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Engine Mechanical - 6.6l (3 of 5) Chevrolet Chevy Express H1500

Mechanical 1 illustration ~7920 words

Tools Required

J 37228 Seal Cutter. See Special Tools .

Removal Procedure

  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 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 turbocharger oil return pipe nuts from the top of the flywheel housing.
  4. Remove the turbocharger oil return pipe studs from the flywheel housing, if necessary.
  5. Remove the oil cooler adapter nuts from the side of the flywheel housing.
  6. Remove the oil cooler adapter studs from the flywheel housing, if necessary.
  7. Remove the flywheel housing bolts.
  8. Separate the flywheel housing from the cylinder block using the J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  9. Remove the flywheel housing.
  10. Remove and discard the turbocharger oil return pipe and oil cooler adapter gaskets.
  11. Remove the oil cooler adapter bolts.
  12. Remove the oil cooler adapter and gaskets.

Installation Procedure

  1. Install the oil cooler adapter with a NEW gasket to the oil cooler.
  2. Install the oil cooler adapter to oil cooler bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  3. Install NEW gaskets to the flywheel housing for the turbocharger oil return pipe and oil cooler adapter.
  4. Install the flywheel housing to the cylinder block.
  5. Install the flywheel housing bolts. Tighten: Tighten the bolts to 80 N.m (60 lb ft).
  6. Install the oil cooler adapter studs to the flywheel housing, if necessary. Tighten: Tighten the studs to 10 N.m (89 lb in).
  7. Install the oil cooler adapter nuts to the side of the flywheel housing. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  8. Install the turbocharger oil return pipe studs, if necessary. Tighten: Tighten the studs to 10 N.m (89 lb in).
  9. Install the turbocharger oil return pipe nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  10. 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) .
  11. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

Engine Flywheel 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 transmission. Refer to «Transmission Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l80-e4l85-e-removal-installation-service-troubleshooting-diagnosis) .
  2. Install the J 44643 in order to lock the flywheel. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  3. Remove and discard the flywheel bolts.
  4. Remove the flywheel washer.
  5. Remove the flywheel assembly.
  6. Remove the J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  1. Install the flywheel to the crankshaft.
  2. Install the flywheel washer to the flywheel with the beveled side facing the engine.
  3. Install NEW flywheel bolts until snug.
  4. Install the J 44643 in order to lock the flywheel. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  5. Tighten the flywheel bolts in the sequence shown. Tighten: Tighten the bolts a first pass to 79 N.m (59 lb ft). Tighten the bolts a second pass an additional 60 degrees using the J 45059 . Tighten the bolts a final pass an additional 60 degrees using the J 45059 .
  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 transmission. Refer to «Transmission Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l80-e4l85-e-removal-installation-service-troubleshooting-diagnosis) .

J 37228 Seal Cutter. See Special Tools .

  1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  2. Disconnect the engine harness electrical connector from the oil level sensor.
  3. Remove the lower oil pan bolts.
  4. Separate the lower oil pan from the upper oil pan using the J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  5. Remove the lower oil pan.
  6. If replacing the lower oil pan perform the following steps, otherwise proceed to step 4 in the installation procedure.
  7. Remove the oil level sensor retaining clip (3).
  8. Remove the oil level sensor bolt (2) and sensor (1).
  1. If the lower oil pan was replaced perform the following steps, otherwise proceed to step 4.
  2. Install the oil level sensor (1) and bolt (2). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  3. Install the oil level sensor retaining clip (3).
  4. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of sealant to the lower oil pan mating surface. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
  5. Install the lower oil pan.
  6. Install the lower oil pan bolts and nuts. Tighten: Tighten the bolts and nuts in the sequence shown to 10 N.m (89 lb in).
  7. Connect the engine wiring harness electrical connector to the oil level sensor.

J 37228 Seal Cutter. See Special Tools .

  1. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Oil Level Indicator and Tube Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  2. Remove the lower oil pan. Refer to «Lower Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  3. 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) .
  4. Remove the front engine crossmember. Refer to «Engine Front Crossmember Replacement (4WD)»(/chevrolet/chevy-express-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Engine Front Crossmember Replacement (RWD)»(/chevrolet/chevy-express-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  5. Remove the 2 flywheel housing to upper oil pan bolts.
  6. Remove the upper oil pan bolts and any brackets. Mark the bolt location of the bracket.
  7. Separate the upper oil pan from the engine block using the J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  8. Remove the upper oil pan.
  1. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the upper oil pan mating surfaces. 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. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the flywheel housing sealing surface. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
  3. Install the upper oil pan to the engine block.
  4. Install any brackets and the upper oil pan bolts. Tighten: Tighten the bolts in the sequence shown to 20 N.m (15 lb ft).
  5. Install the 2 flywheel housing to upper oil pan bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  6. Install the front engine crossmember. Refer to «Engine Front Crossmember Replacement (4WD)»(/chevrolet/chevy-express-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Engine Front Crossmember Replacement (RWD)»(/chevrolet/chevy-express-h1500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  7. 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) .
  8. Install the lower oil pan. Refer to «Lower Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  9. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Oil Level Indicator and Tube Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-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) .
  3. Remove the oil pump screen bolts and nuts.
  4. Remove the oil pump screen.
  5. Remove and discard the oil pump screen gasket.
  6. Block the crankshaft from turning with a wooden handle.
  7. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut.
  8. Remove the oil pump driven gear.
  9. Remove the oil pump drive gear and crankshaft reluctor. Use a brass drift. Tap on the back as close to the center of the reluctor.
  10. Remove the hex head and the allen head bolt in order to remove the oil pump.
  11. Remove the oil pump.
  12. Remove the O-ring seal for the oil pump.
  13. If required, clean and inspect the oil pump. Refer to «Oil Pump Cleaning and Inspection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__oil-pump-cleaning-and-inspection) .
  1. Install a NEW oil pump O-ring seal.
  2. Install the oil pump. NOTE: Refer to «Fastener Notice»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#warnings-and-cautions__fastener-notice) .
  3. Install the oil pump bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  4. Inspect the oil pump drive gear for wear.
  5. Replace the oil pump drive gear pin if worn.
  6. Install the oil pump drive gear and reluctor to the crankshaft.
  7. Install the oil pump driven gear.
  8. 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).
  9. Remove the wooden handle that was used to retain the crankshaft.
  10. Install a NEW oil pump screen gasket to the oil pump.
  11. Install the oil pump screen.
  12. Install the oil pump screen bolts and nuts. Tighten: Tighten the bolts/nuts to 25 N.m (18 lb ft).
  13. 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) .
  14. 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 water pump outlet pipe. Refer to «Water Pump Outlet Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. Remove the five oil filter adapter and oil cooler assembly bolts.
  3. Remove the oil filter adapter and oil cooler assembly.
  1. Install new O-rings (2) to the oil filter adapter and oil cooler assembly. Lubricate the O-rings with engine oil.
  2. Apply sealer to the O-ring sealing area (1). Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__sealers-adhesives-and-lubricants) .
  3. Install the oil filter adapter and oil cooler assembly.
  4. Install the five oil filter adapter and oil cooler assembly bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  5. Install the water pump outlet pipe. Refer to «Water Pump Outlet Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

J 41712 Oil Pressure Switch Socket

IMPORTANTClean the area around the sensor. Do not allow debris to enter the engine.
  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 engine harness electrical connector (2) from the oil pressure sensor.
  3. Using the J 41712 , remove the oil pressure sensor (1).
  1. Apply sealant to the threads of the oil pressure sensor, if necessary. 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.
  2. Using the J 41712 , install the oil pressure sensor (1). Tighten: Tighten the sensor to 30 N.m (22 lb ft).
  3. Connect the engine harness electrical connector (2) to the oil pressure sensor.
  4. Lower the vehicle.
  5. Check and add engine oil, if necessary.
  1. Remove the lower oil pan. Refer to «Lower Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  2. Remove the oil level sensor clip (3).
  3. Remove the oil level sensor bolt (2) and sensor (1).
IMPORTANTWhen routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan.
  1. Install the oil level sensor (1) and bolt (2). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  2. Install the oil level sensor clip (3).
  3. Install the lower oil pan. Refer to «Lower Oil Pan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .

Engine Replacement

Tools Required

  1. J 36857 Engine Lift Bracket. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  2. J 43181 Heater Line Quick Connect Release Tool. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  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 cooling layer. Refer to «Cooling Layer Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-layer-removal) .
  3. Remove the cooling fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  4. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  5. Disconnect the generator electrical connector.
  6. Remove the positive battery cable from the generator, perform the following: Slide the boot down to access the terminal stud. Remove the positive cable nut. Remove the positive cable.
  7. Remove the generator bolts (1).
  8. Remove the generator (2).
  9. Disconnect the RH engine wiring harness connector.
  10. Remove the 2 RH engine wiring harness bracket bolts and position aside.
  11. Remove the 2 wiring harness routing bolts.
  12. Remove the oil indicator tube bracket bolt.
  13. Remove the drive belt tensioner bolt and tensioner.
  14. Remove the bolts and the generator mounting bracket.
  15. If equipped, remove the auxiliary generator. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  16. Remove the auxiliary generator bracket bolt and bracket, if equipped.
  17. If equipped with a dual generator system, remove the bolt from the left side idler pulley and remove the idler pulley.
  18. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  19. Disconnect the A/C cut out switch electrical connector.
  20. Remove the A/C compressor bolts.
  21. Remove the A/C compressor.
  22. Remove the power steering pump and bracket bolts (1).
  23. Remove the power steering pump bracket (2) from the pump.
  24. Position the power steering pump aside and secure.
  25. Remove the rear power steering pump bracket bolts (1) from the bracket.
  26. Remove the fuel line bolt and position the fuel line aside.
  27. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.
  28. Remove the oil fill tube bolts and the oil fill tube.
  29. Remove the exhaust gas recirculation (EGR) valve coolant pipe to thermostat housing bolt.
  30. Disconnect the coolant temperature sensor electrical connector.
  31. Remove the fuel pipe bracket bolt.
  32. Remove the 8 thermostat housing crossover bolts and the thermostat housing crossover.
  33. Remove the thermostat pipe. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  34. Disconnect the intake air heater (IAH) electrical connector.
  35. Disconnect the engine harness electrical connector from the manifold absolute pressure (MAP) sensor.
  36. Disconnect the positive cable from the IAH by performing the following: Reposition the positive battery cable boot. Remove the positive battery cable nut at the IAH. Remove the positive battery cable from the IAH stud.
  37. Remove the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
  38. Remove the 2 rear intake manifold tube bolts (3).
  39. Remove the rear intake manifold tube nut (2).
  40. Remove the engine wiring harness clip from the intake manifold tube.
  41. Remove the engine wiring harness clip bolt (3).
  42. Remove the EGR cooler water pipe bracket bolt (5).
  43. Remove the intake manifold tube bolts (2, 4) and nut (1).
  44. Remove the intake manifold tube with the stud.
  45. Remove and discard the 2 metal EGR gaskets from the EGR valve.
  46. Remove and discard the O-ring seal from the center intake manifold.
  47. 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) .
  48. 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) .
  49. 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) .
  50. Remove the EGR coolant hose. Refer to «Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  51. Compress the clamp and disconnect the EGR heater inlet hose/pipe from the EGR cooler tube.
  52. Remove the EGR cooler tube bracket bolt.
  53. Remove the crankcase ventilation 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) .
  54. Disconnect the EGR solenoid electrical connector.
  55. Remove the EGR nut (1) and bolt (2).
  56. Remove the EGR valve and EGR cooler tube as an assembly.
  57. If necessary, remove the EGR bracket bolt, nut, and EGR bracket.
  58. Remove the 2 bolts and the EGR cooler tube bracket.
  59. Disconnect the engine wiring harness electrical connector from the turbocharger vane position sensor.
  60. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.
  61. Remove the turbocharger upper heat shield bolts.
  62. Remove the turbocharger upper heat shield.
  63. Reposition the turbocharger coolant outlet pipe clamp (1) and remove the hose from the turbocharger pipe.
  64. Using the J 36857 and J 43181 , disconnect the fuel feed and return pipes. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  65. Disconnect the positive battery cable from the glow plug control module.
  66. Remove the glow plug control module bolts.
  67. Remove the glow plug control module.
  68. Remove the glow plug control module bracket bolts (2).
  69. Remove the fuel line bracket bolt (1).
  70. Remove the glow plug control module.
  71. Remove the fuel line bracket bolt.
  72. Remove the turbocharger coolant inlet pipe bolt and remove the hose from the turbocharger.
  73. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer.
  74. Reposition and secure the turbocharger oil fed pipe out of the way.
  75. Remove the turbocharger oil return pipe nuts (1) at the top of the flywheel housing.
  76. Remove the turbocharger bolts.
  77. Remove the turbocharger (with the oil return pipe).
  78. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing. Remove the turbocharger lower heat shield.
  79. Remove the turbocharger oil feed pipe, washer, and pipe.
  80. Disconnect the LH main engine wiring harness connector and remove the bracket bolts (1).
  81. Remove the LH glow plug nuts (2) and the routing bolts (1).
  82. Disconnect the fuel injector electrical connectors.
  83. Disconnect the intake air temperature sensor 2 and fuel rail temperature sensor electrical connector.
  84. Disconnect the ECT wiring harness electrical connector (1) and the oil pressure sensor electrical wiring harness electrical connector (2).
  85. Position the engine wiring harness over the RH side of engine.
  86. Remove the nut, the 2 bolts and position the bracket aside.
  87. Remove the fuel feed/return pipe bracket bolt.
  88. Disconnect the fuel hoses from the fuel pipe.
  89. Remove the fuel line bracket bolt.
  90. Disconnect the fuel pump hose from the fuel pipe.
  91. Remove the fuel pipe.
  92. Remove the fuel pipe clamp bolt (2) and turbocharger coolant inlet pipe bracket bolt (3).
  93. Remove the 4 center intake manifold bolts (1) and 4 nuts (2).
  94. Remove the center intake manifold.
  95. Remove the fuel pump to LH fuel rail pipe.
  96. Compress the clamp and remove the fuel pressure relief hose.
  97. Remove the fuel pipe bracket bolt (2), disconnect the hose (1) at the fuel pump and remove the fuel pipe/hose assembly.
  98. Remove the LH to RH fuel rail pipe.
  99. Remove the LH fuel injector feed pipes.
  100. Remove the 2 bolts and the LH furl rail.
  101. Disconnect the fuel rail pressure (FRP) sensor electrical connector (1).
  102. Remove the RH fuel injector feed pipes.
  103. Remove the 2 bolts and the RH fuel rail.
  104. Remove the 2 bolts and the turbocharger cooling outlet pipe.
  105. Remove the left intake manifold nuts/bolts and remove the manifold.
  106. Remove the right intake manifold nuts/bolts and remove the manifold.
  107. Disconnect the fuel pump electrical connector.
  108. Remove the 4 bolts and fuel injection pump.
  109. Remove the transmission fill tube.
  110. Remove the engine oil indicator tube. Refer to «Oil Level Indicator and Tube Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Oil Level Indicator and Tube Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  111. Remove the transmission. Refer to «Transmission Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l80-e4l85-e-removal-installation-service-troubleshooting-diagnosis) .
  112. 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) .
  113. 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) .
  114. Remove the engine flywheel housing. Refer to «Engine Flywheel Housing Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  115. Remove the oil pump pickup tube. Refer to «Oil Pump Pipe and Screen Assembly Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__oil-pump-pipe-and-screen-assembly) .
  116. Remove the oil filter adapter and the oil cooler assembly replacement. Refer to «Oil Filter Adapter and Oil Cooler Assembly Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  117. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left Side (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  118. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  119. Remove the G102, G103 and G108.
  120. Using J 36857 engine lift hooks, install a suitable lifting device. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) . The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.
  121. Raise the engine off the engine mounts.
  122. Remove the left engine mount to engine mount frame bracket bolts.
  123. Remove the left engine mount to engine bolts.
  124. Remove the left engine mount bracket to frame bolts.
  125. Remove the right engine mount to engine mount frame bracket bolts.
  126. Remove the right engine mount to engine bolts.
  127. Remove the right engine mount bracket to frame bolts.
  128. Remove the engine from the vehicle.
  129. Place the engine on a suitable stand.
  1. Remove the engine from the stand.
  2. Install the engine to the vehicle.
  3. Install the right engine mount bracket to frame bolts. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
  4. Install the right engine mount to engine bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
  5. Install the right engine mount to engine mount bracket bolts. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
  6. Install the left engine mount bracket to frame bolts. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
  7. Install the left engine mount to engine bolts. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
  8. Install the left engine mount to engine mount bracket bolts. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
  9. Lower the engine onto the engine mounts.
  10. Remove the lifting device and the J 36857 engine lift hooks. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  11. Install the G102, G103 and G108. Tighten: Tighten the ground bolts to 34 N.m (25 lb ft).
  12. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Right Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  13. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (4.8L, 5.3L, 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left Side (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement - Left Side (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  14. Install the oil filter adapter and oil cooler assembly replacement. Refer to «Oil Filter Adapter and Oil Cooler Assembly Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  15. Install the oil pump pickup tube. Refer to «Oil Pump Pipe and Screen Assembly Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__oil-pump-pipe-and-screen-assembly) .
  16. Install the engine flywheel housing. Refer to «Engine Flywheel Housing Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-3-of-5) .
  17. 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) .
  18. 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) .
  19. Install the transmission. Refer to «Transmission Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/automatic-trans/#how-to-overhaul-the-automatic-transmission-4l80-e4l85-e-removal-installation-service-troubleshooting-diagnosis) .
  20. Install the engine oil indicator tube. Refer to «Oil Level Indicator and Tube Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Oil Level Indicator and Tube Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  21. Install the transmission fill tube.
  22. Position the fuel injection pump and install the 4 bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  23. Connect the fuel pump electrical connector.
  24. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the right intake manifold mating surface.
  25. Install the right intake manifold.
  26. Install the intake manifold bolts/nuts.
  27. Tighten the right intake manifold bolts/nuts. Tighten: Tighten the bolts/nuts in sequence to 25 N.m (18 lb ft).
  28. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the left intake manifold mating surface.
  29. Install the left intake manifold.
  30. Tighten the left intake manifold bolts/nuts. Tighten: Tighten the bolts/nuts in sequence to 25 N.m (18 lb ft).
  31. Position the turbocharger cooling outlet pipe and install the 2 bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  32. Position the RH fuel rail and install the 2 bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  33. Install the RH fuel injector feed pipes. Tighten: Tighten the fittings to 41 N.m (30 lb in).
  34. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
  35. Connect the fuel rail pressure (FRP) sensor electrical connector (1).
  36. Position the LH fuel rail and install the 2 bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  37. Install the LH fuel injector feed pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  38. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
  39. Install the LH to RH fuel rail pipe. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  40. After installing the fuel pipes, clean the pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
  41. Position the fuel pipe/hose assembly and connect the hose (1) at the fuel pump.
  42. Install the fuel pipe bracket bolt (2). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  43. Compress the clamp and install the fuel system pressure relief hose.
  44. Install the fuel pump to the LH fuel rail pipe. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  45. After installing the fuel pipe, clean the pipe and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
  46. Install NEW center intake manifold gaskets to the center intake.
  47. Install the center intake manifold.
  48. Install the center intake manifold lower 4 nuts (2). Tighten: Tighten the nuts to 10 N.m (89 lb in).
  49. Install the center intake manifold upper 4 nuts (1). Tighten: Tighten the nuts to 10 N.m (89 lb in).
  50. Install the fuel pipe clamp bolt (2) and turbocharger coolant inlet pipe bracket bolt (3). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  51. Install the fuel pipe.
  52. Connect the fuel pump hose to the fuel pipe.
  53. Install the fuel line bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  54. Connect the fuel hoses to the fuel pipe.
  55. Install the fuel feed/return bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  56. Position the bracket, and install the nut and the 2 bolts.
  57. Position the engine wiring harness over from the RH side of the engine.
  58. Connect the ECT wiring harness electrical connector (1) and the oil pressure sensor electrical wiring harness electrical connector (2).
  59. Connect the intake air temperature sensor No. 2 and the fuel rail temperature sensor electrical connector.
  60. Connect the fuel injector electrical connectors.
  61. Install the LH glow plug nuts (2) and the routing bolts (1). Tighten: Tighten the glow plug nut to 1.7 N.m (15 lb in).
  62. Connect the LH main engine wiring harness connector and install the bracket bolts (1).
  63. Position the oil fed pipe and a NEW washer into place.
  64. Install the oil feed pipe bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
  65. Position the turbocharger lower heat shield.
  66. Install a new turbocharger oil return pipe gasket at the flywheel housing.
  67. Install the turbocharger (with the oil return pipe).
  68. Install the turbocharger bolts. Tighten: Tighten the bolts to 108 N.m (80 lb ft).
  69. Install the turbocharger oil return pipe nuts (1) at the top of the flywheel housing. Tighten: Tighten the nuts to 21 N.m (15 lb ft).
  70. Install the turbocharger oil feed pipe banjo bolt and a NEW washer. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
  71. Position the turbocharger coolant inlet pipe hose to the turbocharger and install the bolt with NEW washers. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  72. Install the fuel line to the bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  73. Position the glow plug control module bracket.
  74. Install the glow plug control module bracket bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  75. Install the fuel line bracket bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  76. Position the glow plug control module and install the glow plug control module bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  77. Connect the positive battery cable to the glow plug control module.
  78. Connect the fuel feed and return plugs.
  79. Position the turbocharger coolant outlet pipe clamp (1) and install the hose to the turbocharger pipe.
  80. Install the turbocharger upper heat shield.
  81. Install the turbocharger upper heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  82. Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.
  83. Connect the engine wiring harness electrical connector to the turbocharger vane position sensor.
  84. Install the EGR cooler tube bracket and the 2 bolts. Tighten: Tighten the 2 bolts to 25 N.m (18 lb ft).
  85. If necessary, remove the EGR bracket, nut, and the EGR bracket bolt. Tighten: Tighten the EGR bracket bolt and nut to 25 N.m (18 lb ft).
  86. Install the EGR valve and EGR cooler tube assembly.
  87. Install the EGR nut (1) and bolt (2). Tighten: Tighten the EGR nut and bolt to 50 N.m (37 lb ft).
  88. Connect the EGR solenoid electrical connector.
  89. Install the crankcase ventilation 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) .
  90. Install the EGR cooler tube bracket bolt. Tighten: Tighten the EGR cooler tube bracket bolt to 25 N.m (18 lb ft).
  91. Compress the clamp and connect the EGR heater inlet hose/pipe to the EGR cooler tube.
  92. Install the EGR coolant hose. Refer to «Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY, LBZ)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LMM)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  93. 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) .
  94. 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) .
  95. 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) .
  96. Install a NEW O-ring seal to the center intake manifold.
  97. Install 2 NEW metal EGR gaskets to the EGR valve.
  98. Install the intake manifold tube with the stud. Tighten: Tighten the stud to 25 N.m (18 lb ft).
  99. Install the intake manifold tube bolts (2, 4) and nut (1). Tighten: Tighten the bolt/nut to 25 N.m (18 lb ft).
  100. Install the EGR cooler water pipe bracket bolt (5). Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  101. Install the engine wiring harness clip to the intake manifold tube. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  102. Install the engine wiring harness clip to the intake manifold tube.
  103. Install the rear intake manifold tube nut (2). Tighten: Tighten the nut to 25 N.m (18 lb ft).
  104. Install the 2 rear intake manifold tube bolts (3). Tighten: Tighten the nut to 25 N.m (18 lb ft).
  105. Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
  106. Connect the positive cable to the IAH by performing the following: Position the positive battery cable to the IAH stud. Install the positive battery cable nut to the IAH. Tighten: Tighten the nut to 10 N.m (89 lb in).
  107. Reposition the positive battery cable boot.
  108. Connect the engine harness electrical connector to the MAP sensor.
  109. Connect the IAH electrical connector.
  110. Install the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  111. Position the thermostat housing crossover with the NEW gaskets.
  112. Install the 8 thermostat housing crossover bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  113. Connect the coolant temperature sensor electrical connector.
  114. Install the fuel pipe bracket bolt. Tighten: Tighten the fuel pipe bracket bolt to 25 N.m (18 lb ft).
  115. Install the EGR valve coolant pipe to the thermostat housing bolt.
  116. Install the oil fill tube and the oil fill tube bolts. Tighten: Tighten the oil fill tube bolts to 25 N.m (18 lb ft).
  117. Compress the clamp and connect the turbocharger inlet cooling hose/pipe.
  118. Position the fuel line and install the fuel line bolt.
  119. Position the A/C compressor and power steering pump bracket.
  120. Install the A/C compressor and power steering pump bracket bolts. Tighten: Tighten the bolts to 46 N.m (34 lb ft).
  121. Position the power steering pump and loosely install the front bracket bolts.
  122. Loosely install the rear power steering pump bracket bolts. Tighten: Tighten the front bolts to 50 N.m (37 lb ft). Tighten the rear bolts to 50 N.m (37 lb ft).
  123. Install the A/C compressor.
  124. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  125. Connect the A/C cut out switch electrical connector.
  126. Connect the A/C compressor clutch electrical connector.
  127. If equipped with dual generator system, install the idler pulley and the bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  128. Install the auxiliary generator bracket and bolt, if equipped. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  129. If equipped, install the auxiliary generator. Refer to «Auxiliary Generator Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  130. Install the generator mounting bracket and bolts. Tighten: Tighten the generator mounting bracket bolts to 50 N.m (37 lb ft).
  131. Install the drive belt tensioner and tensioner belt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  132. Install the oil indicator tube bracket bolt. Tighten: Tighten the oil indicator tube bracket bolt to 21 N.m (15 lb ft).
  133. Install the 2 wiring harness routing bolts. Tighten: Tighten the wiring harness routing bolts to 10 N.m (89 lb in).
  134. Install the 2 RH engine wiring harness bracket bolts.
  135. Connect the RH engine wiring main harness connector.
  136. Install the generator (2) and the generator bolts (1). Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
  137. Install the positive battery cable to the generator, perform the following: Install the positive cable. Install the positive cable nut. Tighten: Tighten the positive cable nut to 9 N.m (80 lb in).
  138. Position the boot to cover the terminal stud.
  139. Connect the generator electrical connector.
  140. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  141. Install the cooling fan. Refer to «Fan Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  142. Install the cooling layer. Refer to «Cooling Layer Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-layer-installation) .
  143. Run the vehicle to verify correct engine operation and inspect for engine fluid leaks.
  144. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Position a suitable drain pan under the oil pan drain plug.
  3. Remove the oil drain plug.
  4. Allow the oil to drain completely.
  5. Clean and inspect the oil pan drain plug, replace if necessary.
  6. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary.
  7. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
  8. Position a suitable drain pan under the oil filter
  9. Remove the oil filter.
  10. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket from the adapter.
  1. Apply clean engine oil to the NEW oil filter gasket.
  2. Install the NEW oil filter. Tighten: Tighten the filter after contact plus 1 to 11/4 turn.
  3. Tighten the oil pan drain plug. Tighten: Tighten the plug to 84 N.m (62 lb ft).
  4. Remove the oil drain pan from under the vehicle.
  5. Lower the vehicle.
  6. Fill the engine with new engine oil. Refer to «Approximate Fluid Capacities»(/chevrolet/chevy-express-h1500/2003-2012/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) and «Fluid and Lubricant Recommendations»(/chevrolet/chevy-express-h1500/2003-2012/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
  7. Start the engine.
  8. Inspect for oil leaks after engine start up.
  9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan.
  10. Remove the oil level indicator from the oil level indicator tube.
  11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
  12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
  13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
  14. Check the level of the engine oil on the oil level indicator.
  15. If necessary, adjust the oil level be adding or draining oil.
  16. Check for oil leaks.

Starter Removal

  1. Remove the starter motor bolts.
  2. Remove the starter motor assembly.

J 44643 Flywheel Hold Tool. See Special Tools .

  1. Install J 44643 to lock the flywheel. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  2. Remove the crankshaft balancer bolt.
  3. Remove the crankshaft balancer.

Oil Pump Removal

  1. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut.
  2. Remove the oil pump driven gear.
  3. Remove the oil pump drive gear and crank sensor reluctor assembly.
  4. Remove the oil pump bolts.
  5. Remove the oil pump.
  6. Remove the O-ring and discard.

J 44643 Flywheel Hold Tool. See Special Tools .

  1. Lightly lubricate the crankshaft balancer internal hub with engine oil.
  2. Install the crankshaft balancer to the crankshaft.
  3. Lightly lubricate the crankshaft balancer bolt with engine oil.
  4. Install the crankshaft balancer bolt and washer. Tighten: Tighten the bolt to 100 N.m (74 lb ft) on the first pass. Tighten the bolt an additional 105 degrees.
  5. Remove the J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

Starter Installation

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

Draining Fluids and Oil Filter Removal

  1. Remove the oil drain plug and gasket, and allow engine oil to drain.
  2. Discard the oil drain plug gasket.
  3. Remove the oil filter.
  4. Remove the engine block coolant plugs, and allow coolant to drain.

J 44643 Flywheel Hold Tool. See Special Tools .

  1. Remove the flywheel mounting bolts and discard.
  2. Remove the flywheel washer.
  3. Remove the J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  4. Remove the flywheel assembly.

J 44643 Flywheel Hold Tool. See Special Tools .

  1. Install the J 44643 to the starter opening 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) .
  2. Install two bolts into the clutch pressure plate mounting holes 180 degrees apart.
  3. Using a long pry bar, turn the secondary ring of the dual mass flywheel clockwise until the flywheel mounting bolts can be accessed. It may require to turn the secondary ring past the bolt holes in order to compensate the spring tension.
  4. Remove the flywheel mounting bolts and discard.
  5. Remove the J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  6. Remove the flywheel.

J 44641 Crankshaft Rear Oil Seal Remover. See Special Tools .

  1. 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) .
  2. Remove the crankshaft rear oil seal using J 44641 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

Exhaust Outlet Removal

  1. Remove the exhaust outlet heat shield bolts.
  2. Remove the exhaust outlet heat shield.
  3. Remove the exhaust outlet to right exhaust pipe bracket bolt.
  4. Loosen the exhaust outlet holding clamp.
  5. Remove the exhaust outlet.

Exhaust Pipe Removal - Left Side

  1. Remove the left exhaust pipe heat shield bolts.
  2. Remove the left exhaust pipe heat shield.
  3. Remove the exhaust pipe bolts in the proper sequence.
  4. Remove the exhaust pipe and gaskets.

Exhaust Pipe Removal - Right Side

  1. Remove the exhaust pipe bolts in the proper sequence.
  2. Remove the exhaust pipe, exhaust outlet bracket and gaskets.

J 37228 Seal Cutter. See Special Tools .

  1. Disconnect the oil level sensor.
  2. Remove the lower oil pan bolts.
  3. Separate the lower oil pan from the upper oil pan using J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  4. Remove the lower oil pan.

J 37228 Seal Cutter. See Special Tools .

  1. Remove the oil level indicator tube bracket bolt.
  2. Remove the oil level indicator tube.
  3. Remove the 2 oil pan to flywheel housing bolts.
  4. Remove the 24 upper oil pan bolts using a long bit 6 mm hex driver.
  5. Seperate the upper oil pan from the engine block using J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  6. Remove the upper oil pan.

J 37228 Seal Cutter. See Special Tools .

  1. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing.
  2. Remove the turbocharger oil return pipe studs.
  3. Remove the flywheel housing bolts.
  4. Separate the flywheel housing 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) .
  5. Remove the flywheel housing.
  6. Remove the turbocharger oil return pipe gasket from the flywheel housing.
  7. Remove the oil cooler adapter bolts.
  8. Remove the oil cooler adapter with gaskets.

Scheme 143

Scheme 143: Engine Mounting to Stand
Scheme 143: Engine Mounting to Stand
CAUTIONDo not mount the engine to a engine stand by the flywheel housing. The aluminum flywheel housing is not designed to support the weight of the engine when mounted to a typical rear-mount engine stand. Mounting the engine stand to the aluminum flywheel housing may result in engine damage and serious personal injury.

After the flywheel housing has been removed, mount the engine block to a suitable engine stand.

Cooling Fan Pulley Removal

  1. Disconnect the camshaft position sensor connector.
  2. Remove the cooling fan pulley bolts and nuts.
  3. Remove the cooling fan pulley.
  4. Remove the camshaft position sensor retaining bolt.
  5. Remove the camshaft position sensor.

Power Steering Pump Mounting Bracket Removal

  1. Remove the power steering pump mounting bracket bolts.
  2. Remove the power steering pump mounting bracket.

Drive Belt Tensioner and Generator Mounting Bracket Removal

  1. Remove the electrical harness bracket bolts.
  2. Remove the electrical harness bracket.
  3. Remove the drive belt tensioner bolt.
  4. Remove the drive belt tensioner.
  5. Remove the electrical harness clip bolts.
  6. Remove the drive belt tensioner and generator mounting bracket bolts.
  7. Remove the drive belt tensioner and generator mounting bracket.

Engine Coolant Thermostat Housing Removal

  1. Disconnect and remove the turbocharger vane position sensor.
  2. Disconnect the turbocharger coolant inlet hose.
  3. Remove the fuel and electrical harness bracket bolt.
  4. Remove the fuel and electrical harness bracket.
  5. Remove the oil fill tube bolts.
  6. Remove the oil fill tube.
  7. Disconnect the coolant temperature sensor.
  8. Remove the exhaust gas recirculation (EGR) coolant pipe bolts.
  9. Remove the EGR coolant pipe.
  10. Remove the water pump inlet pipe bolts.
  11. Remove the turbocharger coolant outlet hose and clamps.
  12. Remove the water pump inlet pipe.
  13. Remove the fuel pipe bracket bolt.
  14. Remove the thermostat housing bolts.
  15. Remove the thermostat housing.

Engine Wiring Harness Assembly Removal

  1. Remove the left glow plug harness bracket bolts.
  2. Remove the right glow plug harness bracket bolts.
  3. Disconnect the positive crankcase ventilation (PCV) hose clamp.
  4. Remove the right PCV pipe bolt.
  5. Remove the left PCV pipe bolt.
  6. Remove the PCV pipe.
  7. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  8. Remove the ground bolt.
  9. Disconnect the crankshaft postion sensor electrical connector.
  10. Disconnect the fuel pressure control valve electrical connector.
  11. Disconnect the oil level sensor electrical harness connector.
  12. Disconnect the fuel temperature sensor connector.
  13. Disconnect the glow plug controller electrical connector.
  14. Disconnect and remove the turbocharger vane positon sensor.
  15. Disconnect the fuel injector electrical connections.
  16. Disconnect the turbocharger vane control solenoid valve.
  17. Disconnect the fuel rail pressure sensor.
  18. Disconnect the oil pressure sensor electrical connector.
  19. Remove the oil level sensor harness bolt.
  20. Remove the glow plug controller bolts.
  21. Remove the glow plug controller.
  22. Remove the glow plug controller shield bolts.
  23. Remove the glow plug controller shield.
  24. Remove the glow plug controller bracket bolts.
  25. Remove the glow plug controller bracket.
  26. Remove the left glow plugs.
  27. Remove the right glow plugs.
  28. Remove the engine wiring harness.
  29. Remove the engine harness bracket bolts.
  30. Remove the engine harness bracket.

Exhaust Gas Recirculation and Cooler Removal

  1. Remove the intake pipe to air inlet tube bolts.
  2. Remove the intake pipe.
  3. Remove the intake heater.
  4. Remove the MAP sensor and bolt.
  5. Remove the rear bracket and bolt.
  6. Remove the air inlet tube to intake manifold tube bolt and nut.
  7. Remove the air inlet tube nuts and bolts.
  8. Remove the air inlet tube.
  9. Remove the rear exhaust gas recirculation (EGR) cooler bolts.
  10. Remove the EGR mount bolts and nut.
  11. Remove the EGR and cooler.
  12. Remove the EGR cooler bracket bolts.
  13. Remove the EGR cooler bracket.

Turbocharger Removal

  1. Remove the turbocharger upper heat shield bolts.
  2. Remove the turbocharger upper heat shield.
  3. Remove the eye bolt and washers from the oil supply hose at the top of the turbocharger.
  4. Loosen the hose clamp and remove the turbocharger cooling outlet hose.
  5. Remove the turbocharger cooling bolts and hoses.
  6. Remove the turbocharger mounting bolts.
  7. Remove the turbocharger assembly with the oil return pipe.
  8. Remove the turbocharger lower heat shield from engine block.
  9. Remove the turbocharger oil supply hose eye bolt and washers.
  10. Remove the turbocharger oil supply hose.

Fuel Pipes and Fuel Rail Removal

  1. Remove the fuel feed pipe attaching nuts and bolts.
  2. Remove the fuel feed pipe.
  3. Disconnect the fuel rail balance pipe from fuel rails.
  4. Remove the fuel rail balance pipe bolts.
  5. Remove the fuel rail balance pipe.
  6. Remove the left fuel return hose.
  7. Remove the right fuel return hose.
  8. Disconnect the fuel hoses from the fuel injector pump.
  9. Remove the distribution block and fuel line assembly bolts.
  10. Remove the distribution block and fuel line assembly.
  11. Remove the fuel pipe assembly bracket bolts.
  12. Remove the fuel pipe assembly bracket.
  13. Remove the coolant pipe bolt and nut.
  14. Remove the coolant pipe.
  15. Remove the left fuel rail to pump pipe.
  16. Remove the EGR mounting bracket bolts.
  17. Remove the EGR mounting brackets.
  18. Using compressed air to blow away any debris between the fuel injector line and the fittings. Wipe clean the fittings of debris.
  19. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fitting to contain any debris during removal.
  20. Remove the left fuel injector pipes.
  21. Remove the right fuel injector pipes.
  22. Remove the left fuel rail and bracket bolts.
  23. Remove the left fuel rail and bracket.
  24. Remove the right fuel rail bolts.
  25. Remove the right fuel rail.

J-46594 Fuel Injector Remover

  1. Remove the left fuel injector bracket bolts.
  2. Remove the right fuel injector bracket bolts.
  3. Install the J-46594 into the fuel injector brackets.
  4. Pull back on J-46594 in one steady motion, until the fuel injector breaks free from its seat.
  5. Remove the J-46594 .
  6. Remove the left fuel injectors with brackets.
  7. Remove the right fuel injectors with brackets.
  8. Remove the left injector bracket pins.
  9. Remove the right injector bracket pins.
  10. Remove the copper washer from the injector bore and discard.
  11. Remove the O-ring from the injector and discard.

Valve Rocker Arm Cover Removal - Upper Left Side

  1. Remove the left upper valve rocker arm cover bolts.
  2. Remove the left upper valve rocker arm cover.

Valve Rocker Arm Cover Removal - Upper Right Side

  1. Remove the right upper valve rocker arm cover bolts.
  2. Remove the right upper valve rocker arm cover.

Valve Rocker Arm Cover Removal - Lower Left Side

  1. Remove the left lower valve rocker arm cover bolts.
  2. Remove the left lower valve rocker arm cover.

Valve Rocker Arm Cover Removal - Lower Right Side

  1. Remove the right lower valve rocker arm cover bolts.
  2. Remove the lower valve rocker arm cover.

Intake Manifold Crossover Removal

  1. Remove the intake manifold crossover bolts and nuts.
  2. Remove the intake manifold crossover.

J 37228 Seal Cutter. See Special Tools .

  1. Remove the right intake manifold bolts. Do not forget to remove the bolt inside the intake manifold tube.
  2. Separate the intake manifold from the cylinder head using J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  3. Remove the right intake manifold.

J 37228 Seal Cutter. See Special Tools .

  1. Remove the left intake manifold bolts. Do not forget to remove the bolt inside the intake manifold tube.
  2. Separate the intake manifold from the cylinder head using J 37228 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
  3. Remove the left intake manifold.

Valve Rocker Arm, Shaft, and Push Rod Removal

  1. Loosen the valve clearance lock nuts on each rocker arm.
  2. Loosen the valve clearance adjusting screw on each rocker arm to relieve tension on the valve train.
  3. Remove the rocker arm shaft assembly bolts in the proper sequence.
  4. Remove the rocker arm shaft assembly from the cylinder head.
  5. Remove the valve bridge pins.
  6. Remove the valve bridges.
  7. Remove the pushrods.

Exhaust Manifold Removal - Left Side

  1. Remove the exhaust manifold heat shield bolts.
  2. Remove the exhaust manifold heat shield.
  3. Remove the left exhaust manifold bolts and nuts in the proper sequence.
  4. Remove the left exhaust manifold and gasket.

Exhaust Manifold Removal - Right Side

  1. Remove the exhaust manifold heat shield bolts.
  2. Remove the exhaust manifold heat shield.
  3. Remove the right exhaust manifold bolts and nuts in the proper sequence.
  4. Remove the right exhaust manifold and gasket.

Cylinder Head Removal - Left Side

  1. Remove the cylinder head bolts in the proper sequence.
  2. Discard the large M12 bolts.
  3. Remove the left cylinder head assembly.
  4. Remove the left cylinder head gasket.

Cylinder Head Removal - Right Side

  1. Remove the cylinder head bolts in the proper sequence.
  2. Discard the large M12 bolts.
  3. Remove the right cylinder head assembly.
  4. Remove the right cylinder head gasket.

Valve Lifter Removal

  1. Loosen the valve lifter guide hold down bracket bolts.
  2. Remove the valve lifter guide hold down brackets.
  3. Remove the valve lifter guides.
  4. Remove the valve lifters.

Fuel Injection Pump Removal

  1. Remove the camshaft gear access hole cover bolt.
  2. Remove the camshaft gear access hole cover.
  3. Rotate the crankshaft until the camshaft gear tension relief hole is in line with the front cover access hole.
  4. Use a suitable tool to unload the spring tension from the two piece cam gear. Apply pressure towards the right side of the engine while removing the injection pump.
  5. Remove the four fuel injection pump bolts.
  6. Remove the fuel injection pump.

Water Pump Removal

  1. Remove the engine coolant pipe to water pump nuts.
  2. Remove the water pump bolts.
  3. Remove the water pump assembly.
  4. Remove the water pump seal and discard.
  5. Remove the engine coolant pipe gasket and discard.

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