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

Engine Front Cover Installation

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 GM P/N 12378521 (Canadian P/N 88901148) sealant to the mating surfaces of the engine front cover.
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).

Tools Required

J 44645 Crankshaft Front Oil Seal Installer. See Special Tools .

1. Lubricate the crankshaft sealing surface with engine oil.
2. Place the crankshaft front oil seal onto the crankshaft.
3. 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) .
4. Press the crankshaft front oil seal onto the crankshaft with 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) .
5. Remove the J 44645 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

Oil Filter Adapter and Oil Cooler Assembly Installation

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 GM P/N 12378521 (Canadian P/N 88901148) to the O-ring sealing area (1).
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 oil filter adapter and oil cooler assembly bolts to 25 N.m (18 lb ft).
5. Install a new O-ring onto the engine coolant pipe.
6. Lubricate the O-ring with engine coolant. Do not use oil or grease.
7. Install the engine coolant pipe to the oil filter adapter and oil cooler assembly.

Water Pump Installation

1. Lubricate the water pump O-ring with engine oil.
2. Install the engine coolant pipe gasket.
3. Install the water pump seal.
4. Install the water pump. Be sure the water pump studs align with the coolant tube.
5. Install the water pump bolts. Tighten: Tighten the water pump bolts to 25 N.m (18 lb ft).
6. Install the water pump to coolant tube nuts. Tighten: Tighten the water pump to coolant tube nuts to 25 N.m (18 lb ft).

Fuel Injection Pump Installation

1. Lubricate the O-ring on the fuel injection pump adapter with engine oil.
2. 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 installing the fuel injection pump.
3. Install the fuel injection pump and adapter assembly.
4. Install the fuel injection pump bolts. Tighten: Tighten the fuel injection pump bolts to 25 N.m (18 lb ft).

Valve Lifter Installation

1. Install the valve lifter.
2. Install the valve lifter guides.
3. Install the valve lifter guide hold down bracket.
4. Install the valve lifter guide hold down bracket bolt. Tighten: Tighten the valve lifter guide hold down bracket bolt to 11 N.m (97 lb in).

J 7872 Dial Indicator Set

1. If a reciprocating component (crankshaft, connecting rod, piston, or bearings) has not been replaced, install the same grade head gasket that was removed.
2. The markings on the gasket are as follows: Grade A (1) Grade B (2) Grade C (3) Block over-bored 0.010-0.030 in (0.254-0.762 mm) (4) Block over-bored 0.010-0.030 in (0.254-0.762 mm) and deck milled 0.008 in (0.203 mm) (5)
3. The cylinder head gasket thickness is determined by the piston head projection from the cylinder block deck surface. There are cylinder head gaskets available in three different thicknesses. Follow the procedure below and refer to «Cylinder Head Gasket Selection Specifications»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5) to determine what gasket to use for each bank of cylinders.
4. Be sure the piston and cylinder deck are free of carbon, gasket material, or other objects that may give you an erroneous measurement.
5. Use J 7872 to measure the piston projection across two different points on each piston. Zero the dial indicator to the cylinder deck surface. Place the dial indicator pointer on the piston top. Be sure the pointer is directly above the piston pin centerline to prevent inaccurate readings from piston rocking. Rotate the engine to roll the piston through Top Dead Center while noting the maximum reading on the dial indicator. Repeat procedure at the second measuring point on the piston.
6. Calculate the average value of piston projection for each cylinder.
7. Obtain the maximum piston projection value for that bank of cylinders.
8. Determine the gasket grade by the maximum piston projection value using the chart.
9. If the difference between the highest measured piston head projection and the lowest measured piston projection, within one bank of cylinders, exceeds 0.1 mm (0.0039 in), then the following items need to be checked. Connecting rod to piston pin clearance Piston to piston pin clearance

If any of the above clearances are beyond specifications, then refer to the appropriate section for repair. If all of the above clearances are within the service limits but the piston projection variation is over 0.1 mm (0.0039 in), then replace the connecting rod and piston assembly.

J 45059 Angle Meter

1. The markings on the gasket are as follows: Grade A (1) Grade B (2) Grade C (3) Block over-bored 0.010-0.030 in (0.254-0.762 mm) (4) Block over-bored 0.010-0.030 in (0.254-0.762 mm) and deck milled 0.008 in (0.203 mm) (5)
2. Install the left cylinder head gasket of the correct grade. The left and right cylinder head gaskets are not interchangeable. Refer to «Cylinder Head Gasket Selection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-5-of-5) .
3. Install the left cylinder head.
4. Install the NEW M12 cylinder head bolts. Tighten the M12 cylinder head bolts in three steps: Tighten: 1st step 50 N.m (37 lb ft) 2nd step 80 N.m (59 lb ft) 3rd step tighten 60 degrees using J 45059 4th step tighten 60 degrees using J 45059
5. Reuse the M8 bolts. Install the M8 bolts. Tighten: Tighten the M8 cylinder head bolts to 25 N.m (18 lb ft).

J 45059 Angle Meter

1. The markings on the gasket are as follows: Grade A (1) Grade B (2) Grade C (3) Block over-bored 0.010-0.030 in (0.254-0.762 mm) (4) Block over-bored 0.010-0.030 in (0.254-0.762 mm) and deck milled 0.008 in (0.203 mm) (5)
2. Install the right cylinder head gasket of the correct grade. The left and right cylinder head gaskets are not interchangeable. Refer to «Cylinder Head Gasket Selection»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-5-of-5) .
3. Install the right cylinder head.
4. Install the NEW M12 cylinder head bolts. Reuse the M8 bolts. Tighten the M12 cylinder head bolts in three steps: Tighten: 1st step 50 N.m (37 lb ft) 2nd step 80 N.m (59 lb ft) 3rd step tighten 60 degrees using J 45059 4th step tighten 60 degrees using J 45059
5. Install the M8 bolts. Tighten: Tighten the M8 cylinder head bolts to 25 N.m (18 lb ft).

Exhaust Manifold Installation - Left Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and nuts. Tighten: Tighten the exhaust manifold bolts and nuts to 57 N.m (42 lb ft) in the proper sequence. Tighten: Tighten the center exhaust manifold bolts and nuts an additional pass to 57 N.m (42 lb ft) in sequence.
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

Exhaust Manifold Installation - Right Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and nuts. Tighten: Tighten the exhaust manifold bolts and nuts to 57 N.m (42 lb ft) in the proper sequence. Tighten: Tighten the center exhaust manifold bolts and nuts an additional pass to 57 N.m (42 lb ft) in sequence.
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

Valve Rocker Arm, Shaft, and Push Rod Installation

1. Install the valve bridge.
2. Install the valve bridge pins.
3. Install the pushrods.
4. Install the rocker arm shaft assembly.
5. Install the rocker arm shaft assembly bolts. Tighten: Tighten the rocker arm shaft assembly bolts in the proper sequence. Tighten the rocker arm shaft bolts to 41 N.m (30 lb ft).

Valve Lash Adjustment

1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center 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.
2. Loosen the valve adjusting screws.
3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge.
4. 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 that can be adjusted when the engine is at Top Dead Center. Tighten: Tighten the valve lash lock nut to 22 N.m (16 lb ft).
5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of the exhaust stroke.
6. 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 that can be adjusted when the engine is at Top Dead Center. Tighten: Tighten the valve lash lock nut to 22 N.m (16 lb ft).

Intake Manifold Installation - Left Side

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the intake manifold mating surface.
2. Install the intake manifold.
3. Install the intake manifold bolts and nuts. Tighten: Tighten the intake manifold bolts and nuts to 25 N.m (18 lb ft).

Intake Manifold Installation - Right Side

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the intake manifold mating surface.
2. Install the intake manifold.
3. Install the intake manifold bolts and nuts. Tighten: Tighten the intake manifold bolts and nuts to 25 N.m (18 lb ft).

Intake Manifold Crossover Installation

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

Valve Rocker Arm Cover Installation - Lower Left Side

1. Install the lower valve rocker arm cover.
2. Install the lower valve rocker arm cover bolts. Tighten: Tighten the lower valve rocker arm cover bolts in the proper sequence to 10 N.m (89 lb in). Retighten the lower valve rocker arm cover bolts in the proper sequence to the same torque, 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Lower Right Side

1. Install the lower valve rocker arm cover.
2. Install the lower valve rocker arm cover bolts. Tighten: Tighten the lower valve rocker arm cover bolts in the proper sequence to 10 N.m (89 lb in). Retighten the lower valve rocker arm cover bolts in the proper sequence to the same torque, 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Upper Left Side

1. Install the upper valve rocker arm cover.
2. Install the upper valve rocker arm cover bolts. Tighten: Tighten the upper valve rocker arm cover bolts to 8 N.m (71 lb in).

Valve Rocker Arm Cover Installation - Upper Right Side

1. Install the upper valve rocker arm cover.
2. Install the upper valve rocker arm cover bolts. Tighten: Tighten the upper valve rocker arm cover bolts in the proper sequence to 8 N.m (71 lb in).

Fuel Injectors Installation

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

Fuel Pipes and Fuel Rail Installation

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

Turbocharger Installation

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

Exhaust Gas Recirculation and Cooler Installation

1. Install the exhaust gas recirculation (EGR) cooler bracket.
2. Install the EGR cooler bracket bolts. Tighten: Tighten the EGR cooler bracket bolts to 25 N.m (18 lb ft).
3. Install the EGR and cooler.
4. Install the EGR mount bolts and nut. Tighten: Tighten the EGR mount bolts and nut to 50 N.m (37 lb ft).
5. Install the top EGR cooler bolts. Tighten: Tighten the top EGR cooler bolts to 25 N.m (18 lb ft).
6. Install the air inlet tube.
7. Install the air inlet tube nuts and bolts. Tighten: Tighten the air inlet tube nuts and bolts to 25 N.m (18 lb ft).
8. Install the air inlet tube to intake manifold tube bolt and nut. Tighten: Tighten the air inlet tube to intake manifold tube bolt and nut to 25 N.m (18 lb ft).
9. Install the MAP sensor and bolt. Tighten: Tighten the MAP sensor bolt to 10 N.m (89 lb in).
10. Install the rear bracket.
11. Install the rear bracket bolt. Tighten: Tighten the rear bracket bolt to 10 N.m (89 lb in).

Engine Wiring Harness Assembly Installation

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

Engine Coolant Thermostat Housing Installation

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

Drive Belt Tensioner and Generator Mounting Bracket Installation

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

Power Steering Pump Mounting Bracket Installation

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

Cooling Fan Pulley Installation

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

J 36857 Engine Lift Bracket. See Special Tools .

1. Bolt J 36857 to the ends of the cylinder heads. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
2. Lift the engine and the engine stand with a suitable hoist.
3. Remove the engine stand from the engine adapter.
4. Lower the engine to the floor. Support the engine with blocks.
5. Remove the engine adapter.

Engine Flywheel Housing Installation

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

Upper Oil Pan Installation

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

Lower Oil Pan Installation

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

Exhaust Pipe Installation - Left Side

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

Exhaust Pipe Installation - Right Side

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

Exhaust Outlet Installation

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

J 44642 Crankshaft Rear Oil Seal Installer. See 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) .

Engine Flywheel Installation (Automatic Transmission)

Tools Required

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

Engine Flywheel Installation (Manual Transmission)

Tools Required

1. J 44643 Flywheel Hold 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. Install the pilot bearing.
2. Install the flywheel.
3. Loosely install NEW flywheel bolts.
4. Install J 44643 to hold the flywheel from rotating. See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .
5. Use the following steps and the proper sequence to tighten the flywheel bolts: Tighten: Tighten the flywheel bolts to 79 N.m (59 lb ft). Tighten the flywheel bolts to 60 degrees using the J 45059 . Tighten the flywheel bolts again to 60 degrees using the J 45059 .
6. Remove J 44643 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-66l-1-of-5__special-tools) .

J 45299 Engine Preluber

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

See also:
• Special Tools
• Cylinder Head Gasket Selection Specifications
• Valve Clearance Adjustment Specifications
• Cylinder Head Gasket Selection