Engine Mechanical - 6.6l (2 of 5) Chevrolet Chevy Express H1500

Removal Procedure

1. Remove the upper radiator fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Install a 1/2-inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise.
3. Remove the belt from the tensioner.
4. Slowly release the tension on the tensioner arm.
5. Remove the drive belt from the drive pulleys, if equipped with a single generator.
6. Remove the drive belt from the drive pulleys, if equipped with dual generators.
7. Inspect the drive belt for excessive cracking or any visible damage and replace if necessary.

Installation Procedure

1. Install a 1/2 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise.
2. Install the drive belt, if equipped with dual generators.
3. Route the drive belt over and/or around all the drive pulleys except for the tensioner.
4. Install the drive belt, if equipped with a single generator.
5. Route the drive belt over and/or around all the drive pulleys except for the tensioner.
6. Install the belt over and/or around the tensioner.
7. Slowly release the tension on the tensioner arm.
8. Inspect the drive belt for proper installation on and/or around all pulleys.
9. Install the upper radiator fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner. Align the pin with the hole in the generator bracket.
2. Install the drive belt tensioner bolt. Tighten: Tighten bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the bolt (1) from the right side idler pulley.
3. Remove the idler pulley.
4. Remove the bolt (2) for the center idler pulley.
5. Remove the idler pulley.
6. If equipped with dual generators, remove the bolt from the left side idler pulley.
7. If equipped with dual generators, remove the idler pulley.

1. Install the right side idler pulley and bolt (1). Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2. Install the center idler pulley and bolt (2). Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. If equipped with dual generators, install the left side idler pulley and bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
4. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

Engine Mount Inspection

Note. Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses.

1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. Apply the park brake. Start the engine. Firmly apply and hold the primary brakes. Have an assistant stand to the side of the vehicle in order to observe for engine movement. Slightly load the engine, shifting from drive to reverse a few times. If the engine moves more than 24 mm (0.945 in) from the rest position, in either direction, check for loose, or missing engine mount bolts in the following locations: Engine mount to engine Engine mount bracket to frame Engine mount to engine mount bracket
2. If a engine mount bolt is missing, replace the bolt.
3. If the engine mount bolt torque is within specifications, check the condition of the engine mount.
4. Replace the engine mount if any of the following conditions exist: Heat check cracks cover the rubber cushion surface. The rubber cushion is separated from the metal plate of the mount. There is a split through the rubber cushion.

Note. Refer to ENGINE MOUNTING NOTICE .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
2. Remove the engine mount to engine mount frame bracket bolts.
3. Place a suitable adjustable jack on the lower engine boss, raise the engine. Only raise the engine enough to separate the engine mount to engine mount bracket.
4. Remove the engine mount to engine bolts.
5. Remove the engine mount.
6. Remove the engine mount bracket bolts, if necessary.
7. Remove the engine mount bracket, if necessary.

1. Position the engine mount bracket to the frame, if necessary.
2. Install the engine mount bracket bolts, if necessary. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
3. Position the engine mount to the engine.
4. Install the engine mount to engine mount bolts.
5. Install the engine mount to engine bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
6. Using the adjustable jack lower the engine until the mount rests on the bracket.
7. Install the engine mount to engine mount bracket bolts. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
8. Lower the vehicle.

Note. Refer to ENGINE MOUNTING NOTICE .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
2. Disconnect the transmission oil cooler lines at the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l80-e4l85-e-removal-installation-service-troubleshooting-diagnosis) .
3. Reposition the transmission oil cooler lines.
4. Remove the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Remove the engine mount to engine mount bracket bolts.
6. Place a suitable adjustable jack on the lower engine boss, raise the engine. Only raise the engine enough to separate the engine mount to engine mount bracket.
7. Remove the engine mount to engine bolts.
8. Remove the engine mount.
9. Remove the engine mount bracket bolts, if necessary.
10. Remove the engine mount bracket, if necessary.

1. Position the engine mount bracket to the frame, if necessary.
2. Install the engine mount bracket bolts, if necessary. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
3. Position the engine mount to the engine.
4. Install the engine mount to engine mount bolts.
5. Install the engine mount to engine bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
6. Using the adjustable jack lower the engine until the mount rests on the bracket.
7. Install the engine mount to engine mount bracket bolts. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
8. Install the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
9. Position the transmission oil cooler lines.
10. Connect the transmission oil cooler lines at the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l80-e4l85-e-removal-installation-service-troubleshooting-diagnosis) .
11. Lower the vehicle.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
2. Remove the positive crankcase ventilation (PCV) cover screws.
3. Remove the PCV cover, diaphragm, and spring.
4. Clean and inspect the cover, diaphragm and spring.
5. Discard the diaphragm if damage is found.

1. Install the spring, diaphragm and cover.
2. Install the PCV cover screws. Tighten: Tighten the screws to 4 N.m (35 lb in).
3. Replace the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
3. Remove the charged air cooler inlet pipe from the turbocharger. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
4. Disconnect the wiring harness connector from the glow plug module.
5. Remove the glow plug wiring harness bracket bolt and position the wiring harness and bracket aside.
6. Remove the positive crankcase ventilation (PCV) pipe bolt from the left valve cover and disconnect the PCV pipe.
7. Remove the PCV pipe bolt from the right valve cover and disconnect the PCV pipe.
8. Compress the clamp and disconnect the PCV pipe from the air intake pipe.
9. Remove the PCV hose/pipe.

1. Position the PCV hose/pipe.
2. Compress the clamp and connect the PCV pipe to the air intake pipe.
3. Position the PCV pipe to the right valve cover and loosely install the PCV pipe bolt.
4. Position the PCV pipe to the left valve cover and loosely install the PCV pipe bolt.
5. Tighten the right and left PCV pipe bolts. Tighten: Tighten the PCV pipe bolts to 18 N.m (13 lb ft).
6. Position the glow plug wiring harness to the original position and install the wiring harness bracket bolt.
7. Connect the wiring harness connector to the glow plug module.
8. Install the charged air cooler inlet pipe to the turbocharger. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
3. Remove the charged air cooler inlet pipe from the turbocharger. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
4. Disconnect the wiring harness connector from the glow plug module.
5. Remove the glow plug wiring harness bracket bolt and position the wiring harness and bracket aside.
6. Remove the positive crankcase ventilation (PCV) pipe bolt from the left valve cover and disconnect the PCV pipe.
7. Remove the PCV pipe bolt from the right valve cover and disconnect the PCV pipe.
8. Compress the clamp and disconnect the PCV pipe from the air intake pipe.
9. Remove the PCV hose/pipe.

1. Position the PCV hose/pipe.
2. Compress the clamp and connect the PCV pipe to the air intake pipe.
3. Position the PCV pipe to the right valve cover and loosely install the PCV pipe bolt.
4. Position the PCV pipe to the left valve cover and loosely install the PCV pipe bolt.
5. Tighten the right and left PCV pipe bolts. Tighten: Tighten the PCV pipe bolts to 18 N.m (13 lb ft).
6. Position the glow plug wiring harness to the original position and install the wiring harness bracket bolt.
7. Connect the wiring harness connector to the glow plug module.
8. Install the charged air cooler inlet pipe to the turbocharger. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

Scheme 148

Charged Air Cooler Hoses/Pipes Replacement (Inlet)

Scheme 149

Charged Air Cooler Hoses/Pipes Replacement (Outlet)

Scheme 150

Charged Air Cooler Replacement

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2)
3. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
4. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
5. Disconnect the engine harness electrical connector (2) from the intake air heater (IAH).
6. Remove the front intake manifold tube bolt.
7. Reposition the positive battery cable boot.
8. Remove the positive battery cable nut at the IAH.
9. Remove the positive battery cable from the IAH stud.
10. Remove the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
11. Remove the 2 rear intake manifold tube bolts (3).
12. Remove the rear intake manifold tube nut (2).
13. Remove the engine wiring harness clip from the intake manifold tube.
14. Remove the engine wiring harness clip bolt (3).
15. Remove the exhaust gas recirculation (EGR) cooler water pipe bracket bolt (5).
16. Remove the intake manifold tube bolts (2, 4) and nut (1).
17. Remove the intake manifold tube with the stud.
18. Remove and discard the 2 metal EGR gaskets from the EGR valve.
19. Remove and discard the O-ring seal from the center intake manifold.
20. If replacing the intake manifold tube perform the following steps, otherwise proceed to step 5 in the installation procedure.
21. Remove the MAP sensor bolt.
22. Remove the MAP sensor and bracket.
23. Remove the front intake manifold tube bolts, the front intake manifold tube, and the IAH.

1. If the intake manifold tube was replaced perform the following steps, otherwise proceed to step 5.
2. Position the IAH and the front intake manifold tube to the intake manifold tube, install the front intake manifold tube bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Install the MAP sensor and bracket.
4. Install the MAP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Install a NEW the O-ring seal onto the center intake manifold.
6. Install NEW metal EGR gaskets onto the EGR valve.
7. Install the intake manifold tube with the stud. Tighten: Tighten the stud to 25 N.m (18 lb ft).
8. Install the intake manifold tube bolts (2, 4) and nut (1). Tighten: Tighten the bolt/nut to 25 N.m (18 lb ft).
9. Install the EGR cooler water pipe bracket bolt (5). Tighten: Tighten the bolt to 15 N.m (11 lb ft).
10. Install the engine wiring harness clip bolt (3). Tighten: Tighten the bolt to 15 N.m (11 lb ft).
11. Install the engine wiring harness clip to the intake manifold tube.
12. Install the rear intake manifold tube nut (2). Tighten: Tighten the nut to 25 N.m (18 lb ft).
13. Install the 2 rear intake manifold tube bolts (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
14. Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
15. Install the positive battery cable to the IAH stud.
16. Install the positive battery cable nut at the IAH. Tighten: Tighten the nut to 10 N.m (89 lb ft).
17. Position the positive battery cable boot.
18. Install the front intake manifold tube bolt. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
19. Connect the engine harness electrical connector to the IAH.
20. Connect the engine harness electrical connector to the MAP sensor.
21. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
22. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2)
23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
3. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
4. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
5. Disconnect the engine harness electrical connector (2) from the intake air heater (IAH).
6. Disconnect the engine harness electrical connector (3) from the intake air valve.
7. Remove the front intake manifold tube nut.
8. Reposition the positive battery cable boot.
9. Remove the positive battery cable nut at the IAH.
10. Remove the positive battery cable from the IAH stud.
11. Remove the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
12. Remove the 2 rear intake manifold tube bolts (3).
13. Remove the rear intake manifold tube nut (2).
14. Remove the engine wiring harness clip from the intake manifold tube.
15. Remove the engine wiring harness clip bolt (3).
16. Remove the intake manifold tube bolts (2, 4) and nut (1).
17. Remove the intake manifold tube with the stud.
18. Remove and discard the 2 metal EGR gaskets from the EGR valve.
19. Remove and discard the O-ring seal from the center intake manifold.
20. If replacing the intake manifold tube perform the following steps, otherwise proceed to step 5 in the installation procedure.
21. Remove the MAP sensor bolt.
22. Remove the MAP sensor and bracket.
23. Remove the air intake valve bolts (1).
24. Remove the air intake valve (2) and the IAH (3) from the intake manifold tube.

1. Position the IAH (3) and the air intake valve (2) to the intake manifold tube.
2. Install the air intake valve bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Install the MAP sensor and bracket.
4. Install the MAP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Install a NEW the O-ring seal onto the center intake manifold.
6. Install NEW metal EGR gaskets onto the EGR valve.
7. Install the intake manifold tube with the stud. Tighten: Tighten the stud to 25 N.m (18 lb ft).
8. Install the intake manifold tube bolts (2, 4) and nut (1). Tighten: Tighten the bolt/nut to 25 N.m (18 lb ft).
9. Install the engine wiring harness clip bolt (3). Tighten: Tighten the bolt to 15 N.m (11 lb ft).
10. Install the engine wiring harness clip to the intake manifold tube.
11. Install the rear intake manifold tube nut (2). Tighten: Tighten the nut to 25 N.m (18 lb ft).
12. Install the 2 rear intake manifold tube bolts (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
13. Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
14. Install the positive battery cable to the IAH stud.
15. Install the positive battery cable nut at the IAH. Tighten: Tighten the nut to 10 N.m (89 lb ft).
16. Position the positive battery cable boot.
17. Install the front intake manifold tube nut. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
18. Connect the engine harness electrical connector (3) to the intake air valve.
19. Connect the engine harness electrical connector (2) to the IAH.
20. Connect the engine harness electrical connector (1) to the MAP sensor.
21. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
22. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the turbocharger. Refer to «Turbocharger Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lly-lbz) or «Turbocharger Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lmm) .
2. Loosen the connector bracket bolt and nut.
3. Remove the connector bracket bolt (1).
4. Remove the fuel rail clamp bolt (2).
5. Remove the connector bracket bolt (2) and nut (1), and reposition the bracket.
6. Disconnect the engine wiring harness electrical connector from the intake air temperature (IAT) sensor No. 2. Refer to «Intake Air Temperature (IAT) Sensor 2 Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Remove the center intake manifold 4 bolts (1).
8. Remove the center intake manifold 2 nuts (2) and 2 bolts.
9. Remove the center intake manifold.
10. Remove and discard the center intake manifold gaskets.
11. If replacing the center intake manifold, remove the IAT sensor.

1. If the center intake manifold was replaced, install the IAT sensor No. 2. Tighten: Tighten the sensor to 25 N.m (18 lb ft).
2. Install NEW center intake manifold gaskets to the intake.
3. Install the center intake manifold.
4. Install the center intake manifold lower 2 nuts (2) and 2 bolts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
5. Install the center intake manifold upper 4 bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Connect the engine wiring harness electrical connector to the IAT sensor No. 2. Refer to «Intake Air Temperature (IAT) Sensor 2 Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Position the connector bracket and install the bolt (2) and nut (1). Tighten: Tighten the bolts to 15 N.m (11 lb ft).
8. Install the fuel rail clamp bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
9. Install the connector bracket bolt (1). Tighten: Tighten the bolts to 15 N.m (11 lb ft).
10. Install the turbocharger. Refer to «Turbocharger Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lly-lbz) or «Turbocharger Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lmm) .

1. Remove the turbocharger. Refer to «Turbocharger Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lly-lbz) or «Turbocharger Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lmm) .
2. Loosen the connector bracket bolt and nut.
3. Remove the connector bracket bolt (1).
4. Remove the fuel rail clamp bolt (2).
5. Remove the connector bracket bolt (2) and nut (1), and reposition the bracket.
6. Disconnect the engine wiring harness electrical connector from the intake air temperature (IAT) sensor No. 2. Refer to «Intake Air Temperature (IAT) Sensor 2 Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
7. Remove the center intake manifold 4 bolts (1).
8. Remove the center intake manifold 2 nuts (2) and 2 bolts.
9. Remove the center intake manifold.
10. Remove and discard the center intake manifold gaskets.
11. If replacing the center intake manifold, remove the IAT sensor.

1. If the center intake manifold was replaced, install the IAT sensor No. 2. Tighten: Tighten the sensor to 25 N.m (18 lb ft).
2. Install NEW center intake manifold gaskets to the intake.
3. Install the center intake manifold.
4. Install the center intake manifold lower 2 nuts (2) and 2 bolts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
5. Install the center intake manifold upper 4 bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Connect the engine wiring harness electrical connector to the IAT sensor No. 2. Refer to «Intake Air Temperature (IAT) Sensor 2 Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
7. Position the connector bracket and install the bolt (2) and nut (1). Tighten: Tighten the bolts to 15 N.m (11 lb ft).
8. Install the fuel rail clamp bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
9. Install the connector bracket bolt (1). Tighten: Tighten the bolts to 15 N.m (11 lb ft).
10. Install the turbocharger. Refer to «Turbocharger Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lly-lbz) or «Turbocharger Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lmm) .

1. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the left fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
4. Remove the injection pump. Refer to «Fuel Injection Pump Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
5. Remove the intake manifold bolts/nuts.
6. Remove the intake manifold.
7. To prevent entry of debris into the cylinder head, tape the openings.
8. Clean the gasket surfaces.

1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake manifold. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
2. Install the intake manifold.
3. Install the intake manifold bolts/nuts.
4. Tighten the intake manifold bolts/nuts. Tighten: Tighten the bolts/nuts in the sequence shown to 25 N.m (18 lb ft).
5. Install the fuel injector pump. Refer to «Fuel Injection Pump Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
6. Install the left fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Install the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Install the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the left fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
4. Remove the injection pump. Refer to «Fuel Injection Pump Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
5. Remove the intake manifold bolts/nuts.
6. Remove the intake manifold.
7. To prevent entry of debris into the cylinder head, tape the openings.
8. Clean the gasket surfaces.

1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake manifold. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
2. Install the intake manifold.
3. Install the intake manifold bolts/nuts.
4. Tighten the intake manifold bolts/nuts. Tighten: Tighten the bolts/nuts in the sequence shown to 25 N.m (18 lb ft).
5. Install the fuel injector pump. Refer to «Fuel Injection Pump Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
6. Install the left fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
7. Install the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Install the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the right fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
3. Remove the intake manifold bolts/nuts.
4. Remove the intake manifold.
5. To prevent entry of debris in the cylinder head tape the openings.

1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake manifold. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
2. Install the intake manifold.
3. Install the intake manifold bolts/nuts.
4. Tighten the intake manifold bolts/nuts. Tighten: Tighten the bolts/nuts in the sequence shown to 25 N.m (18 lb ft).
5. Install the right fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
6. Install the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the right fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
3. Remove the intake manifold bolts/nuts.
4. Remove the intake manifold.
5. To prevent entry of debris in the cylinder head tape the openings.

1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake manifold. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
2. Install the intake manifold.
3. Install the intake manifold bolts/nuts.
4. Tighten the intake manifold bolts/nuts. Tighten: Tighten the bolts/nuts in the sequence shown to 25 N.m (18 lb ft).
5. Install the right fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
6. Install the center intake manifold. Refer to «Center Intake Manifold Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Center Intake Manifold Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the oil fill tube bolts.
3. Remove the oil fill tube.
4. Remove and discard the oil fill tube O-ring seal.

1. Install a NEW O-ring seal onto the oil fill tube.
2. Install the oil fill tube.
3. Install the oil fill tube bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
4. Install the upper radiator fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the oil level indicator.
2. Remove the surge tank. Refer to «Surge Tank Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the oil level indicator tube bolt at the indicator tube bracket.
4. Remove the starter motor. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Remove the oil level indicator tube and O-ring seals.
6. Remove and discard the O-ring seals.

1. Install NEW O-ring seals onto the oil level indicator tube.
2. Lightly lubricate the O-ring seals with engine oil.
3. Install the oil level indicator tube.
4. Install the starter motor. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Install the oil level indicator tube bolt at the indicator tube bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
6. Install the surge tank. Refer to «Surge Tank Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Install the oil level indicator.

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the upper oil fill tube bolt (1).
3. Remove the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the lower oil fill tube bolt (1).
5. Remove and discard the oil fill tube O-ring seal.

1. Install a NEW O-ring seal onto the oil fill tube.
2. Install the oil fill tube.
3. Install the lower oil fill tube bolt (1). Tighten: Tighten the bolts to 21 N.m (15 lb ft).
4. Install the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Install the upper oil fill tube bolt (1). Tighten: Tighten the bolts to 21 N.m (15 lb ft).
6. Install the upper radiator fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

Tools Required

J-46594 Fuel Injector Puller

1. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Crankcase Ventilation Hoses/Pipes Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the glow plug control module. Refer to «Glow Plug Control Module Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
5. Remove the glow plug module bracket bolts (1) and bracket.
6. Disconnect the engine harness electrical connectors from the fuel injectors.
7. Remove the engine wiring harness bracket bolt (1).
8. Disconnect the left side main engine harness electrical connector.
9. Remove the wiring harness clip from the main connector bracket.
10. Remove the connector bracket bolts (1).
11. Remove the glow plug wire harness retaining bolts at the lower part of the upper left valve cover.
12. Reposition the engine wiring harness out of the way.
13. Remove the fuel injector return line clip (1) from the injector.
14. Remove the fuel injector return line fitting (2) from the injector.
15. Perform the above 2 steps for the other 3 fuel injectors.
16. Reposition the injector return line out of the way.
17. 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.
18. Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
19. Remove the left fuel injector pipes.
20. Remove No. 8 fuel injector bracket bolt.
21. Install the J-46594 into injector No. 8 bracket bolt hole.
22. Using the J-46594 pull injector No. 8 until it releases.
23. Remove the J-46594 .
24. Remove No. 8 fuel injector and bracket.
25. Remove the upper valve rocker arm cover bolts.
26. Remove the upper valve rocker arm cover.
27. Remove the upper valve rocker arm cover gasket.
28. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the valve rocker arm cover gasket.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts.
4. Tighten the upper valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 8 N.m (71 lb in).
5. Install No. 8 fuel injector and bracket.
6. Install No. 8 fuel injector bracket bolt.
7. Install the left fuel injector pipes. Tighten: Tighten the pipes to 41 N.m (30 lb ft).
8. After installing the fuel injector pipes, clean the injector pipes and apply sealant at the fittings to prevent moisture and debris from collecting between the line and fitting. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
9. Position the injector return line to the injectors.
10. Install the fuel injector return line clip (1) to the injector.
11. Install the fuel injector return line fitting (2) to the injector.
12. Perform the above 2 steps for the other 3 fuel injectors.
13. Position the engine wiring harness.
14. Install the glow plug wire harness retaining bolts at the lower part of the left upper valve cover.
15. Install the connector bracket bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
16. Install the wiring harness clip to the main connector bracket.
17. Connect the left side main engine harness electrical connector.
18. Install the engine wiring harness bracket bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
19. Connect the engine harness electrical connectors to the fuel injectors.
20. Install the glow plug module bracket and bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
21. Install the glow plug control module. Refer to «Glow Plug Control Module Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
22. Install the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
23. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
24. Install the PCV hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Crankcase Ventilation Hoses/Pipes Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
2. Remove the glow plug nuts (3).
3. Remove the engine wiring harness from the glow plugs.
4. Remove the glow plug harness bracket bolts (1) and nut (2).
5. Remove the fuel rail pressure sensor electrical connector bracket bolt and nut.
6. Remove the bracket from the stud.
7. Remove the transmission tube support nut at the bell housing.
8. Remove the transmission fluid fill tube upper nut and reposition the tube.
9. Remove the EGR heater inlet hose/pipe retainer stud at the rear of the engine.
10. Remove the EGR heater inlet hose/pipe retainer nut at the center of the lower right cylinder head.
11. Remove the injector wire harness stud at the center lower right cylinder head.
12. Disconnect the engine harness electrical connectors from the fuel injectors.
13. Remove the fuel injector return line clip (1) from the injector.
14. Remove the fuel injector return line fitting (2) from the injector.
15. Perform the above 2 steps for the other 3 fuel injectors.
16. Reposition the injector return line out of the way.
17. Disconnect the right side main engine harness connector.
18. Remove the main connector bracket bolts.
19. Reposition the engine wiring harness out of the way.
20. 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.
21. Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
22. Remove the right fuel injector pipes.
23. Remove the upper valve rocker arm cover bolts.
24. Remove the upper valve rocker arm cover.
25. Remove the upper valve rocker arm cover gasket.
26. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the upper valve rocker arm cover gasket.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts.
4. Tighten the upper valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 8 N.m (71 lb in).
5. Install the fuel injector pipes. Tighten: Tighten the pipes to 41 N.m (30 lb ft).
6. After installing the fuel injector pipes, clean the injector pipes and apply sealant at the fittings to prevent moisture and debris from collecting between the line and fitting. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
7. Position the engine wiring harness.
8. Position the main connector bracket to the generator bracket.
9. Install the main connector bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Connect the right side main engine harness connector.
11. Position the injector return line.
12. Install the fuel injector return line clip (1) to the injector.
13. Install the fuel injector return line fitting (2) to the injector.
14. Perform the above 2 steps for the other 3 fuel injectors.
15. Install the fuel rail pressure sensor electrical connector bracket to the stud.
16. Install the bracket bolt and nut. Tighten: Tighten the bolt/nut to 10 N.m (89 lb in).
17. Position the transmission fluid fill tube and install the upper nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
18. Install the transmission tube support nut at the bell housing. Tighten: Tighten the nut to 25 N.m (18 lb ft).
19. Install the injector wire harness stud at the center lower right cylinder head.
20. Install the EGR heater inlet hose/pipe retainer nut at the center of the lower right cylinder head.
21. Install the EGR heater inlet hose/pipe retainer stud at the rear of the engine. Tighten: Tighten the stud to N.m ( lb ft).
22. Connect the engine harness electrical connectors to the fuel injectors.
23. Install the engine wiring harness to the glow plugs.
24. Install the glow plug harness bracket bolts (1) and nut (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
25. Install the glow plug nuts (3). Tighten: Tighten the nuts to 2 N.m (18 lb in).
26. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .

1. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
2. Remove the glow plug nuts (3).
3. Remove the engine wiring harness from the glow plugs.
4. Remove the glow plug harness bracket bolts (1) and nut (2).
5. Remove the fuel rail pressure sensor electrical connector bracket bolt and nut.
6. Remove the bracket from the stud.
7. Remove the transmission tube support nut at the bell housing.
8. Remove the transmission fluid fill tube upper nut and reposition the tube.
9. Remove the EGR heater inlet hose/pipe retainer stud at the rear of the engine.
10. Remove the EGR heater inlet hose/pipe retainer nut at the center of the lower right cylinder head.
11. Remove the injector wire harness stud at the center lower right cylinder head.
12. Disconnect the engine harness electrical connectors from the fuel injectors.
13. Remove the fuel injector return line clip (1) from the injector.
14. Remove the fuel injector return line fitting (2) from the injector.
15. Perform the above 2 steps for the other 3 fuel injectors.
16. Reposition the injector return line out of the way.
17. Disconnect the right side main engine harness connector.
18. Remove the main connector bracket bolts.
19. Reposition the engine wiring harness out of the way.
20. 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.
21. Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
22. Remove the right fuel injector pipes.
23. Remove the upper valve rocker arm cover bolts.
24. Remove the upper valve rocker arm cover.
25. Remove the upper valve rocker arm cover gasket.
26. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the upper valve rocker arm cover gasket.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts.
4. Tighten the upper valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 8 N.m (71 lb in).
5. Install the fuel injector pipes. Tighten: Tighten the pipes to 41 N.m (30 lb ft).
6. After installing the fuel injector pipes, clean the injector pipes and apply sealant at the fittings to prevent moisture and debris from collecting between the line and fitting. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
7. Position the engine wiring harness.
8. Position the main connector bracket to the generator bracket.
9. Install the main connector bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Connect the right side main engine harness connector.
11. Position the injector return line.
12. Install the fuel injector return line clip (1) to the injector.
13. Install the fuel injector return line fitting (2) to the injector.
14. Perform the above 2 steps for the other 3 fuel injectors.
15. Install the fuel rail pressure sensor electrical connector bracket to the stud.
16. Install the bracket bolt and nut. Tighten: Tighten the bolt/nut to 10 N.m (89 lb in).
17. Position the transmission fluid fill tube and install the upper nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
18. Install the transmission tube support nut at the bell housing. Tighten: Tighten the nut to 25 N.m (18 lb ft).
19. Install the injector wire harness stud at the center lower right cylinder head.
20. Install the EGR heater inlet hose/pipe retainer nut at the center of the lower right cylinder head.
21. Install the EGR heater inlet hose/pipe retainer stud at the rear of the engine. Tighten: Tighten the stud to N.m ( lb ft).
22. Connect the engine harness electrical connectors to the fuel injectors.
23. Install the engine wiring harness to the glow plugs.
24. Install the glow plug harness bracket bolts (1) and nut (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
25. Install the glow plug nuts (3). Tighten: Tighten the nuts to 2 N.m (18 lb in).
26. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .

1. Remove the upper left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Left Side»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the glow plug nuts.
3. Remove the engine wire harness at glow plugs.
4. Remove the fuel injectors. Refer to «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-left) or «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-right) .
5. Remove the fuel injectors return hose clamp at the left rear of engine (1).
6. Remove the fuel feed and return line clamp bolt.
7. Remove the lower valve rocker arm cover bolts.
8. Remove the lower valve rocker arm cover.
9. Remove the gasket from the lower valve rocker arm cover.
10. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the lower valve rocker arm cover gasket.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover bolts.
4. Tighten the lower valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 10 N.m (89 lb in).
5. Install the fuel injectors return hose clamp at the left rear of engine (1).
6. Install the fuel feed and return line clamp bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
7. Install the fuel injectors. Refer to «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-left) or «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-right) .
8. Install the engine wire harness to glow plugs.
9. Install wires and nuts to glow plugs. Tighten: Tighten the nuts to 2 N.m (18 lb in).
10. Install the upper left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Left Side»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the upper left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Left Side»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the glow plug nuts.
3. Remove the engine wire harness at glow plugs.
4. Remove the fuel injectors. Refer to «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-right) or «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-left) .
5. Remove the fuel injectors return hose clamp at the left rear of engine (1).
6. Remove the fuel feed and return line clamp bolt.
7. Remove the lower valve rocker arm cover bolts.
8. Remove the lower valve rocker arm cover.
9. Remove the gasket from the lower valve rocker arm cover.
10. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the lower valve rocker arm cover gasket.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover bolts.
4. Tighten the lower valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 10 N.m (89 lb in).
5. Install the fuel injectors return hose clamp at the left rear of engine (1).
6. Install the fuel feed and return line clamp bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
7. Install the fuel injectors. Refer to «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-right) or «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-left) .
8. Install the engine wire harness to glow plugs.
9. Install wires and nuts to glow plugs. Tighten: Tighten the nuts to 2 N.m (18 lb in).
10. Install the upper left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Left Side»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the upper right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Upper Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the fuel injectors. Refer to «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-left) or «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-right) .
3. Remove the fuel injector return line clip from the exhaust gas recirculation (EGR) cooler tube bracket stud.
4. Remove the EGR cooler tube bracket bolt and nut.
5. Remove the rear EGR cooler tube bracket bolts and bracket.
6. Remove the lower valve rocker arm cover bolts.
7. Remove the lower valve rocker arm cover.
8. Remove the gasket from the lower valve rocker arm cover.
9. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the lower valve rocker arm cover gasket.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover bolts.
4. Tighten the lower valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 10 N.m (89 lb in).
5. Install the rear EGR cooler tube bracket and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Install the EGR cooler tube bracket bolt and nut. Tighten: Tighten the bolt and nut to 20 N.m (15 lb ft).
7. Install the fuel injector return line clip to the EGR cooler tube bracket stud.
8. Install the fuel injectors. Refer to «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-left) or «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2__fuel-injector-replacement-right) .
9. Install the right upper valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Upper Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the upper right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Upper Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the fuel injectors. Refer to «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-right) or «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-left) .
3. Remove the fuel injector return line clip from the exhaust gas recirculation (EGR) cooler tube bracket stud.
4. Remove the EGR cooler tube bracket bolt and nut.
5. Remove the rear EGR cooler tube bracket bolts and bracket.
6. Remove the lower valve rocker arm cover bolts.
7. Remove the lower valve rocker arm cover.
8. Remove the gasket from the lower valve rocker arm cover.
9. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the lower valve rocker arm cover gasket.
2. Install the lower valve rocker arm cover.
3. Install the lower valve rocker arm cover bolts.
4. Tighten the lower valve rocker arm cover bolts. Tighten: Tighten the bolts in the sequence shown to 10 N.m (89 lb in).
5. Install the rear EGR cooler tube bracket and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Install the EGR cooler tube bracket bolt and nut. Tighten: Tighten the bolt and nut to 20 N.m (15 lb ft).
7. Install the fuel injector return line clip to the EGR cooler tube bracket stud.
8. Install the fuel injectors. Refer to «Fuel Injector Replacement (Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-right) or «Fuel Injector Replacement (Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2__fuel-injector-replacement-left) .
9. Install the right upper valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Upper Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Upper Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the lower valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Lower Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Lower Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and «Valve Rocker Arm Cover Replacement - Lower Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Lower Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Loosen the valve clearance lock nuts on each rocker arm.
3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain.
4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets.
5. Remove the rocker arm shaft assembly from the cylinder head.
6. Remove the valve bridge pins.
7. Remove the valve bridges.
8. Remove the pushrods.
9. Remove the rocker arm shaft bracket bolts (1), if necessary.
10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary.
11. Remove the remaining rocker arms, springs, and brackets, if necessary.
12. If required, clean and inspect the valve rocker arm and shaft. Refer to «Valve Rocker Arm and Shaft Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__valve-rocker-arm-and-shaft-cleaning) .

1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary.
2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary.
3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary.
4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary.
5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil.
6. Install the valve bridge.
7. Install the valve bridge pins.
8. Lubricate the valve lifter end of the pushrod with clean engine oil.
9. Install the pushrods. To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter.
10. Install the rocker arm shaft assembly.
11. Tighten the rocker arm shaft bolts in the sequence shown. Tighten: Tighten the bolts to 41 N.m (30 lb ft).
12. Adjust the valve clearance. Refer to «Valve Lash Adjustment»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-5-of-5__valve-lash-adjustment) .
13. Install the lower valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Lower Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Lower Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and «Valve Rocker Arm Cover Replacement - Lower Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Lower Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

Valve Clearance Adjustment

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
2. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the fan clutch. Refer to «Fan Clutch Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system__fan-clutch-replacement) .
4. Remove the upper valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Upper Left Side»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and «Valve Rocker Arm Cover Replacement - Upper Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Upper Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Rotate the crankshaft in order to bring the number 1 cylinder to top dead center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine.
6. Loosen the valve adjusting screws.
7. Insert a feeler gage between the tip of the rocker arm and the valve bridge.
8. Adjust the valve lash to 0.3 mm (0.012 in). Refer to «Valve Clearance Adjustment Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__valve-clearance-adjustment-specifications) to determine which valves can be adjusted when the engine is at TDC.
9. Tighten the lock nut. Tighten: Tighten nut to 22 N.m (16 lb ft).
10. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke.
11. Loosen the valve adjusting screws.
12. Insert a feeler gage between the tip of the rocker arm and the valve bridge.
13. Adjust the valve clearance to 0.3 mm (0.0112 in). Refer to «Valve Clearance Adjustment Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__valve-clearance-adjustment-specifications) to determine which valves can be adjusted when the engine is at TDC.
14. Tighten the lock nut. Tighten: Tighten nut to 22 N.m (16 lb ft).
15. Install the upper valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Upper Left Side»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and «Valve Rocker Arm Cover Replacement - Upper Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Valve Rocker Arm Cover Replacement - Upper Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
16. Install the fan clutch. Refer to «Fan Clutch Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system__fan-clutch-replacement) .
17. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
18. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

Turbocharger Replacement (LLY, LBZ)

Note. If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.

1. Disconnect the negative battery cable. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
2. Remove the left exhaust pipe. Refer to «Exhaust Pipe Replacement - Left Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Left Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
3. Remove the right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Right Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
4. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
5. Remove the charge air cooler outlet pipe. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
6. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Disconnect the engine wiring harness electrical connector from the turbocharger vane position sensor.
8. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.
9. Loosen the charge air cooler inlet duct clamp (1) at the turbocharger.
10. Remove the charge air cooler inlet duct (2) from the turbocharger
11. Remove the turbocharger upper heat shield bolts.
12. Remove the turbocharger upper heat shield.
13. Reposition the turbocharger coolant outlet pipe clamp (1) and remove the hose from the turbocharger pipe.
14. Reposition the turbocharger coolant inlet pipe clamp (1) and remove the hose from the turbocharger pipe.
15. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer.
16. Reposition and secure the turbocharger oil feed pipe out of the way.
17. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
18. Remove the turbocharger bolts.
19. Remove the turbocharger (with the oil return pipe).
20. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.
21. Remove the turbocharger lower heat shield, if necessary.
22. Remove the turbocharger oil feed pipe bolt, washer, and pipe, if necessary.
23. If the turbocharger has failed, perform the following steps in order to verify the condition of the number 4 camshaft bearing before installing a new turbocharger. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole through the turbocharger oil supply hole in the block. Turn the engine over by hand 1/2 turn and inspect for camshaft bearing movement, indicating a spun camshaft bearing. If the bearing is spun the engine MUST be replaced.
24. If replacing the turbocharger perform the following steps otherwise proceed to step 11 in the installation procedure.
25. Remove the oil return pipe bolts, pipe, and gasket from the turbocharger. Discard the gasket.
26. Remove the turbocharger vane position sensor.
27. Remove the turbocharger coolant feed pipe banjo bolt (1), washers and pipe (2).
28. Remove the turbocharger coolant return pipe banjo bolt (3) and washers.
29. Remove the turbocharger coolant return pipe clip nut (5) and pipe (4).

1. If replacing the turbocharger perform the following steps otherwise proceed to step 11.
2. Install the long bolt (1) with the 2 holes to the coolant inlet pipe and the short bolt (2) with one hole for the coolant outlet pipe.
3. Position the turbocharger coolant return pipe (4) and install the clip nut (5). Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Position the turbocharger coolant return pipe washers and install the banjo bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Position the turbocharger coolant feed pipe washers and pipe (2), and install the banjo bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Install the turbocharger vane position sensor. Tighten: Tighten the sensor to 28 N.m (21 lb ft).
7. Position a NEW oil return pipe gasket to the turbocharger and install the oil return pipe and bolts to the turbocharger. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
8. Install a NEW turbocharger oil feed pipe washer onto the banjo fitting, if necessary.
9. Install the turbocharger oil feed pipe and bolt, if necessary. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
10. Install the turbocharger lower heat shield, if necessary.
11. Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
12. Install the turbocharger.
13. Install the turbocharger bolts. Tighten: Tighten the bolts to 108 N.m (80 lb ft).
14. Install the turbocharger oil return pipe nuts at the top of the flywheel housing. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
15. Unsecure and position the turbocharger oil feed pipe to the correct position.
16. Install a NEW turbocharger oil feed pipe washer onto the banjo fitting and install the feed pipe bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
17. Install the turbocharger coolant inlet pipe hose to the turbocharger pipe and position the clamp (1).
18. Install the turbocharger coolant outlet hose to the turbocharger pipe and position the clamp (1).
19. Install the turbocharger upper heat shield.
20. Install the turbocharger upper heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
21. Remove the tape from the turbocharger openings.
22. Install the charge air cooler inlet duct (2) to the turbocharger.
23. Tighten the charge air cooler inlet duct clamp (1) at the turbocharger. Tighten: Tighten the bolts to 8 N.m (71 lb in).
24. Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.
25. Connect the engine wiring harness electrical connector from the turbocharger vane position sensor.
26. Install the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
27. Install the charge air cooler outlet pipe. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
28. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
29. Install the right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Right Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
30. Install the left exhaust pipe. Refer to «Exhaust Pipe Replacement - Left Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Left Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
31. Connect the negative battery cable. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .

Turbocharger Replacement (LMM)

Note. If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup. Failure to clean excessive oil from the charge air cooler system may cause an engine runaway condition on startup, resulting in severe engine damage.

1. Disconnect the negative battery cable. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
2. Remove the left exhaust pipe. Refer to «Exhaust Pipe Replacement - Left Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Left Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
3. Remove the right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Right Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
4. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
5. Remove the charge air cooler outlet pipe. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
6. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Disconnect the engine wiring harness electrical connector from the turbocharger vane position sensor.
8. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.
9. Loosen the charge air cooler inlet duct clamp (1) at the turbocharger.
10. Remove the charge air cooler inlet duct (2) from the turbocharger
11. Remove the EGR cooler pipe bolt.
12. Reposition the EGR cooler pipe (4) out of the way.
13. Remove the EGR valve adapter pipe bracket bolts (1).
14. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
15. Reposition the turbocharger coolant outlet pipe clamp (1) and remove the hose from the turbocharger pipe.
16. Reposition the turbocharger coolant inlet pipe clamp (1) and remove the hose from the turbocharger pipe.
17. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer.
18. Reposition and secure the turbocharger oil feed pipe out of the way.
19. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
20. Remove the turbocharger bolts.
21. Remove the turbocharger (with the oil return pipe).
22. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.
23. Remove the turbocharger lower heat shield, if necessary.
24. Remove the turbocharger oil feed pipe bolt, washer, and pipe, if necessary.
25. If the turbocharger has failed, perform the following steps in order to verify the condition of the number 4 camshaft bearing before installing a new turbocharger. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole through the turbocharger oil supply hole in the block. Turn the engine over by hand 1/2 turn and inspect for camshaft bearing movement, indicating a spun camshaft bearing. If the bearing is spun the engine MUST be replaced.
26. If replacing the turbocharger perform the following steps otherwise proceed to step 11 in the installation procedure.
27. Remove the oil return pipe bolts, pipe, and gasket from the turbocharger. Discard the gasket.
28. Remove the turbocharger vane position sensor.
29. Remove the turbocharger coolant feed pipe banjo bolt (1), washers and pipe (2).
30. Remove the turbocharger coolant return pipe banjo bolt (3) and washers.
31. Remove the turbocharger coolant return pipe clip nut (5) and pipe (4).

1. If replacing the turbocharger perform the following steps otherwise proceed to step 11.
2. Install the long bolt (1) with the 2 holes to the coolant inlet pipe and the short bolt (2) with one hole for the coolant outlet pipe.
3. Position the turbocharger coolant return pipe (4) and install the clip nut (5). Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Position the turbocharger coolant return pipe washers and install the banjo bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Position the turbocharger coolant feed pipe washers and pipe (2), and install the banjo bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Install the turbocharger vane position sensor. Tighten: Tighten the sensor to 28 N.m (21 lb ft).
7. Position a NEW oil return pipe gasket to the turbocharger and install the oil return pipe and bolts to the turbocharger. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
8. Install a NEW turbocharger oil feed pipe washer onto the banjo fitting, if necessary.
9. Install the turbocharger oil feed pipe and bolt, if necessary. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
10. Install the turbocharger lower heat shield, if necessary.
11. Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
12. Install the turbocharger.
13. Install the turbocharger bolts. Tighten: Tighten the bolts to 108 N.m (80 lb ft).
14. Install the turbocharger oil return pipe nuts at the top of the flywheel housing. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
15. Unsecure and position the turbocharger oil feed pipe to the correct position.
16. Install a NEW turbocharger oil feed pipe washer onto the banjo fitting and install the feed pipe bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
17. Install the turbocharger coolant inlet pipe hose to the turbocharger pipe and position the clamp (1).
18. Install the turbocharger coolant outlet hose to the turbocharger pipe and position the clamp (1).
19. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
20. Install the EGR valve adapter pipe bracket bolts (1). Tighten: Tighten the bolts to 9 N.m (80 lb in).
21. Position the EGR cooler pipe (4).
22. Install the EGR cooler pipe bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
23. Remove the tape from the turbocharger openings.
24. Install the charge air cooler inlet duct (2) to the turbocharger.
25. Tighten the charge air cooler inlet duct clamp (1) at the turbocharger. Tighten: Tighten the bolts to 8 N.m (71 lb in).
26. Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.
27. Connect the engine wiring harness electrical connector from the turbocharger vane position sensor.
28. Install the air intake pipe. Refer to «Air Intake Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
29. Install the charge air cooler outlet pipe. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Inlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Outlet)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
30. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
31. Install the right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Right Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
32. Install the left exhaust pipe. Refer to «Exhaust Pipe Replacement - Left Side (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Pipe Replacement - Left Side (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
33. Connect the negative battery cable. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .

1. Remove the turbocharger. Refer to «Turbocharger Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lly-lbz) or «Turbocharger Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lmm) .
2. Remove the turbocharger oil feed pipe bolt.
3. Remove the oil feed pipe and washer.

1. Position the oil feed pipe and a NEW washer into place.
2. Install the oil feed pipe bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
3. Install the turbocharger. Refer to «Turbocharger Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lly-lbz) or «Turbocharger Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__turbocharger-replacement-lmm) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the auxiliary generator bracket bolt and bracket, if equipped.
5. Remove the auxiliary generator idler pulley, if equipped.
6. Disconnect the engine harness electrical connectors from the air conditioning (A/C) compressor.
7. Remove the A/C compressor bolts.
8. Reposition and secure the A/C compressor with the hoses attached out of the way.
9. Remove the front power steering pump bracket bolts (1).
10. Remove the rear power steering pump bracket bolts (1).
11. Reposition and secure the power steering pump out of the way.
12. Remove the A/C compressor and power steering pump bracket bolts and bracket.

1. Position the A/C compressor and power steering pump bracket.
2. Install the A/C compressor and power steering pump bracket bolts. Tighten: Tighten the bolts to 46 N.m (34 lb ft).
3. Position the power steering pump and loosely install the front bracket bolts (1).
4. Loosely install the rear power steering pump bracket bolts (1). Tighten: Tighten the front bolts to 50 N.m (37 lb ft). Tighten the rear bolts to 50 N.m (37 lb ft).
5. Position the A/C compressor.
6. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
7. Connect the engine harness electrical connectors to the A/C compressor.
8. Install the auxiliary generator idler pulley, if equipped. Tighten: Tighten the bolt to 50 N.m (37 lb ft)
9. Install the auxiliary generator bracket bolt and bracket, if equipped. Tighten: Tighten the bolt to 50 N.m (37 lb ft)
10. Install the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
11. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Remove the auxiliary generator bracket bolt and bracket, if equipped.
5. Remove the auxiliary generator idler pulley, if equipped.
6. Disconnect the engine harness electrical connectors from the air conditioning (A/C) compressor.
7. Remove the A/C compressor bolts.
8. Reposition and secure the A/C compressor with the hoses attached out of the way.
9. Remove the front power steering pump bracket bolts (1).
10. Remove the rear power steering pump bracket bolts (1).
11. Reposition and secure the power steering pump out of the way.
12. Remove the engine lift bracket bolts (1).
13. Remove the engine lift bracket.
14. Remove the A/C compressor and power steering pump bracket bolts and bracket.

1. Position the A/C compressor and power steering pump bracket.
2. Install the A/C compressor and power steering pump bracket bolts. Tighten: Tighten the bolts to 46 N.m (34 lb ft).
3. Position the engine lift bracket.
4. Install the engine lift bracket bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Position the power steering pump and loosely install the front bracket bolts (1).
6. Loosely install the rear power steering pump bracket bolts (1). Tighten: Tighten the front bolts to 50 N.m (37 lb ft). Tighten the rear bolts to 50 N.m (37 lb ft).
7. Position the A/C compressor.
8. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Connect the engine harness electrical connectors to the A/C compressor.
10. Install the auxiliary generator idler pulley, if equipped. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
11. Install the auxiliary generator bracket bolt and bracket, if equipped. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
12. Install the auxiliary generator, if equipped. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
13. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

J 45059 Angle Meter

1. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold. Refer to «Intake Manifold Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
4. Remove the bolt and ground straps from the rear of the cylinder head.
5. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
6. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
7. Remove the cylinder head bolts in the sequence shown.
8. Discard the large M12 bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Clean the sealing surface of the engine block and the cylinder head. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
12. Clean the cylinder head bolt holes in the engine block.
13. For service to the cylinder head refer to the following: Refer to «Cylinder Head Disassemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Assemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__cylinder-head-assemble) .

1. Install the cylinder head gasket of the correct grade. Refer to «Cylinder Head Gasket Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5) .
2. Install the cylinder head.
3. Install NEW M12 cylinder head bolts.
4. Reuse the M8 cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown. Tighten: Tighten the M12 bolts a first pass to 50 N.m (37 lb ft). Tighten the M12 bolts a second pass to 80 N.m (59 lb ft). Tighten the M12 bolts a third pass to 60 degrees, using J 45059 . Tighten the M12 bolts a final pass to 60 degrees, using J 45059 . Tighten the M8 bolts to 25 N.m (18 lb ft).
6. Position the ground straps to the rear of the cylinder head, and install the bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
7. Install the glow plugs. Refer to «Glow Plug Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
8. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
9. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
10. Install the intake manifold. Refer to «Intake Manifold Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
11. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Road test the vehicle for normal operation.
13. Inspect for coolant, oil, or exhaust leaks.

J 45059 Angle Meter

1. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold. Refer to «Intake Manifold Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
4. Remove the bolt and ground straps from the rear of the cylinder head.
5. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
6. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
7. Remove the cylinder head bolts in the sequence shown.
8. Discard the large M12 bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Clean the sealing surface of the engine block and the cylinder head. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
12. Clean the cylinder head bolt holes in the engine block.
13. For service to the cylinder head refer to the following: Refer to «Cylinder Head Disassemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Assemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__cylinder-head-assemble) .

1. Install the cylinder head gasket of the correct grade. Refer to «Cylinder Head Gasket Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5) .
2. Install the cylinder head.
3. Install NEW M12 cylinder head bolts.
4. Reuse the M8 cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown. Tighten: Tighten the M12 bolts a first pass to 50 N.m (37 lb ft). Tighten the M12 bolts a second pass to 80 N.m (59 lb ft). Tighten the M12 bolts a third pass to 60 degrees, using J 45059 . Tighten the M12 bolts a final pass to 60 degrees, using J 45059 . Tighten the M8 bolts to 25 N.m (18 lb ft).
6. Position the ground straps to the rear of the cylinder head, and install the bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
7. Install the glow plugs. Refer to «Glow Plug Replacement - Bank 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
8. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
9. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
10. Install the intake manifold. Refer to «Intake Manifold Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
11. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Road test the vehicle for normal operation.
13. Inspect for coolant, oil, or exhaust leaks.

J 45059 Angle Meter

1. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold. Refer to «Intake Manifold Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
4. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
6. Remove the cylinder head bolts in the sequence shown.
7. Discard the large M12 bolts.
8. Remove the cylinder head.
9. Remove and discard the cylinder head gasket.
10. Clean the sealing surface of the engine block and the cylinder head.
11. Clean the cylinder head bolt holes in the engine block.
12. For service to the cylinder head refer to the following: Refer to «Cylinder Head Disassemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Assemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__cylinder-head-assemble) .

1. Install the cylinder head gasket of the correct grade. Refer to «Cylinder Head Gasket Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5) .
2. Install the cylinder head.
3. Install the NEW M12 cylinder head bolts.
4. Reuse the M8 cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown. Tighten: Tighten the M12 bolts a first pass to 50 N.m (37 lb ft). Tighten the M12 bolts a second pass to 80 N.m (59 lb ft). Tighten the M12 bolts a third pass to 60 degrees, using J 45059 . Tighten the M12 bolts a final pass to 60 degrees, using J 45059 . Tighten the M8 bolts to 25 N.m (18 lb ft).
6. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
7. Install the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lbz-and-lly-introduction-2-of-2) .
8. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
9. Install the right intake manifold. Refer to «Intake Manifold Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
10. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
11. Road test the vehicle for normal operation.
12. Inspect for coolant, oil, or exhaust leaks.

J 45059 Angle Meter

1. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold. Refer to «Intake Manifold Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
4. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
6. Remove the cylinder head bolts in the sequence shown.
7. Discard the large M12 bolts.
8. Remove the cylinder head.
9. Remove and discard the cylinder head gasket.
10. Clean the sealing surface of the engine block and the cylinder head.
11. Clean the cylinder head bolt holes in the engine block.
12. For service to the cylinder head refer to the following: Refer to «Cylinder Head Disassemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . Refer to «Cylinder Head Assemble»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__cylinder-head-assemble) .

1. Install the cylinder head gasket of the correct grade. Refer to «Cylinder Head Gasket Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5) .
2. Install the cylinder head.
3. Install the NEW M12 cylinder head bolts.
4. Reuse the M8 cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown. Tighten: Tighten the M12 bolts a first pass to 50 N.m (37 lb ft). Tighten the M12 bolts a second pass to 80 N.m (59 lb ft). Tighten the M12 bolts a third pass to 60 degrees, using J 45059 . Tighten the M12 bolts a final pass to 60 degrees, using J 45059 . Tighten the M8 bolts to 25 N.m (18 lb ft).
6. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to «Valve Rocker Arm, Shaft, and Push Rod Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
7. Install the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
8. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
9. Install the right intake manifold. Refer to «Intake Manifold Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Intake Manifold Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
10. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Thermostat Housing Crossover Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
11. Road test the vehicle for normal operation.
12. Inspect for coolant, oil, or exhaust leaks.

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 8062 Valve Spring Compressor
2. J 26999-20 Valve Stem Oil Seal Remover. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. J 44640 Valve Stem Seal Installer. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

1. Remove the cylinder head. Refer to «Cylinder Head Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and/or «Cylinder Head Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Using the J 8062 , compress the valve spring.
3. Remove the valve keys (1) from the valve stem.
4. Remove the J 8062 from the cylinder head.
5. Remove the valve spring upper seat (2).
6. Remove the valve spring (3).
7. Remove the valve stem oil seal (4) using the J 26999-20 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
8. Remove the valve spring lower seat (5).
9. Continue removing the necessary components using the above procedure.

1. Install the valve spring lower seat.
2. Install the valve stem using the J 44640 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. Install the valve spring with the painted end towards the cylinder head.
4. Install the valve spring upper seat.
5. Using the J 8062 , compress the valve spring.
6. Install the valve keys.
7. Remove the J 8062 from the cylinder head.
8. Measure the valve installed height using a ruler. Measure from the base of the valve spring to the top of the valve. Refer to «Engine Mechanical Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__engine-mechanical-specifications) .
9. Install the remaining spring and other components as necessary.
10. Install the cylinder head. Refer to «Cylinder Head Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and/or «Cylinder Head Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

1. Remove the cylinder head. Refer to «Cylinder Head Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and/or «Cylinder Head Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Loosen the valve lifter guide hold down bracket bolts.
3. Remove the valve lifter guide hold down brackets.
4. Remove the valve lifter guides.
5. Remove the valve lifters.

1. Apply clean engine oil to the lifters.
2. Install the valve lifter.
3. Install the valve lifter guides.
4. Install the valve lifter guide hold down brackets.
5. Install the valve lifter guide hold down bracket bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
6. Install the cylinder head. Refer to «Cylinder Head Replacement - Left Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Left Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) and/or «Cylinder Head Replacement - Right Side (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Cylinder Head Replacement - Right Side (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

Crankshaft Balancer Replacement

Tools Required

1. J 44643 Flywheel Holding Tool. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. J 45059 Angle Meter

1. Remove the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Install the J 44643 in order to hold the flywheel. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. Remove the radiator fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the crankshaft balancer bolt.
5. Remove the crankshaft balancer.

1. Lightly lubricate the crankshaft balancer internal hub with engine oil.
2. Install the crankshaft balancer to the crankshaft.
3. Lightly lubricate the crankshaft balancer bolt with engine oil.
4. Install the crankshaft balancer bolt and washer. Tighten: Tighten the bolt a first pass to 100 N.m (74 lb ft). Tighten the bolt a final pass an additional 90 degrees using the J 45059 .
5. Install the radiator fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Remove the J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
7. Install the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

Crankshaft Front Oil Seal Replacement

Tools Required

1. J 44644 Crankshaft Front Oil Seal Remover. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. J 44645 Crankshaft Front Oil Seal Installer. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__crankshaft-balancer-replacement) .
2. Install the J 44644 to the crankshaft front oil seal. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) . The jaws of the J 44644 fit into the inner sleeve of the front oil seal. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. Using the J 44644 , remove the crankshaft front oil seal. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

1. Clean the front crankshaft seal bore and the crankshaft.
2. Lubricate the crankshaft sealing surface with clean engine oil.
3. Place the crankshaft front oil seal onto the crankshaft.
4. Install the J 44645 to the crankshaft. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
5. Press the crankshaft front oil seal onto the crankshaft using the J 44645 until the tool bottoms out. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
6. Remove the J 44645 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
7. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5__crankshaft-balancer-replacement) .

J 37228 Seal Cutter. See Special Tools .

1. Remove the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the upper oil pan. Refer to «Upper Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
3. Remove the idler pulley.
4. Remove the water pump. Refer to «Water Pump Replacement (6.6L Engine)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
6. Remove the engine oil fill tube bolts.
7. Remove the engine oil fill tube.
8. Remove the crankshaft position sensor bolt.
9. Remove the crankshaft position sensor.
10. Remove the engine front cover bolts.
11. Separate the engine front cover from the cylinder block using J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
12. Remove the engine front cover.

1. Install the relief valve O-ring to the engine front cover.
2. Lubricate the O-ring with engine oil.
3. Apply a 2-3 mm wide and 0.5-1.5 mm high bead of sealant to the mating surfaces of the engine front cover. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) for the correct part number.
4. Install the engine front cover.
5. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
6. Install a new O-ring to the crankshaft position sensor spacer.
7. Lubricate the O-ring with engine oil.
8. Install the crankshaft position sensor spacer.
9. Install the crankshaft position sensor spacer bolts. Tighten: Tighten the crankshaft position sensor spacer bolts to 10 N.m (89 lb in).
10. Install a new O-ring to the crankshaft position sensor.
11. Lubricate the O-ring with engine oil.
12. Install the crankshaft position sensor.
13. Install the crankshaft position sensor bolt. Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
14. Install the engine oil fill tube. Refer to «Oil Fill Tube Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
15. Install the water pump. Refer to «Water Pump Replacement (6.6L Engine)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
16. Install the crankshaft balancer. Refer to «Crankshaft Balancer Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
17. Install the idler pulley.
18. Install the upper oil pan. Refer to «Upper Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
19. Install the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the upper oil pan. Refer to «Upper Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut.
4. Remove the oil pump driven gear.
5. Remove the oil pump drive gear and crankshaft sensor reluctor.
6. Remove the camshaft reluctor screws.
7. Remove the camshaft reluctor.

1. Position the camshaft reluctor to the camshaft gear.
2. Install the camshaft reluctor bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
3. Install the oil pump drive gear and reluctor to the crankshaft.
4. Install the oil pump driven gear.
5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten: Tighten the nut to 100 N.m (74 lb ft).
6. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
7. Install the upper oil pan. Refer to «Upper Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .

1. Remove the upper oil pan. Refer to «Upper Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
2. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) . NOTE: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft.
3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut.
4. Remove the oil pump driven gear.
5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth.
6. Remove the crankshaft reluctor to oil pump drive gear bolts.
7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped.
8. Inspect the oil pump drive gear for damaged or worn teeth.
9. Inspect the oil pump drive gear crankshaft pin for wear.
10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear.
11. Replace any parts that are damaged or worn.

1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in)
2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins.
3. Install the crankshaft reluctor bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
4. Install the oil pump drive gear and reluctor to the crankshaft.
5. Install the oil pump driven gear.
6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten: Tighten the nut to 100 N.m (74 lb ft).
7. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
8. Install the upper oil pan. Refer to «Upper Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .

Camshaft Replacement

Tools Required

1. J 44643 Flywheel Holding Tool. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. J 26900-13 Magnetic Base. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. J 26900-12 Dial Indicator. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

1. Remove the valve lifters. Refer to «Valve Lifter Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
2. Remove the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Install the J 44643 in order to hold the flywheel. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
4. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
5. Remove the oil pump driven gear nut.
6. Remove the oil pump driven gear.
7. Remove the oil pump drive gear and crankshaft reluctor. Do not remove the crankshaft reluctor bolts. Do not damage the reluctor teeth.
8. Using J 26900-12 (1) and J 26900-13 (2), measure the camshaft end play. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) . The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). Replace the camshaft gear or the camshaft thrust plate if measured value exceeds service limit.
9. Remove the camshaft reluctor screws.
10. Remove the camshaft reluctor.
11. In order to loosen the camshaft gear bolt use J 44643 in order to hold the engine from turning. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
12. Loosen the camshaft gear bolt and leave the bolt finger tight.
13. Remove the camshaft thrust plate bolts through the holes in the camshaft gear.
14. Remove the camshaft with the camshaft gear attached.
15. Remove the camshaft gear bolt and discard.
16. Remove the camshaft gear.
17. Remove the camshaft thrust plate.
18. Clean and inspect the camshaft and bearings. Refer to «Camshaft and Bearings Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5) . If the camshaft bearings are worn or damaged the engine will require removal in order to replace the camshaft bearings. Refer to «Engine Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5__engine-replacement) .

1. Install the camshaft thrust plate to the camshaft.
2. Install the camshaft driven gear.
3. Install a NEW camshaft driven gear bolt. Leave the bolt finger tight.
4. Install the camshaft into the cylinder block, align the camshaft gear to the crankshaft gear as shown.
5. Apply threadlock to the threads of the camshaft thrust plate bolts. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) for the correct part number.
6. Install the camshaft thrust plate bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
7. Install the camshaft reluctor to the camshaft gear.
8. Install the camshaft reluctor bolts. Tighten: Tighten the bolts in a cross-bolt pattern to 9 N.m (80 lb in).
9. Reinstall J 44643 in the starter opening, if removed. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
10. Install a NEW camshaft gear bolt. Tighten: Tighten the bolt to 234 N.m (173 lb ft).
11. Using J 26900-12 (1) and J 26900-13 (2) measure the camshaft end play. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) . The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the service limit.
12. Install the oil pump drive gear and reluctor to the crankshaft.
13. Install the oil pump driven gear.
14. Install the oil pump driven gear nut. Tighten: Tighten the nut to 100 N.m (74 lb ft).
15. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
16. Remove the J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
17. Install the starter. Refer to «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
18. Install the valve lifters. Refer to «Valve Lifter Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .

Crankshaft Rear Oil Seal Replacement

Tools Required

1. J 44641 Crankshaft Rear Oil Seal Remover. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. J 44642 Crankshaft Rear Oil Seal Installer. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5__engine-flywheel-replacement)
2. Install the J 44641 to the crankshaft rear oil seal. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. Remove the crankshaft rear oil seal using the J 44641 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

1. Place the crankshaft rear oil seal onto the crankshaft.
2. Install the J 44642 to the crankshaft. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
3. Press the crankshaft rear oil seal into position using the J 44642 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) . The J 44642 will bottom out when the seal reaches the proper depth. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
4. Remove the J 44642 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
5. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5__engine-flywheel-replacement) .

See also:
• Engine Coolant Fan Upper Shroud Replacement (6.6L)
• Fastener Notice
• ENGINE MOUNTING NOTICE
• Lifting and Jacking the Vehicle
• ENGINE LIFTING NOTICE
• Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
• Starter Motor Replacement (6.6L)
• Engine Cover Replacement
• Air Cleaner Outlet Duct Replacement
• Air Cleaner Outlet Duct Replacement
• Fastener Tightening Specifications
• Radiator Replacement (Diesel)
• Radiator Replacement (Gas)
• Sealers, Adhesives, and Lubricants
• Fuel Injector Replacement (Left)
• Fuel Injector Replacement (Right)
• Fuel Injector Replacement (Right)
• Fuel Injector Replacement (Left)
• Valve Rocker Arm and Shaft Cleaning and Inspection
• Valve Lash Adjustment
• Fan Clutch Replacement
• Valve Clearance Adjustment Specifications
• Exhaust Pipe Replacement - Left Side (6.6L (LBZ/LLY))
• Cylinder Head Disassemble
• Cylinder Head Assemble
• Cylinder Head Gasket Selection Specifications
• Special Tools
• Engine Mechanical Specifications
• Upper Oil Pan Replacement
• Engine Replacement
• Engine Flywheel Replacement
• Drive Belt Replacement
• Turbocharger Replacement (LLY, LBZ)
• Turbocharger Replacement (LMM)
• Crankshaft Balancer Replacement