engine. Lower the fuel bundle while moving it foreword and out.

1. Install the fuel pipe bundle using the following procedure: Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
2. Install the fuel bundle nuts to the chassis. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
3. Connect the fuel feed and return lines to the fuel tank lines. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Install the fuel system cooler, if necessary. Refer to «Fuel Cooler Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Cooler Replacement (Cab/Chassis)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Connect the fuel bundle clips (2) to the transmission brackets (1).
6. Tighten the EBCM bracket bolts (4). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Lower the vehicle.
8. Install the fuel line bracket to the stud.
9. Install the fuel line bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
10. Connect the fuel feed and return lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
11. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

1. Remove the front and auxiliary fuel tanks. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Disconnect the pressure balance pump electrical connector.
3. Remove the fuel bundle nuts.
4. Remove the fuel bundle.

1. Install the fuel bundle.
2. Install the fuel bundle nuts. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
3. Connect the pressure balance pump electrical connector.
4. Install the front and auxiliary fuel tanks. Refer to «Fuel Tank Replacement (Pickup)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Front)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Remove the glow plug control module. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the fuel injection fuel return pipe clips (1).
3. Disconnect the fuel injection fuel return pipe from the fuel injectors.
4. Cut the tie strap (1) securing the fuel injection fuel return pipe to the engine wiring harness.
5. Disconnect the fuel injection fuel return pipe from the fuel return pipe.
6. Remove the fuel injection fuel return pipe from the engine.

1. Position the fuel injection fuel return pipe to the engine. Ensure to route the fuel injection fuel return pipe under the engine wiring harness.
2. Connect the fuel injection fuel return pipe to the fuel return pipe.
3. Install a NEW tie strap (1) securing the fuel injection fuel return pipe to the engine wiring harness in the location shown.
4. Connect the fuel injection fuel return pipe to the fuel injectors.
5. Install the fuel injection fuel return pipe clips (1).
6. Install the glow plug control module. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
8. Start the engine. If the engine stalls, repeat the above step.
9. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel filter and bracket. Refer to «Fuel Filter Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the intake air heater. Refer to «Intake Air Heater Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the fuel injection fuel return pipe clips (1).
4. Disconnect the fuel injection fuel return pipe from the fuel injectors.
5. Disconnect the fuel injection fuel return pipe from the fuel injection fuel feed manifold.
6. Remove the fuel injection fuel return pipe from the engine.

1. Position the fuel injection fuel return pipe to the engine. Ensure to route the fuel injection fuel return pipe under/behind the engine wiring harness.
2. Connect the fuel injection fuel return pipe to the fuel injection fuel feed manifold.
3. Connect the fuel injection fuel return pipe to the fuel injectors.
4. Install the fuel injection fuel return pipe clips (1).
5. Install the intake air heater. Refer to «Intake Air Heater Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
6. Install the fuel filter and bracket. Refer to «Fuel Filter Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2)
7. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
8. Start the engine. If the engine stalls, repeat the above step.
9. Once the engine starts, inspect for fuel leaks.

1. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
4. Disconnect the chassis fuel feed pipe quick connect fitting from the fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Disconnect the engine wiring harness electrical connectors (1) from the engine coolant temperature (ECT) sensors, and reposition the wiring out of the way.
6. Reposition the fuel filter hose clamp (2) at the fuel feed pipe.
7. Remove the fuel filter hose (2) from the fuel feed pipe.
8. Reposition the fuel hose clamp (2) at the fuel injection pump.
9. Remove the fuel hose (1) from the injection pump and reposition the hose out of the way.
10. Remove the fuel feed pipe clip nuts (1 and 2) and bolt (3).
11. Remove the fuel pipe bracket bolt (1) and fuel feed pipe clip (2).
12. Remove the fuel feed pipe.

1. Position and install the fuel feed pipe to the engine.
2. Position fuel feed pipe clip (2) behind the fuel pipe bracket and install the bolt (1). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
3. Install the fuel feed pipe clip nuts (1 and 2) and bolt (3). Tighten: Tighten the bolt/nuts to 24 N.m (18 lb ft).
4. Position the fuel hose and install the hose (1) to the injection pump.
5. Position the fuel hose clamp (2) at the fuel injection pump.
6. Install the fuel filter hose (2) to the fuel feed pipe.
7. Position the fuel filter hose clamp (2) at the fuel feed pipe.
8. Position the engine wiring harness and connect the engine wiring harness electrical connectors (1) to the ECT sensors.
9. Connect the chassis fuel feed pipe quick connect fitting to the fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Install the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
11. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
12. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
13. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
14. Start the engine. If the engine stalls, repeat the above step.
15. Once the engine starts, inspect for fuel leaks.

1. Remove the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the glow plug control module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Remove the fuel temperature sensor. Refer to «Fuel Temperature Sensor Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Reposition the fuel hose clamp (1) at the fuel return pipe.
6. Remove the fuel hose (1) from the return pipe.
7. Reposition the fuel return hose clamp (2) at the fuel return pipe.
8. Remove the fuel return pipe clip bolt (2) and clip.
9. Remove the fuel return pipe clamp bolt (1) and bracket.
10. Reposition the fuel return hose clamp (1) at the return pipe.
11. Remove the fuel return hose from the return pipe.
12. Remove the fuel return pipe clamp bolt (2) and clamp.
13. Disconnect the fuel injection fuel feed pipe (3) from the fuel return pipe.
14. Remove the fuel return pipe from the fuel return hose and the vehicle.

1. Position and install the fuel return pipe to the vehicle and the fuel return hose.
2. Connect the fuel injection fuel feed pipe (3) to the fuel return pipe.
3. Position and install the fuel return pipe clamp and bolt (2). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
4. Install the fuel return hose to the return pipe.
5. Position the fuel return hose clamp (1) at the return pipe.
6. Install the fuel return pipe bracket, clamp, and bolt (1). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
7. Install the fuel return pipe clip and bolt (2). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
8. Position the fuel return hose clamp (2) at the fuel return pipe.
9. Install the fuel hose (1) to the return pipe.
10. Position the fuel hose clamp (1) at the fuel return pipe.
11. Install the fuel temperature sensor. Refer to «Fuel Temperature Sensor Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
12. Install the glow plug control module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
13. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
14. Install the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
15. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
16. Start the engine. If the engine stalls, repeat the above step.
17. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel feed pipe. Refer to «Fuel Feed Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the fuel rail fuel feed pipe clamp bolts (2 and 3) and upper clamps.
4. Loosen the fuel rail fuel feed pipe fitting (1) at the left fuel rail.
5. Loosen the fuel rail fuel feed pipe fitting (4) at the right fuel rail.
6. Remove the right fuel rail fuel feed pipe.

1. Position and install the right fuel rail fuel feed pipe.
2. Install the fuel rail fuel feed pipe upper clamps and bolts (2 and 3). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
3. Tighten the fuel rail fuel feed pipe fitting (4) at the right fuel rail. Tighten: Tighten the fitting to 41 N.m (30 lb ft).
4. Tighten the fuel rail fuel feed pipe fitting (1) at the left fuel rail. Tighten: Tighten the fitting to 41 N.m (30 lb ft).
5. Install the EGR valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
6. Install the fuel feed pipe. Refer to «Fuel Feed Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
8. Start the engine. If the engine stalls, repeat the above step.
9. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel return pipe to fuel injection pump fuel hose. Refer to «Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Loosen the left fuel rail fuel feed pipe fittings (1).
3. Remove the left fuel rail fuel feed pipe.

1. Position and install the left fuel rail fuel feed pipe.
2. Tighten the left fuel rail fuel feed pipe fittings (1). Tighten: Tighten the fittings to 41 N.m (30 lb ft).
3. Install the fuel return pipe to fuel injection pump fuel hose. Refer to «Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
5. Start the engine. If the engine stalls, repeat the above step.
6. Once the engine starts, inspect for fuel leaks.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the fuel filter assembly. Refer to «Fuel Filter Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Remove the fuel filter/heater element housing to fuel feed block fuel hoses. Refer to «Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Disconnect the engine wiring harness electrical connector (1) from the exhaust gas recirculation (EGR) valve.
6. Disconnect the engine wiring harness electrical connector (1) from the fuel injection fuel rail pressure sensor wiring harness extension electrical connector.
7. Remove the fuel injection fuel rail pressure sensor wiring harness extension retainer (3) from the bracket.
8. Remove the engine wiring harness bracket bolts and remove the bracket (2).
9. Reposition the engine wiring harness slightly in order to access the front fuel injection fuel feed pipe.
10. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
11. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
12. Remove the fuel injector pipes.

1. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
2. Reposition the engine wiring harness as necessary.
3. Position the engine wiring harness bracket (2) to the valve rocker arm cover and install the bracket bolts. Tighten: Tighten the bolts to 24 N.m (18 lb ft).
4. Connect the engine wiring harness electrical connector (1) to the fuel injection fuel rail pressure sensor wiring harness extension electrical connector.
5. Install the fuel injection fuel rail pressure sensor wiring harness extension retainer (3) to the bracket.
6. Connect the engine wiring harness electrical connector (1) to the EGR valve.
7. Install the fuel filter/heater element housing to fuel feed block fuel hoses. Refer to «Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Install the fuel filter assembly. Refer to «Fuel Filter Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
9. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
11. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

1. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the glow plug control module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Disconnect the chassis fuel feed and return line quick connect fittings from the engine fuel feed and return pipes. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Remove the fuel line bracket nut.
6. Remove the fuel line bracket from the stud.
7. Remove the engine wiring harness clip from the fuel line bracket.
8. Remove the fuel line bracket bolts (1 and 4), clamp (2), and bracket (3).
9. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
10. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
11. Remove the left fuel injector pipes.

1. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
2. Position the fuel line bracket (3) to the valve rocker arm cover, and install the clamp (2) and bolts (1 and 4). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
3. Install the engine wiring harness clip to the fuel line bracket.
4. Install the fuel line bracket to the stud.
5. Install the fuel line bracket nut. Tighten: Tighten the nut to 21 N.m (15 lb ft).
6. Connect the chassis fuel feed and return line quick connect fittings to the engine fuel feed and return pipes. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Install the glow plug control module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Install the water outlet. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
11. Start the engine. If the engine stalls, repeat the above step.
12. Once the engine starts, inspect for fuel leaks.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Disconnect the fuel lines at the cooler (1). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the fuel cooler bolts (4, 6).
4. Remove the fuel cooler (1).
5. Remove the fuel cooler support bracket bolt (2, 5), and bracket (3) from the fuel cooler (1), if necessary.

1. Install the fuel cooler support bracket (3), and bolts (2, 5) to the fuel cooler (1), if necessary. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
2. Install the fuel cooler (1) to the chassis and crossover.
3. Install the fuel cooler bolts (4, 6). Tighten: Tighten the bolts to 18 N.m (13 lb ft).
4. Connect the fuel lines at the fuel cooler (1). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Lower the vehicle.
6. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Disconnect the fuel lines at the fuel cooler (1). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the fuel cooler nuts (2).
4. Remove the fuel cooler (1).

1. Install the fuel cooler (1).
2. Install the fuel cooler nuts (2). Tighten: Tighten the nuts to 40 N.m (30 lb ft).
3. Connect the fuel lines at the fuel cooler (1). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Lower the vehicle.
5. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
6. Start the engine. If the engine stalls, repeat the above step.
7. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel tank filler housing to body screws (1) and retainer (2).
2. Remove the fuel tank filler pipe housing to fuel tank fill pipe screws.
3. Remove the fuel tank filler housing.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
5. Remove the fuel tank ground strap bolt (1).
6. Remove the chassis harness ground strap (2) and fuel tank ground strap (3).
7. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
8. Loosen the fuel tank vent hose and fill hose clamps (1, 2).
9. Remove the vent hose from the tank.
10. Remove the fill hose from the tank and the vehicle.
11. Cap the opening on the fuel tank in order to prevent possible fuel system contamination.

1. Remove the cap from the opening on the fuel tank.
2. Install the fill hose to the vehicle and tank.
3. Install the vent hose to the tank. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
4. Tighten the fuel tank vent hose and fill hose clamps (1, 2). Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
6. Position the chassis harness ground strap (2) and fuel tank ground strap (3).
7. Install the ground strap anti-rotation tab into the frame hole.
8. Install the fuel tank ground strap bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
9. Lower the vehicle.
10. Install the fuel tank filler housing.
11. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
12. Install the fuel tank filler housing to body screws (1) and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).

1. Relieve the fuel system pressure.
2. Disconnect the fuel feed and pressure balance rear lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Loosen the fuel fill and vent hose clamps (1, 2) at the tank.
4. Remove the fuel fill and vent hoses from the tank.
5. Cap the fuel and vent holes in the fuel tank in order to prevent possible fuel system contamination.

1. Remove the caps from the fuel and vent holes in the fuel tank.
2. Install the fuel fill and vent hoses to the tank. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
3. Tighten the fuel fill and vent hose clamps (1, 2) at the tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
4. Connect the fuel feed and pressure balance rear lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

Fuel System Cleaning

Fungi and other microorganisms can survive and multiply in diesel fuel if water is present. The fungi can be present in any part of the fuel handling system. These fungi grow into long strings and will form into large globules. The growths appear slimy and are usually black, green, or brown. The fungi may grow anywhere in the fuel but are most plentiful where diesel fuel and water meet. As the fuel is agitated, when service station tanks are being filled, fungi are distributed throughout the tank and may be pumped into a vehicle.

Fungi use the fuel as their main energy supply and need only trace amounts of water and minerals. As they grow and multiply, they change fuel into water, sludge, acids, and products of metabolism. The most common symptom is fuel filter plugging; however, various metal components including the fuel sending unit, pipes, fuel injectors, and injection pump can corrode.

If fungi have caused fuel system contamination, use a diesel fuel biocide to sterilize the fuel system. Do not exceed the dosage recommended on the label. Discontinue the use of a biocide when towing a trailer. It is permissible to have biocide in the fuel when starting to tow, but do not add any biocide while towing.

Steam cleaning may be necessary if most of the fungus growth cannot be removed with biocides.

The presence of water or gasoline in diesel fuel may also cause injection pump and nozzle damage.

This procedure checks for the presence of water and gasoline in diesel fuel that may cause injection pump and nozzle damage.

Remove and inspect the fuel filter element.

1. If water, gasoline or fungi/bacteria are not present, end the inspection.
2. If water or fungi/bacteria are present, proceed to Cleaning Water from the Fuel System.
3. If gasoline is present, proceed to Cleaning Gasoline from the Fuel System.

Cleaning Water from the Fuel System

1. Disconnect the negative battery. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Inspect the fuel tank and the fuel sender for rust, fungi or bacteria. If there is rust, replace the rusted components.
4. Clean the inside of the fuel tank and the fuel sender with hot water.
5. Use compressed air in order to dry the fuel tank and the fuel sender.
6. Disconnect the ends of the following lines: The fuel filter inlet line (both ends) The transfer pump pressure line and suction line (if applicable) The fuel filter outlet line (both ends) The fuel filter drain The fuel return line (both ends)
7. Inspect each of the pipes and lines.
8. Replace any rusted pipes.
9. Clean the inside of the fuel filter housing.
10. Dry the fuel filter housing with compressed air.
11. Dry the inside of each line with low pressure air.
12. Disconnect the crankshaft position sensor.
13. Install a new fuel filter. Refer to «Fuel Filter Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
14. Install the sending unit Refer to «Fuel Sender Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
15. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
16. Reconnect the following lines: The fuel filter inlet line The fuel filter outlet line The transfer pump pressure and suction (both ends) lines The fuel return line (tank end)
17. Connect the fuel filter drain to a line that flows into a clean metal container.
18. Connect the batteries.
19. Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into a metal container.
20. Close the fuel filter drain and remove the bleeder hose.
21. Install a hose on the fuel return line near the glow plug relay, and insert other end into a 7.6 liters (2 gallon) metal container.
22. Crank the engine for 15 second time intervals, with 1 minute cool-down periods. Continue until 3.8 liters (1 gallon) of fuel has passed into the container.
23. Connect the fuel return line.
24. Reconnect the crankshaft position sensor.
25. Start and run the engine.
26. Stop the engine.
27. Clean any fuel spillage from the engine.
28. Fill the fuel tank and add a biocide, if needed.

Cleaning Gasoline from the Fuel System

1. Drain the fuel tank.
2. Fill the fuel tank to 1/4 full.
3. Loosen the fuel filter drain and connect the filter to a hose that flows into a metal container.
4. Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into the metal container.
5. Hand tighten the fuel filter drain and disconnect the hose.
6. Install a hose on the fuel return line near the glow plug relay, and insert the other end into a 7.6 liters (2 gallon) metal container.
7. Crank the engine for 30 second time intervals, with 1 minute cool-down periods. Continue until 3.8 liters (1 gallon) of fuel has passed into the container.
8. Reconnect the fuel return line.
9. Attempt to start and run the engine for 15 minutes. If the engine does not start, operate the hand primer for 30 strokes, or until firm.
10. Stop the engine.
11. Clean any fuel spillage from the engine.
12. Clear the engine of any diagnostic trouble codes (DTCs).

Fuel Feed and Return Pipe Purging

1. Pump the primer (1) located on top of the fuel filter 30 times or until stiff.
2. Attempt to start and run the engine. If the engine does not start, repeat step 1.
3. Allow to run for 5 minutes at idle.
4. Check for fuel leaks.
5. Clear all engine diagnostic trouble codes (DTCs).

1. Remove the heater outlet pipe. Refer to «Heater Outlet Hose Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the fuel filter assembly. Refer to «Fuel Filter Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the turbocharger coolant outlet pipe. Refer to «Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Disconnect the engine wiring harness electrical connector (1) from the fuel injection fuel rail fuel pressure sensor wiring harness extension.
5. Remove the fuel injection fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket.
6. Remove the wiring harness bracket bolts and bracket (2).
7. Prior to removing the fuel injection fuel feed pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
8. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
9. Remove the fuel injection fuel feed pipes.
10. Loosen the right fuel rail fuel feed pipe fitting (4) at the fuel rail.
11. Remove the fuel injection fuel rail bolts.
12. Remove the fuel rail.

1. Position the fuel injection fuel rail to the intake manifold.
2. Install the fuel injection fuel rail bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Tighten the right fuel rail fuel feed pipe fitting (4) at the fuel rail. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
4. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
5. Position the wiring harness bracket (2) and install the bolts. Tighten: Tighten the bolts to 24 N.m (18 lb ft).
6. Connect the engine wiring harness electrical connector (1) to the fuel injection fuel rail fuel pressure sensor wiring harness extension.
7. Install the fuel injection fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket.
8. Install the turbocharger coolant outlet pipe. Refer to «Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Install the fuel filter assembly. Refer to «Fuel Filter Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Install the heater outlet pipe. Refer to «Heater Outlet Hose Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel line bracket nut.
2. Remove the fuel line bracket from the stud.
3. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Remove the right fuel rail fuel feed pipe. Refer to «Fuel Injection Fuel Feed Front Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
6. Remove the fuel return pipe. Refer to «Fuel Return Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Remove the fuel pipe bracket bolt (4) and bracket (3).
8. Loosen the left fuel rail fuel feed pipe fittings (1).
9. Remove the left fuel rail fuel feed pipe.
10. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
11. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
12. Remove the left fuel injection fuel feed pipes.
13. Remove the fuel injection fuel rail bolts.
14. Remove the fuel injection fuel rail and bracket.
15. Reposition the fuel hose clamp at the rail and remove the fuel hose, if required.

1. Install the fuel hose to the fuel injection fuel rail and position the clamp, if required.
2. Position the fuel injection fuel rail and bracket to the left intake manifold.
3. Install the fuel injection fuel rail bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Position the fuel injection fuel feed pipes.
5. Tighten the left fuel rail fuel feed pipe fittings (1). Tighten: Tighten the fittings to 41 N.m (30 lb ft).
6. Position the fuel pipe bracket (3) and install the bolt (4). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
7. Install the fuel return pipe. Refer to «Fuel Return Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Install the right fuel rail fuel feed pipe. Refer to «Fuel Injection Fuel Feed Front Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
9. Install the PCV hose/pipe. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
10. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
11. Install the fuel line bracket to the stud.
12. Install the fuel line bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
13. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
14. Start the engine. If the engine stalls, repeat the above step.
15. Once the engine starts, inspect for fuel leaks.

1. Remove the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the fuel filter/heater element housing to fuel feed block fuel hose. Refer to «Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
4. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.
6. Remove the fuel hose (4) from the fuel injection fuel feed manifold.
7. Reposition the fuel return hose clamp (1) at the fuel injection fuel feed manifold.
8. Remove the fuel pipe clip bolt (1) and clip.
9. Disconnect the fuel injector fuel feed pipe (2) from the fuel injection fuel feed manifold.
10. Remove the fuel injection fuel feed manifold from the fuel return hose and the vehicle.

1. Install the fuel injection fuel feed manifold to the vehicle and the fuel return hose.
2. Connect the fuel injector fuel feed pipe (2) to the fuel injection fuel feed manifold.
3. Install the fuel pipe clip and bolt (1). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
4. Position the fuel return hose clamp (1) at the fuel injection fuel feed manifold.
5. Install the fuel hose (4) to the fuel injection fuel feed manifold.
6. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
7. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
9. Install the fuel filter/heater element housing to fuel feed block fuel hose. Refer to «Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Install the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
11. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

1. Remove the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Unbolt and reposition the air conditioning (A/C) compressor (with the hoses attached) to the right side of the engine compartment. Refer to «Air Conditioning Compressor Replacement (LLY/LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (HP2)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Disconnect the engine coolant temperature (ECT) sensor electrical connectors (1) and reposition the harness branches.
6. Disconnect the wiring harness extension electrical connector (1) from the fuel pressure regulator.
7. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.
8. Reposition the fuel hose clamp (3) at the fuel injection pump.
9. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump.
10. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
11. Using compressed air, thoroughly blow dry the regulator and pump.
12. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX®.
13. Remove the fuel pressure regulator (2).
14. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following: Place a clean rag over the bore on order to collect the excess fuel. Bump the engine over in order to flush any debris out of the regulator bore.

Note. If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.

1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.
2. Install the fuel pressure regulator (2).
3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX®. Tighten: Tighten the screws a first pass to 4 N.m (35 lb in). Tighten the screws a final pass to 7 N.m (62 lb in).
4. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump.
5. Position the fuel hose clamp (3) at the fuel injection pump.
6. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
7. Connect the wiring harness extension electrical connector (1) to the fuel pressure regulator.
8. Position the engine wiring harness branches to the ECT sensors and connect the ECT sensor electrical connectors (1).
9. Position and install the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LLY/LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (HP2)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
11. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
12. Install the generator. Refer to «Generator Replacement (4.3L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (6.6L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
13. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
14. Start the engine. If the engine stalls, repeat the above step.
15. Once the engine starts, inspect for fuel leaks.

1. Remove the glow plug module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the fuel pressure relief valve from the left fuel rail.

1. Install the fuel pressure relief valve to the left fuel rail. Tighten: Tighten the valve to 100 N.m (74 lb ft).
2. Install the glow plug module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
4. Start the engine. If the engine stalls, repeat the above step.
5. Once the engine starts, inspect for fuel leaks.

1. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Reposition the fuel hose clamp (1) at the fuel return pipe.
4. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.
5. Reposition the fuel hose clamp (2) at the fuel injection pump.
6. Reposition the fuel hose clamp (3) at the fuel injection pump.
7. Remove the fuel hose (1) from the return pipe and injection pump.
8. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump.
9. Loosen the left fuel rail fuel feed pipe fittings (1).
10. Remove the left fuel rail fuel feed pipe.
11. Remove the fuel injection pump. Refer to «Fuel Injection Pump Removal»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-3-of-5__fuel-injection-pump-removal) .

Preparing The Fuel Injection Pump

1. Hold the fuel pump by the drive gear in a vice with copper jaw liners.
2. Loosen the gear nut until the nut is even with the end of the gear shaft.
3. Remove the gear from the tapered shaft of the injection pump.
4. Separate the injection pump and adapter by removing the 3 bolts and spacers.
5. Inspect the O-ring for damage on the pump adapter and replace, if necessary. Lubricate the O-ring with clean engine oil.
6. Clean all mating surfaces.
7. Install the adapter on the pump. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
8. Install the 3 bolts and spacers. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
9. Install the gear and nut. Tighten: Tighten nut to 70 N.m (52 lb ft).

1. Install the fuel injection pump. Refer to «Fuel Injection Pump Installation»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-4-of-5__fuel-injection-pump-installation) .
2. Position the left fuel rail fuel feed pipe.
3. Tighten the left fuel rail fuel feed pipe fittings (1). Tighten: Tighten fittings to 41 N.m (30 lb ft).
4. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump.
5. Install the fuel hose (1) from the return pipe and injection pump.
6. Position the fuel hose clamp (3) at the fuel injection pump.
7. Position the fuel hose clamp (2) at the fuel injection pump.
8. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
9. Position the fuel hose clamp (1) at the fuel return pipe.
10. Install the center intake manifold. Refer to «Center Intake Manifold Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
11. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
13. Start the engine. If the engine stalls, repeat the above step.
14. Once the engine starts, inspect for fuel leaks.

1. EN-47909 Injector Bore and Sleeve Cleaning Kit. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. J-46594 Fuel Injector Puller. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Remove the right fuel injection fuel feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the right fuel injection fuel return pipe. Refer to «Fuel Injection Fuel Return Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Disconnect the engine wiring harness electrical connectors from the fuel injectors.
4. Remove the engine wiring harness clip (1) from the wiring harness bracket and remove the bracket (2).
5. Remove the engine wiring harness clips from the wiring harness bracket.
6. Remove the engine wiring harness bracket bolts (1) and bracket.
7. Remove the engine wiring harness clip from the oil level indicator tube bracket (2).
8. Remove the oil level indicator tube bolt (3).
9. Remove the oil level indicator tube bracket bolts (1).
10. Remove the oil level indicator tube bracket (2).
11. Remove the fuel injector bracket bolts.
12. Install the J-46594 (1) into the bolt hole in the fuel injector bracket. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
13. Install a flare nut wrench onto the J-46594 and pull back away from the fuel injector, until the injector releases from its seat. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
14. Remove the J-46594 . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
15. Remove the fuel injectors with brackets.
16. If necessary, remove the fuel injector bracket pins.
17. Remove and discard the copper washer from the fuel injector bore.
18. Remove and discard the O-ring from the fuel injector.

Fuel Injector Cleaning and Inspection

Note. If reusing the old injectors perform the following

1. Use a soft bristle non-metallic brush and Top Engine Cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before re-installation.
2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat.
3. Replace the injector if any damage is found.
4. Clean the fuel injector high pressure line.
5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found.

Injector Bore Cleaning

Note. The procedure below will aid in the cleaning of carbon deposits from the injector sleeve during an injector replacement

1. Install the EN-47909-2 Radial Brush (brass), to the EN-47909-1 Handle Assembly.
2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole.
3. Using compressed air, evacuate any debris from the injector bore.
4. Remove the radial brush from the handle assembly.
5. Install the EN-47909-3 Axial Brush (nylon), to the EN-47909-1.
6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore.
7. Using compressed air, evacuate any debris from the injector bore.
8. Lightly dampen EN-47909-20 Cotton Swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore.
9. Inspect the injector bore for any deposits and repeat brushing if necessary.
10. If necessary, crank the engine in order to expel any solvent before starting the engine. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) and/or «Glow Plug Replacement - Bank 2»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) . Disable the fuel system. Disconnect the crankshaft position (CKP) sensor electrical connector. Crank the engine in order to expel any excessive solvent. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris. Connect the CKP sensor electrical connector. Enable the fuel system. Reinstall the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) and/or «Glow Plug Replacement - Bank 2»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Install a NEW copper washer to the fuel injector bore.
2. Install a NEW O-ring onto the fuel injector.
3. If necessary, install the fuel injector bracket pins.
4. Install the fuel injectors with brackets.
5. Install the fuel injector bracket bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
6. Position the oil level indicator tube bracket (2) to the generator bracket.
7. Install the oil level indicator tube bracket bolts (1). Tighten: Tighten the bolts to 21 N.m (15 lb ft).
8. Install the oil level indicator tube bolt (3). Tighten: Tighten the bolt to 21 N.m (15 lb ft).
9. Install the wiring harness clip to the oil level indicator tube bracket (2).
10. Position the engine wiring harness bracket onto the upper valve rocker arm cover and install the bolts (1). Tighten: Tighten the bolts to 21 N.m (15 lb ft).
11. Install the engine wiring harness clips to the wiring harness bracket.
12. Position the engine wiring harness bracket (2) onto the upper valve rocker arm cover and install the engine wiring harness clip (1) to the wiring harness bracket.
13. Connect the engine wiring harness electrical connectors to the fuel injectors.
14. Install the right fuel injection fuel return pipe. Refer to «Fuel Injection Fuel Return Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
15. Install the right fuel injection fuel feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
16. If the fuel injectors were replaced, refer to «Fuel Injector Flow Rate Programming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
17. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
18. Start the engine. If the engine stalls, repeat the above step.
19. Once the engine starts, inspect for fuel leaks.

1. EN-47909 Injector Bore and Sleeve Cleaning Kit. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. J-46594 Fuel Injector Puller. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Remove the left fuel injection fuel feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Left Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the left fuel injection fuel return pipe. Refer to «Fuel Injection Fuel Return Pipe Replacement - Left Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Disconnect the engine wiring harness electrical connectors from the fuel injectors.
4. Remove the fuel injector bracket bolts.
5. Install the J-46594 (1) into the bolt hole in the fuel injector bracket. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
6. Install a flare nut wrench onto the J-46594 and pull back away from the fuel injector, until the injector releases from its seat. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Remove the J-46594 . See «Special Tools»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Remove the fuel injectors with brackets.
9. If necessary, remove the fuel injector bracket pins.
10. Remove and discard the copper washer from the fuel injector bore.
11. Remove and discard the O-ring from the fuel injector.

Note. If reusing the old injectors perform the following

1. Use a soft bristle non-metallic brush and Top Engine Cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before re-installation.
2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat.
3. Replace the injector if any damage is found.
4. Clean the fuel injector high pressure line.
5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found.

Note. The procedure below will aid in the cleaning of carbon deposits from the injector sleeve during an injector replacement

1. Install the EN-47909-2 Radial Brush (brass), to the EN-47909-1 Handle Assembly.
2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole.
3. Using compressed air, evacuate any debris from the injector bore.
4. Remove the radial brush from the handle assembly.
5. Install the EN-47909-3 Axial Brush (nylon), to the EN-47909-1.
6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore.
7. Using compressed air, evacuate any debris from the injector bore.
8. Lightly dampen EN-47909-20 Cotton Swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore.
9. Inspect the injector bore for any deposits and repeat brushing if necessary.
10. If necessary, crank the engine in order to expel any solvent before starting the engine. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) and/or «Glow Plug Replacement - Bank 2»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) . Disable the fuel system. Disconnect the crankshaft position (CKP) sensor electrical connector. Crank the engine in order to expel any excessive solvent. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris. Connect the CKP sensor electrical connector. Enable the fuel system. Reinstall the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) and/or «Glow Plug Replacement - Bank 2»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Install a NEW copper washer to the fuel injector bore.
2. Install a NEW O-ring onto the fuel injector.
3. If necessary, install the fuel injector bracket pins.
4. Install the fuel injectors with brackets.
5. Install the fuel injector bracket bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
6. Connect the engine wiring harness electrical connectors to the fuel injectors.
7. Install the left fuel injection fuel return pipe. Refer to «Fuel Injection Fuel Return Pipe Replacement - Left Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Install the left fuel injection fuel feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Left Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
9. If the fuel injectors were replaced, refer to «Fuel Injector Flow Rate Programming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
11. Start the engine. If the engine stalls, repeat the above step.
12. Once the engine starts, inspect for fuel leaks.

1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/exhaust/#engine-exhaust-system) .
3. Disconnect the engine wiring harness electrical connector (1) from the fuel rail fuel pressure sensor wiring harness extension electrical connector.
4. Remove the fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket.
5. Remove the EGR valve cooler rear bracket bolts and bracket.
6. Disconnect the fuel rail fuel pressure sensor wiring harness extension (1) from the fuel rail fuel pressure sensor.
7. Prior to removal, clean the fuel rail fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
8. Using compressed air, thoroughly blow dry the sensor and surrounding area.
9. Remove the fuel rail fuel pressure sensor (2).

1. Install the fuel rail fuel pressure sensor (2). Tighten: Tighten the sensor to 70 N.m (52 lb ft).
2. Connect the fuel rail fuel pressure sensor wiring harness extension (1) to the fuel rail fuel pressure sensor.
3. Position the EGR valve cooler rear bracket to the cylinder head and install the bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the engine wiring harness electrical connector (1) to the fuel rail fuel pressure sensor wiring harness extension electrical connector.
5. Install the fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket.
6. Install the right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right Side»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/exhaust/#engine-exhaust-system) .
7. Install the EGR valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
8. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
9. Start the engine. If the engine stalls, repeat the above step.
10. Once the engine starts, inspect for fuel leaks.

1. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Disconnect the engine wiring harness electrical connector from the fuel temperature sensor.
3. Remove the fuel temperature sensor (1) from the fuel return pipe.

1. Install the fuel temperature sensor (1) to the fuel return pipe. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
2. Connect the engine wiring harness electrical connector to the fuel temperature sensor.
3. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__fuel-system-priming) .
4. Start the engine. If the engine stalls, repeat the above step.
5. Once the engine starts, inspect for fuel leaks.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the right wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Remove the engine wiring harness nut(s) from the glow plug(s).
4. Remove the engine wiring harness lead(s) from the glow plug(s).
5. Remove the glow plug(s) from the cylinder head.

1. Install the glow plug(s) to the cylinder head and tighten to 18 N.m (13 lb ft).
2. Install the engine wiring harness lead(s) to the glow plug(s).
3. Install the engine wiring harness nut(s) to the glow plug(s) and tighten to 1.7 N.m (15 lb in).
4. Install the right wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the left wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Remove the engine wiring harness nut(s) from the glow plug(s).
4. Remove the engine wiring harness lead(s) from the glow plug(s).
5. Remove the glow plug(s) from the cylinder head.

1. Install the glow plug(s) to the cylinder head and tighten to 18 N.m (13 lb ft).
2. Install the engine wiring harness lead(s) to the glow plug(s).
3. Install the engine wiring harness nut(s) to the glow plug(s) and tighten to 1.7 N.m (15 lb in).
4. Install the left wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Disconnect the positive battery cable (1) from the glow plug control module.
3. Disconnect the engine wiring harness electrical connector (2) from the glow plug control module.
4. Remove the glow plug control module bolts and module.
5. Remove the fuel return pipe clamp bolt (1).
6. Remove the glow plug control module protector bolts and protector (1), if required.
7. Remove the glow plug control module bracket and bolts (2), if required.

1. Position the glow plug control module bracket (2) to the lower valve rocker arm cover and install the bolts, if required. Tighten: Tighten the bolts to 10 N.m (89 lb in).
2. Position the glow plug control module protector (1) and install the bolts, if required. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the fuel return pipe clamp bolt (1). Tighten: Tighten the bolt to 24 N.m (18 lb ft).
4. Position the glow plug control module onto the bracket and install the bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Connect the engine wiring harness electrical connector (2) to the glow plug control module.
6. Connect the positive battery cable (1) to the glow plug control module.
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
8. If a NEW glow plug control module was installed, program the module. Refer to «Control Module References»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .
2. Remove the right wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Remove the CKP sensor bolt.
5. Remove the CKP sensor.
6. If necessary, remove the CKP sensor spacer bolts.
7. If necessary, remove the CKP sensor spacer.

1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil.
2. If necessary, install the NEW O-ring to the CKP sensor spacer. NOTE: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer.
3. If necessary, install the CKP sensor spacer. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
4. If necessary, install the CKP sensor spacer bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Lubricate a NEW CKP sensor O-ring with clean engine oil.
6. Install the NEW O-ring to the CKP sensor.
7. Install the CKP sensor.
8. Install the CKP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Connect the CKP sensor electrical connector.
10. Install the right wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (With Single Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) or «Battery Negative Cable Disconnection and Connection (With Dual Batteries)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/charging-system/#battery-charging-system-starting-system) .

1. Remove the cooling fan pulley. Refer to «Fan Pulley Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the camshaft position (CMP) sensor bolt.
3. Remove the CMP sensor.

1. Lubricate the CMP sensor O-ring with clean engine oil.
2. Install the CMP sensor. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
3. Install the CMP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the cooling fan pulley. Refer to «Fan Pulley Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

Note. There is no gasket between the motor and the valve. However, some vehicles may have a thin metal spacer between the motor and the valve that appears to be a gasket. This spacer is used to correct for production variances in some valves and should be reinstalled with the new motor.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Disconnect the engine wiring harness electrical connector (1) from the exhaust gas recirculation (EGR) valve motor.
3. Remove the EGR valve motor screws.
4. Remove the EGR valve motor, and spacer (if equipped) from the EGR valve.

1. Position the EGR spacer (if equipped), and NEW EGR valve motor to the EGR valve.
2. Install the EGR valve motor screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
3. Connect the engine wiring harness electrical connector (1) to the EGR valve motor.
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Cycle the ignition to relearn the new EGR valve motor pintle position.

1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the EGR valve gaskets (1), if required.
3. Remove the EGR valve bolts (2).
4. Remove the EGR valve (3).
5. Remove and discard the EGR valve to valve cooler gasket.

Note. Use a NEW EGR valve gasket when installing the EGR valve.

1. Position a NEW EGR valve to valve cooler gasket to the valve cooler.
2. Position the EGR valve (3) to the valve cooler.
3. Install the EGR valve bolts (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install NEW EGR valve gaskets (1) onto the EGR valve, if required.
5. Install the EGR valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the charger air outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Reposition the heater inlet hose clamp (1) at the exhaust gas recirculation (EGR) valve cooler.
6. Remove the heater inlet hose from the EGR valve cooler and reposition out of the way.
7. Remove the EGR valve cooler coolant hose clamp nut (2).
8. Reposition the EGR valve cooler coolant hose clamp (1).
9. Remove the EGR valve cooler coolant hose from the EGR valve cooler. Reposition the hose out of the way.
10. Remove the right exhaust pipe to EGR valve cooler nuts (2).
11. Remove the rear EGR valve cooler bolts (1).
12. Remove the front EGR valve cooler bolts (1).
13. Remove the EGR temperature sensors (3). Refer to «Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
14. Remove the EGR valve cooler (2) and gasket (1). Discard the gasket.
15. If necessary, perform the following steps in order to remove the EGR brackets: Remove the fuel injection fuel feed manifold bolt (3). Remove the fuel feed pipe nut (1) and reposition the clip. Remove the EGR bracket bolt (2). Remove the EGR brackets (4).
16. If replacing the EGR valve cooler, perform the following steps: Reposition the EGR valve cooler hose clamp and remove the hose (4). Remove the EGR valve bolts (2). Remove the EGR valve (3). Remove and discard the EGR valve gaskets (1).

1. If the EGR valve cooler was replaced, perform the following steps: Position the EGR valve (3) to the cooler. Install the EGR valve bolts (2). Tighten: Tighten the bolts to 20 N.m (15 lb ft). Install the EGR valve cooler hose (4) and position the hose clamp. Install NEW EGR valve gaskets (1).
2. If necessary, perform the following steps in order to install the EGR brackets: Position the EGR brackets (4). Install the EGR bracket bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft). Position the clip and install the fuel feed pipe nut (1). Tighten: Tighten the nut to 25 N.m (18 lb ft). Install the fuel injection fuel feed manifold bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Install a NEW EGR valve cooler gasket (1) onto the cooler studs, and install the EGR cooler (2) to the engine.
4. Install the EGR temperature sensors (3). Refer to «Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) or «Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Install the front EGR valve cooler bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
6. Install the rear EGR valve cooler bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Install the right exhaust pipe to EGR valve cooler nuts (2). Tighten: Tighten the nuts to 53 N.m (39 lb ft).
8. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler.
9. Position the EGR valve cooler coolant hose clamp (1).
10. Install the EGR valve cooler coolant hose clamp nut (2). Tighten: Tighten the nut to 24 N.m (18 lb ft).
11. Position the heater inlet hose and install the hose to the EGR valve cooler.
12. Position the heater inlet hose clamp (1) at the EGR valve cooler.
13. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
14. Install the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
15. Install the charger air outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
16. Fill the cooling system. Refer to «Cooling System Draining and Filling (Vac-N-Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 15

Scheme 16

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2).
3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3).
4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor.
5. Remove the exhaust differential pressure sensor bracket bolts (1).
6. Remove the exhaust differential pressure sensor (2).

1. Position the exhaust differential pressure sensor (2) to the bracket.
2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor.
4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3).
5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2).
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2).
3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3).
4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor.
5. Remove the exhaust differential pressure sensor bracket bolts (1).
6. Remove the exhaust differential pressure sensor (2).

1. Position the exhaust differential pressure sensor (2) to the bracket.
2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor.
4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3).
5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2).
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3).
3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor.
4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut.
5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1).
6. Remove the exhaust differential pressure sensor pipe assembly.

1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle.
3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten: Tighten the fittings to 45 N.m (33 lb ft).
4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten: Tighten the bracket bolt/nut to 9 N.m (80 lb in).
5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor.
6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3).
7. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3).
3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor.
4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut.
5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1).
6. Remove the exhaust differential pressure sensor pipe assembly.

1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle.
3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten: Tighten the fittings to 45 N.m (33 lb ft).
4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten: Tighten the bracket bolt/nut to 9 N.m (80 lb in).
5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor.
6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3).
7. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2).
3. Remove the exhaust temperature sensor.

1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
2. Install the exhaust temperature sensor. Tighten: Tighten the sensor to 45 N.m (33 lb ft).
3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2).
4. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4).
3. Remove the exhaust temperature sensor.

1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
2. Install the exhaust temperature sensor. Tighten: Tighten the sensor to 45 N.m (33 lb ft).
3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4).
4. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .

1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Remove the turbocharger oil feed pipe banjo bolt and washer.
3. Reposition the turbocharger oil feed pipe out of the way.
4. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.
5. Remove the turbocharger vane control solenoid valve bracket bolt (1) and bracket (2).
6. Remove the turbocharger vane control solenoid valve (3) from the turbocharger.

1. Install the turbocharger vane control solenoid valve (3) to the turbocharger.
2. Install the turbocharger vane control solenoid valve bracket (2) and bolt (1). Tighten: Tighten the bolt to 23 N.m (17 lb ft).
3. Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.
4. Position the turbocharger oil feed pipe to the turbocharger.
5. Install a NEW turbocharger oil feed pipe washer and the banjo bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
6. Install the EGR valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
7. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__turbocharger-learn) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Disconnect the engine wiring harness electrical connector (1) from the turbocharger vane position sensor electrical connector (2).
3. Remove the turbocharger vane position sensor electrical connector clips from the wiring harness bracket.
4. Remove the thermal reflective shield/tape from the vane position sensor, if required.
5. Remove the turbocharger vane position sensor from the turbocharger.

1. Install the turbocharger vane position sensor to the turbocharger. Tighten: Tighten the sensor to 28 N.m (21 lb ft).
2. Install the turbocharger vane position sensor electrical connector clips to the wiring harness bracket.
3. Connect the engine wiring harness electrical connector (1) to the turbocharger vane position sensor electrical connector (1).
4. Install the thermal reflective shield/tape, if required, refer to the following procedure.

Thermal Reflective Shield/Tape Installation

Note. Ensure outside surface of sensor body is clean and oil-free prior to beginning the installation procedure. If sensor body surface is oily, use a mild degreaser in order to remove the oil from the surface. Ensure degreased surface is dry prior to beginning the installation. The thermal reflective shield and tie strap are to be installed over the vane position sensor AFTER the sensor is installed and torqued in the turbo centerhousing. Graphics below show the sensor prior to the installation process for clarity purposes only.

1. Peel off the protective backing from the back side of the thermal reflective shield/tape.
2. With the sticky side of the shield/tape applied against the sensor body, align the bottom edge of the shield/tape with the bottom edge of the hex, and begin wrapping the sensor.
3. Completely wrap the shield/tape around the sensor.
4. Tuck the top of the shield/tape under the head of the brass cable crimp sleeve all around, allowing the shield/tape to fold over and overlap itself at the top.
5. The top of the shield/tape is now shown tucked under the head of the brass cable crimp sleeve all around.
6. Wrap the tie strap around the necked porting of the sensor body just above the hex. Insert the end of the strap in the buckle and tighten by pulling the end with needlenose pliers.
7. Bend the end of the tie strap 180 degrees over the top of the buckle.
8. Cut off the tie strap using side cutters so that the cut end will lie approximately over the center of the buckle. Push down the end of the tie strap over the buckle in order to minimize protrusion of the cut end or any sharp edges.
9. Finished installation is shown.
10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
11. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2__turbocharger-learn) .

Turbocharger Learn

The engine control module (ECM) performs the turbocharger learn procedure automatically when the engine coolant temperature (ECT) is least 72°C (162°F). After each ignition cycle, and before the enable criteria have been met, the ECM will use the previously learned value. If the ECM does not have a previously learn value, it will default to a stored calibrated value. The ECM will use this value until the enable criteria have been met. It will then perform this procedure to learn the new value. If the ECM attempts to perform the turbocharger (TC) Learn procedure and fails, DTCs P003A or P2563 may set.

If a TC Learn is not performed after a related turbocharger repair, the ECM will use a stored vane position value that may be invalid. The ECM may then cause a diagnostic to fail and set an invalid DTC. Certain enable criteria must be met for the ECM to perform this procedure.

The turbocharger learn procedure is required when the following service procedures have been performed

1. TC vane position control solenoid valve replacement
2. TC vane position sensor replacement
3. ECM replacement
4. TC replacement
5. Any service that disturbs the TC components

Learn Procedure With the Tech 2

1. The following conditions must be met for the ECM to perform the turbocharger learn procedure: The A/C is OFF. The vehicle is in Park or Neutral. Start and idle the engine. The engine coolant temperature (ECT) is greater than 40°C (104°F).
2. After the enable conditions have been met and the engine idle is stabilized, enter the TC Learn Output function from the Module Setup Menu. Command the TC Learn ON for at least 5 seconds, then command it OFF. The system should have learned the new turbocharger position. The TC Vane Pos. Lrn This Run Cycle parameter should have toggled from No to Yes.

1. Loosen the screw holding the air cleaner housing door in place.
2. Remove the air cleaner housing door.
3. Remove the air filter element.

1. Stand facing the front fender on the passenger side of the vehicle. Insert the element into the housing. Place the palm of your hand on the inboard end of the element, and press the element into position.
2. Press both downward and inboard until the outboard end of the element clicks into place inboard of the locating tab.
3. Install the air cleaner housing door and tighten the screw. Tighten: Tighten the screw to 4 N.m (35 lb in).

1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor.
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Grasp the air cleaner assembly and pull up on the assembly in order to disengage the retaining pins from the grommets.

1. Line up the retaining pins with the grommets.
2. Install the air cleaner assembly until the air cleaner is seated fully on the mounts and is up against the fender apron.
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor.

1. Loosen the outlet duct clamps at the air cleaner assembly and the turbocharger.
2. Remove the air cleaner outlet duct.

Note. The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet and also must be fully seated against the positive stop features on both sides of the air cleaner assembly.

1. Install the air cleaner outlet duct.
2. Tighten the outlet duct clamps at the turbocharger and the air cleaner assembly. Tighten: Tighten the clamps to 4 N.m (35 lb in).

1. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the positive crankcase ventilation (PCV) hose/pipe from the air intake pipe. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
4. Disconnect the engine wiring harness electrical connector from the turbocharger control solenoid valve.
5. Remove the engine wiring harness clip (1) from the bracket on the turbocharger.
6. Reposition the turbocharger control solenoid valve wiring harness extension out of the way.
7. Loosen the air intake pipe to turbocharger clamp (1).
8. Remove the air intake pipe (2) from the turbocharger.

1. Clean the mating surfaces on the air intake pipe and the turbocharger.
2. Align the arrow (2) on the air intake pipe to the arrow (1) on the turbocharger.
3. Install the air intake pipe (2) into the turbocharger.
4. Tighten the air intake pipe to turbocharger clamp (1). Tighten: Tighten the clamp to 4.6 N.m (41 lb in).
5. Route the turbocharger control solenoid valve wiring harness extension into position.
6. Install the engine wiring harness clip (1) to the bracket on the turbocharger.
7. Connect the engine wiring harness electrical connector to the turbocharger control solenoid valve.
8. Install the PCV hose/pipe to the air intake pipe. Refer to «Positive Crankcase Ventilation Hose/Pipe/Tube Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
10. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (LU3)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Water Outlet Tube Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Loosen the charge air cooler inlet pipe connector clamp (1) at the turbocharger.
3. Remove the charge air cooler inlet pipe connector (2) from the turbocharger.
4. Cover the turbocharger opening with tape in order to prevent possible entry of foreign objects.
5. Remove the wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Working through the wheelhouse, loosen the charge air cooler inlet pipe connector clamp (1) at the charge air cooler.
7. Remove the charge air cooler inlet pipe connector (2) from the charge air cooler.
8. Lower the vehicle.
9. Remove the charge air cooler inlet pipe from the vehicle.

1. Install the charge air cooler inlet pipe to the vehicle.
2. Remove the turbocharger opening cover.
3. Install the charge air cooler inlet pipe connector (2) onto the turbocharger.
4. Tighten the charge air cooler inlet pipe to turbocharger connector clamp (1). Tighten: Tighten the clamp to 8 N.m (70 lb in).
5. Raise and support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/hoistjack/#general-information) .
6. Working through the wheelhouse, install the charge air cooler inlet pipe connector onto the charge air cooler.
7. Tighten the charge air cooler inlet pipe to charge air cooler connector clamp (1). Tighten: Tighten the clamp to 8 N.m (70 lb in).
8. Install the wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
9. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
2. Using a pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip (1) from the charge air cooler outlet pipe.
3. Remove the charge air cooler outlet pipe (2) from the intake air heater.
4. Remove the wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Working through the wheelhouse, Using the pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip (1) from the charge air cooler outlet pipe.
6. Remove the charge air cooler outlet pipe (2) from the charge air cooler and the vehicle.

1. Install NEW quick connect fitting clips to both ends of the charge air cooler outlet pipe.
2. Working through the wheelhouse, install the charge air cooler outlet pipe onto the charge air cooler.
3. Install the wheelhouse panel. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/frames-subframes-crossmembers/#frame-and-underbody) .
4. Install the charge air cooler outlet pipe onto the intake air valve.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .

1. Remove the upper tie bar. Refer to «Front End Upper Tie Bar Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
2. Remove the charge air cooler inlet and outlet pipes. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) and «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
3. Remove the radiator. Refer to «Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Radiator Replacement (HP2)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Radiator Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the charge air cooler bolts. NOTE: Do not damage the charged air cooler fins while removing.
5. Remove the charge air cooler. Disengage the bottom mounts from the radiator support. Remove the left side from the radiator support. Angle up the right side and rotate in order to remove.
6. Clean the charge air cooler by flushing with mild soap and water. Do not use stream pressure to clean.
7. Inspect the charge air cooler for the following damage: Damaged fins Cracked or distorted hose connections Broken or loose welds Leaks in the core or the tank connections
8. Replace the charge air cooler if damage is found.
9. Inspect the charged air cooler mounting insulators and replace if required.

1. Install the charge air cooler. Angle in the left side. Slide to the left. Move in the right side. Position bottom insulators in the radiator support. CAUTION: Refer to «Fastener Caution»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
2. Install the charge air cooler bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
3. Install the radiator. Refer to «Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Radiator Replacement (HP2)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) or «Radiator Replacement (LMM)»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Install the charge air cooler inlet and outlet pipes. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) and «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/testing-diagnostics/#engine-controls-and-fuel-66l-introduction-1-of-2) .
5. Install the upper tie bar. Refer to «Front End Upper Tie Bar Replacement»(/chevrolet/cab-chassis-silverado-3500-hd/2008-2011/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .

Scheme 17

The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position.

The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control.

Scheme 18

The exhaust particulate filter (EPF) captures diesel exhaust gas particulates, preventing their release into the atmosphere. This is accomplished by forcing particulate-laden exhaust (1) through a filter substrate of porous cells, which removes the particulates from the exhaust gas. The exhaust gas enters the filter, but because every other cell of the filter is capped at the opposite end, the exhaust particulates cannot exit the cell. Instead, the exhaust gas passes through the porous walls of the cell leaving the particulates trapped on the cell wall. The cleaned exhaust gas exits the filter through the adjacent cell. The EPF is capable of reducing more than 90 percent of particulate matter (PM).

Scheme 19

Diesel Oxidation Catalyst

The diesel oxidation catalyst (DOC) (7) has two functions. One function is to reduce emissions of non methane hydro-carbons (NMHC) and carbon monoxide (CO), from the exhaust gases. The other function is to help start a regeneration event by converting the fuel-rich exhaust gases to heat. The engine control module (ECM) monitors the functionally of the DOC by determining if the exhaust gas temperature (EGT) sensor 1 (1) reaches a predetermined temperature during a regeneration event. The DOC and the exhaust particulate filter (EPF) (6) are downstream of the turbocharger, and are two separate components under the vehicle.

Differential Pressure Sensor (DPS) and Pressure Lines

The differential pressure sensor (DPS) (3) measures the pressure difference between the inlet and outlet of the exhaust particulate filter (EPF). When pressure difference has increased above a calibrated threshold, a high particulate loading condition is indicated. The ECM will command a regeneration event in order to restore the filter. If the pressure differential continues to increase across the exhaust filter without a regeneration event, the ECM will illuminate an EPF lamp or send a message to the driver information center (DIC) referring the customer to clean the exhaust filter. To clean the exhaust filter the vehicle must be driven under the conditions necessary for a regeneration to take place. If these lamps and messages are ignored, the ECM will eventually illuminate the malfunction indicator lamp (MIL) and revert to Reduced Engine Power which will require the vehicle to be serviced.

The DPS sensor provides a voltage signal to the ECM on a signal circuit relative to the pressure differential changes in the EPF. The ECM converts the signal voltage input to a pressure value.

The DPS pressure lines (2) are connected before and after the EPF. To provide the pressure sensor with accurate back pressure measurements, the DPS pressure lines should have a continuous downward gradient, without any sharp bends or kinks.

Exhaust Gas Temperature Sensors

The ECM uses two exhaust gas temperature (EGT) sensors to measure the temperature of the exhaust gases at the inlet and outlet of the exhaust particulate filter (EPF). The EGT sensors are variable resistors, when the EGT sensors are cold, the sensor resistance is low, and as the temperature increases, the sensor resistance increases. When sensor resistance is high, the ECM detects a high voltage on the signal circuit. When sensor resistance is low, the ECM detects a lower voltage on the signal circuit. Proper EGTs at the inlet and outlet of the EPF are crucial for proper operation and for initiating the regeneration process. A temperature that is too high in the EPF will cause the EPF substrate to melt or crack. The ECM monitors the temperatures at the EPF inlet and outlet to regulate EPF temperatures.

Intake Air (IA) Valve

The intake air (IA) valve is located upstream of the intake air heater, and is normally in the open position. The ECM commands the valve to close in order to precisely control combustion temperature control during exhaust particulate filter (EPF) regeneration. The IA valve will ensure the temperature of the exhaust gas remains in an efficient range under all operating conditions. The IA valve system uses a position sensor located within the valve assembly to monitor the position of the valve. The IA valve uses a motor to move the valve to a closed position and spring tension returns it to the open position. The motor is operated through Motor Control 1 and 2 circuits.

Exhaust Cooler

The exhaust system has been designed to reduce exhaust gas temperatures during regeneration. The exhaust cooler (4) at the end of the tailpipe draws in cooler air as exhaust gases flow through its openings. The cooler air mixes with the warmer exhaust gas, reducing exhaust gas temperatures at the tailpipe outlet.

Normal Regeneration

Regeneration is the process of removing the captured particulates through incineration within the exhaust particulate filer (EPF). Elevated temperatures are created in the diesel oxidation catalyst (DOC) through a calibrated strategy in the engine control system.

Regeneration occurs when the ECM calculates that the particulate level in the filter has reached a calibrated threshold using a number of different factors, including engine run time, distance traveled, fuel used since the last regeneration, and the exhaust differential pressure. In general, the vehicle will need to be operating continuously at speeds above 48 km/h (30 mph) for approximately 20-30 minutes for a full and effective regeneration to complete. During regeneration the exhaust gases reach temperatures above 550°C (1,022°F). The ECM monitors the EGT sensors during regeneration. If the sensors indicate that regeneration temperatures are exceeding a calibrated threshold, regeneration will be temporally suspended until the sensors return to a normal temperature. If EGT temperatures fall below a normal calibrated threshold, regeneration will be terminated and a corresponding DTC should set. If a regeneration event is interrupted for any reason, it will continue, including the next key cycle, when the conditions are met for regeneration enablement. Normal regeneration is transparent to the customer.

Service Regeneration

A scan tool is an essential tool that is required for service regeneration. Commanding a service regeneration is accomplished using the output control function. The vehicle will need to be parked outside the facility and away from nearby objects, such as other vehicles and buildings, due to the elevated exhaust gas temperature at the tail pipe during regeneration. The service regeneration can be terminated by applying the brake pedal, commanding service regeneration OFF using the scan tool, or disconnecting the scan tool from the vehicle.

Regeneration Process

A number of engine components are required to function together for the regeneration process to be performed. These components are the fuel injectors, turbocharger, IA valve, fuel pressure control, and the intake air heater (IAH).

The regeneration process consists of several stages

Warming up the diesel oxidation catalyst (DOC) to 350°C (662°F) by performing the following

1. Reducing air flow with the intake air valve
2. Increasing or decreasing boost pressure with the turbocharger, depending on engine load
3. Elevating the engine speed
4. Reduce fuel rail pressure
5. Retard fuel injection timing
6. Add late fuel injection pulses. The added fuel is not combusted but is oxidized by the DOC and exhaust particulate filter (EPF) to create heat.

Ash Loading

Ash is a non-combustible by product from normal oil consumption. Low Ash content engine oil (CJ-4 API) is required for vehicles with the exhaust particulate filter (EPF) system. Ash accumulation in the EPF will eventually cause a restriction in particulate filter. Regeneration will not burn off the ash, only particulate matter is burned off. An ash loaded EPF will need to be removed from the vehicle and cleaned or replaced.

Engine Control Module Description

The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM.

Malfunction Indicator Lamp (MIL) Operation

The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON

Scheme 20

Scheme 21

The MIL indicates that an emissions related fault has occurred and vehicle service is required.

The following is a list of the modes of operation for the MIL

1. The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate.
2. The MIL turns OFF after the engine is started if a diagnostic fault is not present.
3. The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate.
4. The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter.
5. When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON.
6. When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON.

High Idle Switch

The high idle switch will slowly increase engine RPM to the calibrated high idle speed when depressed. The high idle speed can be programmed by using a scan tool. Refer to High Idle Switch Programming . If the High Idle Switch is not operating as desired, refer to High Idle Switch Diagnosis .

Manual High Idle

The diesel engine has a high idle system to improve the warm-up time of the engine in cold weather conditions. This system allows the engine control module (ECM) to increase the idle speed above the normal calibrated value. The ECM increases the idle speed using the following adjustments

1. The fuel injection timing is changed
2. The fuel injection quantity is changed
3. The turbocharger vane position is commanded closed-The vane position will be farther closed than any other normal operating condition.

The instrument panel will indicate the high idle system is active one of two ways

1. The driver information center (DIC) will indicate an active high idle system on light duty trucks.
2. An indicator lamp will flash on medium duty trucks.
3. The manual high idle feature comes enabled from the factory. The Elevated Idle function in the scan tool will disable or enable this feature. If the engine does not increase to the calibrated high idle speed after the procedure is performed, use the scan tool to verify the Elevated Idle speed feature is enabled.

Manual High Idle Speed Enable and Disable

To enable or disable the manual high idle system perform the following procedure

1. Turn the ignition ON, with the engine OFF.
2. Depress the accelerator pedal to the floor and hold down.
3. While the accelerator pedal is depressed, depress the brake pedal 3 times in less than 8 seconds.
4. Release the accelerator pedal.
5. Start the engine.

When the procedure is followed the engine idle speed will slowly increased to the calibrated high idle speed. This is 1,200 RPM for light duty, and 1,500 RPM for medium duty trucks.

The idle speed will return to normal if any of the following conditions occur

1. There is brake, clutch, or throttle input from the driver.
2. The automatic transmission is shifted out of Park or Neutral.
3. The air temperature is more than 7°C (45°F).
4. The engine coolant temperature (ECT) is more than 68°C (154°F).
5. The vehicle speed exceeds 0 km/h (0 mph).

The high idle system will reactivate automatically when the following conditions occur

1. The engine has been idling for more than 30 seconds.
2. The transmission is placed in Park or Neutral.
3. The vehicle speed is 0 km/h (0 mph).
4. The ambient air temperature is less than 3°C (37°F).
5. The ECT is less than 68°C (154°F).
6. The brake, clutch and throttle pedals are not depressed.

Exhaust Gas Recirculation (EGR) System Description

The Exhaust Gas Recirculation (EGR) System is used to reduce the amount of nitrogen oxide (NOx) emission levels caused by high combustion temperatures. At temperatures above 1 371°C (2,500°F), oxygen and nitrogen combine to form oxides of nitrogen (NOx). Introducing small amounts of exhaust gas back into the combustion chamber displaces the amount of oxygen entering the engine. With less oxygen in the air/fuel mixture, the combustion pressures are reduced, and as a result, combustion temperatures are decreased, restricting the formation of NOx.

The EGR valve motor is a direct current (DC) stepper motor utilizing a worm gear that extends from the motor to push on the EGR valve stem. The worm gear is not attached to the valve stem, and can only force the valve open. A return spring is used to force the valve closed.

The mass air flow (MAF) sensor signal is used by the engine control module (ECM) to detect the proper amount of EGR flow. One EGR flow test is performed per ignition cycle. The ECM will close the EGR valve for 5 seconds, then open the EGR valve to 100 percent for 5 seconds. The ECM will then calculate the MAF difference and determine if the proper EGR flow has been detected.

Scheme 22

The exhaust gas recirculation (EGR) valve is controlled by the engine control module (ECM) through the EGR motor high control and EGR motor low control circuits. The ECM supplies voltage that is near ignition voltage to the high and low control circuits at all times. This voltage is used by the ECM as a reference voltage during non EGR operation in order to detect circuit failures. The ECM will pulse width modulate (PWM) the low control circuit to ground and an increase in amperage on the high control circuit can be observed with a DMM when the EGR valve is commanded open. A lower pulse width will increase the open position of the valve. In order to close the EGR valve, the ECM will PWM the high control circuit to ground.

When the ignition is turned ON, the ECM will drive the EGR motor worm gear out with just enough force to touch the EGR valve stem. The ECM will do this 3 times in quick succession. This action determines the minimum closed position of the valve and only happens once per ignition cycle. If the valve is prevented from closing all of the way after the minimum closed position is learned, the scan tool EGR Position parameter will not reflect this position until the next ignition cycle. The EGR motor worm gear is not connected to the EGR valve stem and can only push the valve open. The valve is returned to the closed position by a return spring.

The ECM uses the EGR position sensor to determine the position of the EGR valve. The ECM sends a reference voltage through the 5-volt reference circuit to the EGR position sensor. The ECM provides a voltage return path for the sensor through the low reference circuit. A variable voltage signal, based on the EGR valve position, is sent from the sensor to the ECM through the EGR position sensor signal circuit.

EGR Valve Control Enabling Conditions.

Exhaust gas recirculation (EGR) valve control will only be enabled during idle and cruising conditions while the following conditions are met

1. The intake air temperature (IAT) is more than 5.25°C (41.5°F). EGR valve control will remain enabled until the IAT is less than 0°C (32°F) and will not enable again until the IAT is more than 5.25°C (41.5°F).
2. The engine coolant temperature (ECT) is between 60-96.75°C (140-206.15°F). EGR valve control will remain enabled until the ECT is less than 57°C (134.6°F) or more than 99.75°C (211.55°F) and will not enable again until the ECT is between 60-96.75°C (140-206.15°F).
3. The barometric pressure (BARO) is more than 74 kPa. EGR valve control will remain enabled until the BARO is less than 72 kPa and will not enable again until 74 kPa.

Fuel System Description

The fuel tank (6) stores the fuel supply. A mechanical fuel injection pump (9), located below the engine intake, includes the fuel supply pump and the high-pressure pump. Fuel is drawn through the fuel filter/heater element housing (7), which combines a water separator, a hand prime pump, a fuel heater element and a filter element. An integrated hand prime pump is used to prime the fuel system after changing the fuel filter or servicing the fuel system. The mechanical fuel injection pump output is controlled by the ECM, and provides fuel at the pressure needed by the fuel injectors (3). The fuel injectors supply fuel directly to the combustion chambers of the engine. A separate pipe returns unused fuel through a fuel cooler (5) to the fuel tank.

Scheme 23

The fuel tanks store the fuel supply. The primary fuel tank (2) is located on the left side of the vehicle. On vehicles that are equipped with dual fuel tanks, the auxiliary fuel tank is located in the rear of the vehicle. The fuel tanks are each held in place by 2 metal straps that attach to the frame. The fuel tanks are molded from high density polyethylene.

Scheme 24

The fuel filler cap has a torque-limiting device that prevents the cap from being over tightened. To install, turn the cap clockwise until you hear audible clicks. This indicates that the cap is fully seated.

Scheme 25

The fuel sender consists of the following major components

1. The fuel level sensor (1)
2. The fuel strainer (2)

Scheme 26

The auxiliary fuel sender on vehicles equipped with dual fuel tanks consists of the following major components

1. The fuel level sensor (1)
2. The fuel strainer (2)

Fuel Level Sensor

The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics.

Fuel Strainer

The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment.

Scheme 27

On vehicles equipped with dual fuel tanks, an electric fuel pump is located on the left frame rail. This fuel pump is powered by the fuel pump relay that is controlled by the engine control module (ECM). Fuel is transferred from the auxiliary fuel tank to the primary fuel tank in order to ensure all of the usable fuel volume is available to the fuel injection pump.

Scheme 28

The fuel injection pump is a mechanical high pressure pump. The fuel injection pump is located below the intake manifold. Fuel is pumped to the fuel rails at a specified pressure. Fuel pressure is regulated by a valve on the inlet of the fuel pump, controlled by the engine control module (ECM). Excess fuel from the fuel injection pump returns to the fuel tank through the fuel return pipe and a fuel cooler.

Scheme 29

The fuel filter is located on the rocker cover. The paper filter element traps particles in the fuel that may damage the fuel injection system.

CHANGE FUEL FILTER will appear on the driver information center when a fuel filter change is required.

The fuel filter life monitor uses two control paths consistent with driving conditions. The primary control is based on the accumulated fuel burned, and the secondary control is based on the fuel rail deviations and high pressure pump duty cycle. If the fuel has been contaminated with water or other contaminates, the monitor will see erratic system corrections and display the message or warning lamp. If the fuel filter is not changed when the message or warning light is displayed, then a fuel restriction could occur and cause other diagnostics to fail. The filter life monitor does not drive the diagnostics, but is a result of the restriction.

You must reset the fuel filter life monitor after each fuel filter change. It will not reset itself. Resetting the filter monitor without changing the filter will cause the fuel filter monitor to be inaccurate until the next fuel filter change and reset.

Fuel Heater

The fuel heater is an integrated part of the diesel fuel conditioning module (DFCM). Fuel is heated by passing through the fuel heater element, which is operated by a built-in thermostatic switch. The thermostatic switch turns the heater element ON and OFF, depending on the fuel temperature. The fuel heater element has voltage anytime the ignition is turned ON. The warmed fuel then passes through the fuel filters to the fuel injection pump.

Fuel Feed and Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the fuel filter/heater element housing. The fuel return pipe carries fuel from the fuel rail assemblies back to the fuel tank. The fuel pipes consist of 2 sections

1. The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of steel with sections of rubber hose covered with braiding.
2. The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel with sections of rubber hose covered with braiding.

Quick-Connect Fittings

Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together.

Fuel Pipe O-Rings

O-rings seal the connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part.

Scheme 30

The left and right fuel rail assemblies attach to the cylinder heads. The fuel rail assemblies distribute pressurized fuel to the fuel injectors through the fuel lines.

The fuel rail assemblies consists of the following components

1. The fuel rail pressure sensor in the right fuel rail
2. The fuel pressure relief valve in the left fuel rail

The fuel rail pressure sensor gives the engine control module (ECM) an indication of fuel pressure. The ECM uses this information to regulate fuel pressure, by commanding the fuel pressure regulator open or closed on the inlet of the fuel injection pump.

The fuel pressure relief valve opens only to prevent excessive pressure in the event of a malfunction. Fuel from the fuel pressure relief valve is returned to the fuel tank.

Scheme 31

Scheme 32

A fuel injector is a solenoid device, controlled by the engine control module (ECM), that meters pressurized fuel to a single engine cylinder. Fuel pressure is released from above the fuel injector pintle, and is returned to the fuel tank through the fuel return lines. The difference in fuel pressure above and below the pintle causes the pintle to open. Fuel from the fuel injector tip is sprayed directly into the combustion chamber on the compression stroke of the engine.

The control functions for the fuel injection system are integrated in the ECM. During the manufacturing process, each injector's flow rate is measured and recorded as injection quantity adjustment (IQA) flow rate data. The flow rate data is then etched as a hexadecimal number on the body of the injector. This data, together with the injector's cylinder position, is stored in the memory of both the glow plug control module (GPCM) and the ECM. When the ignition is turned ON, both the GPCM and the ECM monitor to ensure that the fuel injection flow rate numbers are present. If any of the injector flow rate numbers are missing, the diagnostic for that control module will set the appropriate DTC.

Scheme 33

The fuel system cooler (1) is located in front of the primary fuel tank. The fuel system cooler cools the fuel before it is returned to the fuel tank.

Glow Plug System Description

In the diesel engine, air alone is compressed in the cylinder. Then, after the air has been compressed, a charge of fuel is sprayed into the cylinder and ignition occurs, due to the heat of compression. Eight glow plugs are used as an aid to starting.

Control of the instant start system (ISS) glow plugs is accomplished by a glow control module unit and 4.7 volt glow plugs, requiring 2 seconds to heat up to 1,000°C (1,832°F). The temperature and the power consumption is controlled between the engine control module (ECM) and the controller within a wide range to suit the engine's pre-heating requirements. Each glow plug is energized individually. This capability yields more optimum heat times for the glow plugs, thus pre-glow times can be kept to a minimum for short wait to crank times and maximum glow plug durability. A DTC will set if there is a glow plug system fault.

A normal functioning system operates as follows

1. Turn the ignition ON with the engine OFF, and at room temperature.
2. The glow plugs turn ON and heat up in 2 seconds and then are pulse-width modulated (PWM) for another 2 seconds.
3. The glow plug wait lamp is ON for 1 second during cold start.
4. The glow plug wait lamp may not illuminate during a warm engine start.
5. If the engine is cranked during or after the above sequence, the glow plugs may cycle ON and OFF after the ignition switch is returned from the start position, whether the engine starts or not. The engine does not have to be running to terminate the glow plug cycling.

The glow plug initial ON time will vary based on the system voltage and temperature. Lower temperatures cause longer ON times.

The ECM provides glow plug operation after starting a cold engine. This post-start operation is initiated when the ignition switch is returned to Run, from the Start position. This function helps clean up excessive white smoke and/or poor idle quality after starting.

Glow Plugs

The glow plugs are 4.7 volt heaters in each of the cylinders that turn ON, then pulse-width modulated when the ignition switch is turned to the RUN position prior to starting the engine. They remain pulsing a short time after starting, then they are turned OFF.

A Wait to Start lamp on the instrument panel provides information on engine starting conditions. The Wait to Start lamp will not illuminate during post-start glow plug operation.

Glow Plug/Controller

The glow plug controller is a solid state device which operates the glow plugs. The glow plug controller is connected to the following circuits

1. The fuel heater ignition 1 voltage circuit
2. The battery voltage circuit
3. The CAN communication circuit located between the engine control module (ECM) and the glow plug controller
4. The engine ground circuit
5. The glow plug supply voltage circuits located between the glow plug controller and the glow plugs.

The glow plug diagnostic circuits are directly monitored individually by using a separate transistor to control current to each glow plug. Individual diagnosis is thus possible for every glow plug.

Intake Air Heater System Description

The intake air heater (IAH) is located in the air inlet tube and is used to warm the incoming air to aid in starting the engine and for proper cylinder combustion. The glow plug control module (GPCM) will command the IAH on when the engine coolant temperature is below 40°C (104°F).

The IAH is commanded ON by the GPCM through the command 1 circuit and the command 2 circuits. The command 1 signal is ON or OFF from the GPCM to the IAH. The command 2 circuits are digital signal from the GPCM to the IAH. Without both signals the IAH will not operate. The feedback signal is digital and informs the GPCM of the status of IAH. The temperature, current, and voltage circuits are analog signals from the IAH to the GPCM.

The IAH will be commanded to 100 percent when the engine coolant temperature is below 5°C (41°F) for 180 seconds after key up, then it will ramp down to 42 percent after 180-300 seconds and will hold it there until 300-500 seconds. After 500-600 seconds the IAH will ramp down to 0 percent. When the engine coolant is 10-40°C (50-104°F) the IAH is 100 percent for 30 seconds after key up then ramps down to 42 percent after 30-90 seconds and holds it there for up to 500 seconds, then it ramps down to 0 percent from 500-600 seconds.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

The turbocharger increases engine power by pumping compressed air into the combustion chambers, allowing a greater quantity of fuel to combust at the optimal air/fuel ratio. The turbine spins as exhaust gas flows out of the engine and over the turbine blades, and turns the compressor wheel at the other end of the turbine shaft, pumping more air into the intake system.

The engine control module (ECM) controls nine vanes for the turbocharger. The vanes are used to vary the amount of boost pressure and can control the boost pressure independent of engine speed. The vanes mount to a unison ring which are rotated to change the vane angle. The ECM will vary the vane angle which adjusts the boost dependent upon the load requirements of the engine.

The turbocharger vanes are normally open when the engine is not under load. However, the ECM will often close the turbocharger vanes to create back pressure to drive exhaust gas through the exhaust gas recirculation (EGR) valve as required. At extreme cold temperatures, the ECM may close the vanes at low load conditions in order to accelerate engine coolant heating. The ECM may also close the turbocharger vanes under exhaust braking conditions, only with RPO K40.

During regeneration, the ECM will vary the turbocharger vanes to assist with the exhaust system warm-up, and to maintain proper engine exhaust temperatures needed to properly regenerate the exhaust particulate filter (DPF).

The turbocharger control system utilizes the following components

Turbocharger Vane Position Control Solenoid Valve

The vane position control solenoid valve (2) works in conjunction with oil pressure to control the turbocharger vanes. The ECM uses a pulse width modulation on both control circuits to control the solenoid valve. The solenoid valve allows the engine oil pressure to move a piston. This piston rotates the unison ring, thus controlling the engine boost dependent upon engine load.

Turbocharger Vane Position Sensor

The ECM uses the turbocharger vane position sensor to monitor the TC vane angle. The voltage is low when the TC vanes are open, and high when the TC vanes are closed.

Illustration Tool Number/Description CH-48027 Digital Pressure Gage EN-47909 Injector Bore and Sleeve Cleaning Kit EN-47969 Fuel Supply Diagnostic Hose EN-48565 EGR Test Harness J-25070 Heat Gun 500-750°F J-28428-E High Intensity Black Light Kit J-34730-405 Injector Test Lamp J-35555 Metal MityVac J-35616-200 Test Light - Probe Kit J-38641-B Diesel Fuel Quality Tester J-43178 Fuel Line Disconnect Tool J-43244 Relay Puller Pliers J-44581 Fuel Line Disconnect Tool J-45004 Fuel Tank Drain Hose J-45722 Fuel Sender Lock Ring Wrench J-45873 Fuel Return Volume Test Kit J-45873-30 Injector Flow Test Adapter J-46091 Charge Air Cooler Tester J-46091-5 Charge Air Cooler Tester Adapter J-46091-15 Engine Pressure Test Adapter J-46594 Fuel Injector Puller

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

See also:
• DTC P0016
• DTC P02E8 or P02E9
• DTC P1448
• DTC P2544
• Control Module References
• Battery Negative Cable Disconnection and Connection (With Single Battery)
• Diagnostic Trouble Code (DTC) List - Vehicle
• Symptoms - Vehicle
• Cooling System Draining and Filling (Vac-N-Fill)
• Fastener Caution
• Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
• Fuel Pipe Fitting Warning
• Lifting and Jacking the Vehicle
• Fuel Tank Strap Fastener Caution
• Fuel Tank Draining
• Metal Collar Quick Connect Fitting Service
• Intake Manifold Tube Replacement
• Heater Outlet Hose Replacement
• Fuel Injection Pump Removal
• Fuel Injection Pump Installation
• Exhaust Pipe Replacement - Right Side
• Front Wheelhouse Liner Replacement - Right Side (Chevrolet)
• Front End Upper Tie Bar Replacement
• High Idle Switch Diagnosis
• Special Tools
• Water-in-Fuel Draining
• Fuel System Priming
• Turbocharger Learn
• High Idle Switch Programming