Engine Mechanical - 6.6l (Lgh) - Repair Instructions - off Vehicle Chevrolet Express G2500

Draining Fluids and Oil Filter Removal

1. Remove the oil drain plug 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.

Starter Removal

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

Crankshaft Balancer Removal

Special Tools

J 44643 Flywheel Hold Tool

For equivalent regional tools, refer to Special Tools .

1. Install J 44643 tool (1, 2) to lock the flywheel.
2. Remove and discard the crankshaft balancer bolt (1).
3. Remove the crankshaft balancer washer (2) and crankshaft balancer (3).

Engine Flywheel Removal (Automatic Transmission)

Special Tools

J 44643 Flywheel Hold Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the flywheel mounting bolts and discard.
2. Remove the flywheel washer.
3. Remove the J 44643 tool.
4. Remove the flywheel assembly.

Crankshaft Rear Oil Seal Removal

Tools Required

J 44641 Crankshaft Rear Oil Seal Remover

1. Install the button of J 44641 crankshaft rear oil seal remover into the crankshaft.
2. Press the jaws of J 44641 crankshaft rear oil seal remover into the felt portion of the seal far enough to engage the inner lip of the seal.
3. While holding the jaws of J 44641 crankshaft rear oil seal remover tightly to the seal's inner sleeve, tighten the jaw bolts.
4. Remove the crankshaft rear oil seal using the J 44641 crankshaft rear oil seal remover.

Exhaust Turbocharger Outlet Pipe Adapter Removal

Special Tools

CH 49736 Hydrocarbon Injector Quick Connect Release Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the exhaust adapter heat shield bolts (1).
2. Remove the exhaust adapter heat shield (2).
3. Remove the exhaust adapter to right exhaust pipe bracket bolt (1).
4. Remove the NOx sensor (1).
5. Remove the exhaust temperature sensor (1).
6. Remove the indirect fuel injector bolts (1).
7. Remove the fuel feed pipe clip bolts (2).
8. Remove the indirect fuel injector retainer (1) from the fitting.
9. Remove the indirect fuel injector (2) using the CH 49736 tool.
10. Loosen the exhaust adapter holding clamp (1).
11. Remove the exhaust adapter (2) and exhaust adapter holding clamp (1).

Exhaust Gas Recirculation Manifold Cooling Feed Pipe Removal

1. Remove the exhaust gas recirculation (EGR) manifold cooling feed pipe bolts (1).
2. Remove the EGR manifold cooling feed pipe (2).
3. Remove the EGR manifold cooling feed pipe O-ring seal (3).

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 (LGH)

1. Remove the exhaust pipe heat shield bolts (2) and exhaust pipe heat shield (1).
2. Remove the exhaust gas recirculation (EGR) sensor (1).
3. Remove the exhaust pipe nuts (1) and bolts (2-3) in the proper sequence.
4. Remove the exhaust outlet pipe bracket (3), exhaust pipe (1), and exhaust pipe gaskets (2).

Lower Engine Oil Pan Removal

Special Tools

J 37228 Seal Cutter

For equivalent regional tools, refer to Special Tools .

1. Disconnect the oil level sensor.
2. Remove the lower oil pan bolts (3) and nuts (2).
3. Separate the lower oil pan from the upper oil pan using J 37228 cutter.
4. Remove the lower oil pan (1).

Upper Engine Oil Pan Removal

Special Tools

J 37228 Seal Cutter

For equivalent regional tools, refer to Special Tools .

1. Remove the oil level indicator tube bracket bolt (3) and stud (2).
2. Remove the oil level indicator tube (1).
3. Remove the 2 oil pan to flywheel housing bolts (1).
4. Remove the upper oil pan bolts (2) and (4).
5. Remove the wiring harness clips (3).
6. Separate the upper oil pan from the engine block using J 37228 cutter.
7. Remove the upper oil pan (1).

Flywheel Housing Removal

Special Tools

J 37228 Seal Cutter

For equivalent regional tools, refer to Special Tools .

1. Remove the turbocharger oil return pipe nuts (1) from the top of the flywheel housing.
2. Remove the turbocharger oil return pipe studs (2).
3. Remove the oil cooler adapter nuts (1) and studs (2).
4. Remove the flywheel housing bolts (2) and (3).
5. Separate the flywheel housing from the cylinder block using J 37228 cutter.
6. Remove the flywheel housing (1).
7. Remove the turbocharger oil return pipe gasket from the flywheel housing.
8. Remove the oil cooler adapter bolts (2).
9. Remove the oil cooler adapter (3) with gaskets (1) and (4).

Scheme 86

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

Fan Pulley Removal

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

Power Steering Pump Mounting Bracket Removal

1. Remove the power steering pump mounting bracket bolts (4) and nuts (1).
2. Remove the power steering pump mounting bracket (3).
3. Remove the power steering pump mounting bracket studs (2).

Generator and Drive Belt Tensioner Bracket Removal

1. Remove the upper intake manifold brace bolts (2).
2. Remove the upper intake manifold brace (1).
3. Remove the drive belt tensioner bolt (1).
4. Remove the drive belt tensioner (2).
5. Remove the generator and drive belt tensioner mounting bracket bolt (4) and nuts (1).
6. Remove the generator and drive belt tensioner mounting bracket (3).
7. Remove the generator and drive belt tensioner mounting bracket studs (2).

Engine Coolant Thermostat Housing Removal

1. Disconnect and remove the turbocharger vane position sensor (1).
2. Remove the oil fill tube bolts (2)
3. Remove the oil fill tube (1).
4. Remove the oil fill tube O-ring seal (3).
5. Remove the fuel feed manifold assembly bolt (1).
6. Remove the fuel feed manifold assembly (2).
7. Remove the fuel pipe bracket bolts (3).
8. Remove the fuel pipe bracket (4).
9. Remove the turbocharger coolant return hose (1).
10. Disconnect the engine coolant temperature sensor (1) and the turbocharger coolant feed hose (2).
11. Remove the thermostat bypass pipe bolts (7).
12. Remove the thermostat housing bolts (5) and nuts (1).
13. Remove the thermostat housing (4).
14. Remove the thermostat housing gaskets (2).
15. Remove the thermostat housing studs (3).
16. Remove the thermostat bypass pipe O-ring seal (6).
17. Remove the thermostat bypass pipe (2).
18. Remove the thermostat bypass pipe O-ring seal (1).

Engine Wiring Harness Assembly Removal

1. Remove the left side engine wiring harness bolts (1, 2).
2. Remove the right side engine wiring harness bolts (1).
3. Remove the engine wiring harness ground bolt (1).
4. Disconnect the crankshaft position sensor electrical connector (1).
5. Disconnect the exhaust gas recirculation (EGR) valve temperature sensor electrical connector (1).
6. Disconnect the right side fuel injector electrical connectors (1).
7. Disconnect the hydrocarbon injector (HCI) electrical connector (1).
8. Remove the right side glow plug connector nuts (1).
9. Disconnect the turbocharger control solenoid valve electrical connector (1).
10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
11. Disconnect the throttle body electrical connector (2).
12. Disconnect the intake heater electrical connector (1).
13. Disconnect the EGR valve electrical connector (1).
14. Disconnect the fuel temperature sensor electrical connector (1).
15. Disconnect the fuel pressure sensor electrical connector (2).
16. Disconnect the glow plug controller electrical connector (3).
17. Disconnect the left side fuel rail fuel pressure sensor electrical connector (1).
18. Disconnect the left side fuel injector electrical connectors (1).
19. Remove the left side glow plug connector nuts (1).
20. Remove the engine wiring harness (1).
21. Remove the glow plug controller bolts (1).
22. Remove the glow plug controller (2).
23. Remove the fuel feed return pipe clip bolt (2).
24. Remove the fuel feed return pipe clip (1).
25. Remove the glow plug controller bracket bolts (1).
26. Remove the glow plug controller bracket (2).
27. Remove the left side glow plugs (1).
28. Remove the right side glow plugs (1).
29. Remove the engine wiring harness bracket bolts (1, 3).
30. Remove the engine wiring harness brackets (2, 4).
31. Remove the turbocharger vane position sensor connector bracket bolt (1).
32. Remove the turbocharger vane position sensor connector bracket (2).

Exhaust Gas Recirculation Valve and Cooler Removal

1. Remove the throttle body bolts (4).
2. Remove the throttle body (3).
3. Remove the intake heater (2) and gasket (1).
4. Remove the manifold absolute pressure (MAP) sensor bolt (1).
5. Remove the MAP sensor (2).
6. Remove the exhaust gas recirculation (EGR) valve bracket bolts (1) and (2).
7. Remove the EGR valve bracket (3).
8. Remove the intake manifold tube bolts (2).
9. Remove the intake manifold tube (1).
10. Remove the intake manifold tube seal (3) and gaskets (4).
11. Remove the EGR valve temperature sensor (1).
12. Remove the EGR valve and cooler bolts (1) and (3).
13. Remove the EGR valve and cooler (2).
14. Remove the EGR cooler bracket bolts (2).
15. Remove the EGR cooler bracket (1).

Positive Crankcase Ventilation Oil Separator Removal

1. Remove the crankcase depression regulator (CDR) bolts (1).
2. Using a suitable tool, cut a slot in the tamper-resistant positive crankcase ventilation (PCV) oil separator bolt heads (3) and remove with a flat blade screwdriver.
3. Disconnect the PCV oil separator drain hose clamp (7).
4. Remove the PCV oil separator and CDR assembly (2).
5. Remove the PCV oil separator drain hose bracket bolt (4).
6. Using a suitable tool, cut a slot in the tamper-resistant PCV oil separator drain hose bolt (5) and remove with a flat blade screwdriver.
7. Remove the PCV oil separator drain hose (6).

Turbocharger Removal

1. Remove the CDR valve, separator and hose bolts (1-3).
2. Remove the CDR valve, separator and hose (4) as an assembly.
3. Remove the turbocharger upper heat shield bolts (1).
4. Remove the turbocharger upper heat shield (2).
5. Remove the eye bolt (1) and washers (2) from the turbocharger oil feed pipe.
6. Remove the turbocharger cooling return pipe bolts (3) and (4).
7. Remove the turbocharger cooling return pipe (2) and the turbocharger cooling return hose (1).
8. Remove the turbocharger cooling feed pipe bolt (4).
9. Remove the turbocharger cooling feed pipe (2) and the turbocharger cooling feed tubes (1) and (3).
10. Remove the turbocharger mounting bolts (1).
11. Remove the turbocharger cooling return pipe bolt (3).
12. Remove the turbocharger assembly (2) with the oil feed pipe, oil return pipe and cooling return pipe.
13. Remove the turbocharger lower heat shield (1).
14. Remove the oil feed pipe eye bolt (1) and washers (2).
15. Remove the oil feed pipe (3).
16. Loosen the turbocharger air inlet adapter holding clamp (2).
17. Remove the turbocharger air inlet adapter (1).

Intake Manifold Removal

1. Remove the fuel return pipe bolt (1) from the top of the intake manifold.
2. Remove the intake manifold bolts (2) and nuts (4).
3. Remove the intake manifold (3).
4. Remove the intake manifold gaskets (1).
5. Remove the intake manifold studs (5).

Fuel Feed Pipe and Fuel Rail Removal

1. Remove the fuel pressure sensor (2).
2. Remove the fuel pressure regulator vacuum tube (1).
3. Remove the fuel pressure sensor bracket bolt (3) and bracket (4).
4. Disengage the fuel return line by pulling upward on the cylindrical locking sleeve (1).
5. Remove the fuel return line (2) from the fuel injector (3).
6. Repeat steps 4-5 for the remaining injectors.
7. Remove the fuel injector fuel return line assembly (1).
8. Remove the fuel feed pipe nut (1) and bolt (3).
9. Remove the fuel feed pipe (2).
10. Remove the fuel pipe bracket bolts (1) and (3).
11. Remove the fuel pipe brackets (2) and (4).
12. Remove the fuel return hose (1).
13. Remove the fuel return pipe nut (2).
14. Remove the fuel return pipe (3).
15. Remove the indirect fuel injector feed pipe eye bolt (6) and washers (7).
16. Remove the fuel pipe bracket bolt (1).
17. Remove the fuel feed pipe assembly (2).
18. Remove the indirect fuel injector feed pipe bracket bolts (3).
19. Remove the indirect fuel injector feed pipe clip bolts (4).
20. Remove the indirect fuel injector assembly (5).
21. Remove the fuel feed hose bolt (1).
22. Remove the high pressure fuel rail pipe bolt (1).
23. Remove the high pressure fuel rail pipe (2).
24. Remove the fuel feed hose (1).
25. Remove the fuel return hose (2).
26. Remove the high pressure fuel rail crossover pipe bolts (1), (2), and (3).
27. Remove the high pressure fuel rail crossover pipe (4).
28. Remove the fuel feed pipe clip bracket bolt (1) and bracket (2).
29. Remove the exhaust gas recirculation (EGR) valve bracket bolt (2).
30. Remove the EGR bracket (1).
31. Remove the right fuel injector pipe bolts (1).
32. Remove the right fuel injector pipes (2).
33. Remove the left fuel injector pipe bolts (1).
34. Remove the left fuel injector pipes (2).
35. Remove the right fuel rail bolts (2).
36. Remove the right fuel rail (1).
37. Remove the intake manifold shield bolts (1) and stud (3).
38. Remove the intake manifold shield (2).
39. Remove the left fuel rail bolt (2).
40. Remove the left fuel rail bolt (1).

Fuel Injector Removal

Special Tools

EN 49774 Fuel Injector Remover

For equivalent regional tools, refer to Special Tools .

1. Remove the fuel injector bracket bolts (1).
2. Install the EN 49774 remover onto the fuel injector brackets.
3. Pull back on EN 49774 remover in one steady motion, until the fuel injector breaks free from its seat.
4. Remove the EN 49774 remover.
5. Remove the fuel injector with bracket (1).
6. Remove the fuel injector bracket pin (2).
7. Remove the copper washer from the injector bore and discard.
8. Remove the O-ring seal (3) from the fuel injector and discard.
9. Repeat steps 1-8 to remove the remaining fuel injectors.

Valve Rocker Arm Cover Removal - Upper Left Side

1. Remove the left upper valve rocker arm cover bolts (4).
2. Remove the left upper valve rocker arm cover (2).
3. Remove and discard the valve rocker arm cover gasket (1) and valve rocker arm cover grommets (3).

Valve Rocker Arm Cover Removal - Upper Right Side

1. Remove the right upper valve rocker arm cover bolts (4).
2. Remove the right upper valve rocker arm cover (2).
3. Remove and discard the valve rocker arm cover gasket (1) and valve rocker arm cover grommets (3).

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.
3. Remove and discard the valve rocker arm cover gasket, valve rocker arm cover grommets and valve rocker arm cover bolts if they are serviced with the grommet.

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.
3. Remove and discard the valve rocker arm cover gasket, valve rocker arm cover grommets and valve rocker arm cover bolts if they are serviced with the grommet.

Lower Intake Manifold Cover Removal - Right Side

Special Tools

J 37228 Seal Cutter

For equivalent regional tools, refer to 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 cutter.
3. Remove the right intake manifold.

Lower Intake Manifold Cover Removal - Left Side

Special Tools

J 37228 Seal Cutter

For equivalent regional tools, refer to Special Tools .

1. Remove the left intake manifold bolts (1). Do not forget to remove the bolt inside the intake manifold tube.
2. Separate the intake manifold from the cylinder head (3) using J 37228 cutter.
3. Remove the left intake manifold (2).

Valve Rocker Arm, Shaft, and Push Rod Removal

1. Remove the valve rocker arm shaft oil deflector bolts (2).
2. Remove the valve rocker arm shaft oil deflector (1).
3. Loosen the valve clearance lock nuts on each rocker arm.
4. Loosen the valve clearance adjusting screw on each rocker arm to relieve tension on the valve train.
5. Remove the rocker arm shaft assembly bolts in the proper sequence.
6. Remove the rocker arm shaft assembly from the cylinder head.
7. Remove the valve bridge pins.
8. Remove the valve bridges.
9. 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 plug (1).
2. Rotate the crankshaft until the fuel injection pump gear timing marks (5) are aligned with camshaft gear timing marks (6).
3. Remove the fuel injection pump bolts (1) and (2).
4. Remove the turbocharger cooler return pipe bracket (3).
5. Remove the fuel injection pump (4).

Water Pump Removal

1. Remove the engine coolant pipe to water pump nuts.
2. Remove the water pump bolts (1) and (5) and the water pump nut (6).
3. Remove the water pump assembly (2).
4. Remove the water pump seal (3) and discard.
5. Remove the engine coolant pipe gasket (4) and discard.

Engine Oil Filter Adapter and Engine Oil Cooler Assembly Removal

1. Remove the engine coolant pipe.
2. Remove the engine coolant pipe O-ring and discard.
3. Remove the five oil filter adapter and oil cooler assembly bolts.
4. Remove the oil filter adapter and oil cooler assembly.

Crankshaft Front Oil Seal Removal

Tools Required

J 44644 Crankshaft Front Oil Seal Remover

1. Install the button of J 44644 Crankshaft Front Oil Seal Remover into the crankshaft.
2. Press the jaws of J 44644 Crankshaft Front Oil Seal Remover into the felt portion of the seal far enough to engage the inner lip of the seal.
3. While holding the jaws of J 44644 Crankshaft Front Oil Seal Remover tightly to the seal's inner sleeve, tighten the jaw bolts.
4. Remove the crankshaft rear oil seal using the J 44644 Crankshaft Front Oil Seal Remover.

Engine Front Cover Removal

Special Tools

J 37228 Seal Cutter

For equivalent regional tools, refer to Special Tools .

1. Remove the crankshaft position sensor bolt (1).
2. Remove the crankshaft position sensor (2).
3. Remove the crankshaft position sensor spacer bolts (3).
4. Remove the crankshaft position sensor spacer (4).
5. Remove the engine front cover bolts (3) and (4).
6. Remove the engine wiring harness clip (2).
7. Separate the engine front cover from the cylinder block using J 37228 cutter.
8. Remove the engine front cover (1).

Oil Pump Suction Pipe and Screen Assembly Removal

1. Remove the oil pump pipe and screen assembly bolts (3) and (4).
2. Remove the oil pump pipe and screen assembly (2).
3. Remove the oil pump pipe and screen assembly seal (1) and discard.

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.

Piston Oil Nozzle Removal

1. Rotate crankshaft as necessary to obtain access to piston oil cooling nozzles.
2. Remove the piston oil cooling nozzle eye bolt.
3. Remove the piston oil cooling nozzle.

Piston, Connecting Rod, and Bearing Removal

Special Tools

J 24270 Ridge Reamer

For equivalent regional tools, refer to Special Tools .

1. Rotate the crankshaft to place the piston at the bottom of the piston stroke.
2. Place a cloth on top of the piston.
3. Use the J 24270 reamer to remove the ridge at the top of the cylinder bore.
4. Remove cloth.
5. Remove cutting debris from the cylinder and piston.
6. Remove the connecting rod cap bolts. Set the bolts aside for use in plastic gauging if needed. New bolts will be used for final assembly.
7. Remove the connecting rod cap.
8. Remove the bearing insert from connecting rod.
9. Push piston assembly out of cylinder.
10. Reassemble the connecting rod bearing, cap, and bolts upon removal.

Camshaft Removal

Special Tools

J 7872 Dial Indicator Set

For equivalent regional tools, refer to Special Tools .

1. Measure the camshaft end play using J 7872 set. The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). Replace the camshaft or the camshaft thrust plate if the measured value exceeds the service limit.
2. Block the crankshaft from turning with a wooden handle (2).
3. Loosen the camshaft gear bolt (1) and leave the bolt finger tight.
4. Remove the camshaft exciter ring bolts (1).
5. Remove the camshaft exciter ring (2).
6. Align the threaded hole with a suitable tool and install an exciter ring bolt to secure the spring tension.
7. Remove the camshaft thrust plate bolts (1) through the holes in the camshaft gear.
8. Remove the camshaft (1) with the camshaft gear attached.
9. Remove the camshaft gear bolt (1) and washer (2).
10. Remove the camshaft gear (3).
11. Remove the camshaft thrust plate (4).

Crankshaft and Bearing Removal

Special Tools

J 7872 Dial Indicator Set

1. Remove the oil pressure sensor.
2. Measure crankshaft end play using J 7872 dial indicator set. The production value is 0.04-0.205 mm (0.0016-0.0081 in) and the service limit is 0.54 mm (0.0213 in). Replace the thrust bearings upon reassembly if the measured value exceeds the service limit.
3. Remove the crankshaft bearing cap side bolts.
4. Remove the crankshaft bearing cap bolts.
5. Mark or identify the crankshaft bearing cap locations, direction and positions for assembly.
6. Remove the crankshaft bearing caps.
7. Set the bolts aside for use in plastic gauging if needed.
8. Remove the crankshaft assembly.
9. Remove the crankshaft bearings from the engine block and the bearing caps.

Engine Block Cleaning and Inspection

Special Tools

EN-28410 Gasket Remover

For equivalent regional tools, refer to Special Tools .

Note. All remanufactured cylinder blocks are steel stamped on both sides of the fuel pressure pump boss. The stamp indicates whether the cylinder is standard or over-bored, and if the deck is standard or has been milled.

1. Inspect the block for stampings (1) indicating cylinder overbore or a milled deck.
2. Remove the engine block heater.
3. Remove the O-ring from the block heater and discard.
4. Remove the oil gallery plugs.
5. Remove the left engine mount bolts.
6. Remove the left engine mount.
7. Remove the right engine mount bolts.
8. Remove the right engine mount.
9. Remove the right engine coolant drain plug (1) and gasket (2).
10. Discard the gasket (2).
11. Remove the left engine coolant drain plug (1) and gasket (2).
12. Discard the gasket (2).
13. Remove the right engine block coolant freeze plugs.
14. Remove the left engine block coolant freeze plugs.
15. Remove the engine block oil gallery cup plugs (1) from the rear of the engine block.
16. Clean the sealing material from the gasket mating surfaces and the cup plug bores of the block. Use the EN-28410 remover or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) , wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding debris from building up and contaminating the oil and coolant cavities. Clean the head gasket surfaces with Brake Parts Cleaner, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) , to remove any traces of oil or debris.
17. Clean the block in cleaning solvent.
18. Flush the engine block with clean water or steam.
19. Clean the oil passages.
20. Clean the cylinder bores.
21. Inspect the cylinder bores for scratches. Replace the engine if a scratch can be felt with a fingernail.
22. Inspect the cylinder honing cross hatch marks. Replace the engine if there are spots, larger than a quarter, where the cross hatching is worn away.
23. Inspect the block for cracks. Use the Magnaflux Spot check dye method, or the equivalent. Inspect the cylinder walls. Inspect the coolant jackets. Inspect the crankshaft bearing webs.
24. Inspect the crankshaft bearing bores and caps. The crankshaft bearing bore inside diameters should be round and uniform at all of the bearing supports.
25. Inspect the area where the crankshaft bearing inserts contact the crankshaft bearing bore. This area must be free of burrs and scratches.
26. Inspect the engine mount bosses.
27. Inspect the cylinder head gasket mating surfaces for pitting.
28. Inspect the engine block to cylinder head gasket surface area for warping. Use a straight edge and feeler gauge. Replace the block if it is warped more than 0.15 mm (0.006 in) longitudinally or more than 0.08 mm (0.003 in) transversely.
29. Apply sealer to the oil gallery plugs.
30. Apply sealant to the engine block oil gallery cup plugs (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) .
31. Install the engine block oil gallery cup plugs (1) to the rear of the engine block.
32. Install the oil gallery plugs and tighten to 53 N.m (39 lb ft).
33. Apply sealant to the left engine block coolant freeze plugs. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) .
34. Install the left engine block coolant freeze plugs.
35. Apply sealant to the right engine block coolant freeze plugs. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) .
36. Install the right engine block coolant freeze plugs.
37. Install the left engine coolant drain plug (1) and NEW gasket (2).
38. Tighten the plug to 18 N.m (13 lb ft).
39. Install the right engine coolant drain plug (1) and NEW gasket (2).
40. Tighten the plug to 18 N.m (13 lb ft).
41. Install the left engine mount and engine mount bolts. Tighten the engine mount bolts to 58 N.m (43 lb ft).
42. Install the right engine mount and engine mount bolts. Tighten the right engine mount bolts to 58 N.m (43 lb ft).
43. Install a new O-ring to the block heater.
44. Lubricate the O-ring with engine coolant.
45. Install the engine block heater.

Upper Oil Pan Cleaning and Inspection

1. Clean the upper oil pan.
2. Carefully clean the sealer from the threaded holes.
3. Inspect the upper oil pan for cracks.
4. Inspect the upper oil pan sealing surfaces for damage.
5. Replace the upper oil pan if any damage is found.

Camshaft and Bearings Cleaning and Inspection

Tools Required

J 7872 Dial Indicator Set

1. Clean the camshaft.
2. Visually inspect the camshaft bearings in the engine block for the following conditions: Scoring Nicks Damage caused by lack of lubrication Misaligned oil feed holes
3. Measure the camshaft journal diameter. The production value is 60.932-60.962 mm (2.3990-2.4001 in) and service limit is 60.920 mm (2.3984 in). Replace the camshaft if the measured value is less than service limit.
4. Measure the camshaft lobe lift. The production value for intake is 7.273 mm (0.2863 in).
5. The production value for exhaust is 5.907 mm (0.2326 in).
6. Replace the camshaft if the measured value is less than the service limit.
7. Measure the camshaft runout. Mount the camshaft on the V-blocks. Use J 7872 dial indicator set to measure the camshaft runout. The runout service limit is 0.05 mm (0.0020 in).
8. Replace the camshaft if the run-out is over the service limit.

Crankshaft and Bearing Cleaning and Inspection

Special Tools

1. J 7872 Dial Indicator Set
2. J 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Clean the crankshaft and bearings.
2. Inspect the crankshaft for the following conditions. Excessive wear or damage on the surface of the crankshaft journals. Excessive wear or damage to the crankshaft gear. Excessive wear or damage on the oil seal fitting surface. Inspect the oil ports for obstructions. Replace the crankshaft if there is excessive wear or damage to the journals, oil seal fitting surface or to the crankshaft gear.
3. Measure the crankshaft run out. Mount the crankshaft in wooden V-blocks. Set J 7872 set on the center of the crankshaft journal. Turn the crankshaft in the normal direction of rotation. Record readings. The production value is 0.05 mm (0.0020 in) and the service limit is 0.44 mm (0.0173 in).
4. Measure the crankshaft journal diameter across four points. The crankshaft journal outside diameter is 79.905-79.925 mm (3.1459-3.1466 in) and the service limit is 79.89 mm (3.1453 in). Replace the crankshaft if the measured value is less than the service limit.
5. Measure the crankpin outside diameter across four points. The crankpin outside diameter is 62.902-62.922 mm (2.4765-2.4772 in) and the service limit is 62.88 mm (2.4756 in). Replace the crankshaft if the measured value is less than the service limit.

Crankshaft Bearing Selection

There are two methods for selecting the proper size crankshaft bearings. The first one is to select the bearing grade (color code) based on the cylinder block grade and the crankshaft journal grade from the Crankshaft Bearing Grade chart. The second is the plastic gauge method.

Crankshaft Bearing Selection Grade Chart Method

1. Inspect the crankshaft for stamping (1) indicating undersized main and/or rod journals.
2. The engine block main bearing bore grade is indicated on the top of the high pressure pump bore. The first 5 digits (1) of the top number, next to the 2D bar code, indicate the main bearing bore grades for main bores 1-5, respectively. In the case of the illustrated example, block number 1222292430009 has main bearing bore grades of: Main bearing bore #1 = Grade 1 Main bearing bore #2 = Grade 2 Main bearing bore #3 = Grade 2 Main bearing bore #4 = Grade 2 Main bearing bore #5 = Grade 2
3. The crankshaft main bearing journal grade is indicated on the back side of the rear counterweight. The first 5 digits (1) equal the grade for crankshaft main bearing journals 1-5, respectively. In the case of the illustrated example, crankshaft number 221112550900 has main journal grades of: Main journal #1 = Grade 2 Main journal #2 = Grade 2 Main journal #3 = Grade 1 Main journal #4 = Grade 1 Main journal #5 = Grade 1
4. Match the cylinder block grade and the crankshaft journal grade, refer to «Crankshaft Bearing Selection Specifications»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__crankshaft-bearing-selection-specifications) .
5. From the Crankshaft Bearing Grade chart, determine which bearing grade (color code) is required.
6. Verify the crankshaft bearing clearance using the plastic gauge method.

Crankshaft Bearing Selection Plastic Gauge Method

Special Tools

J 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Clean the cylinder block bearing fitting surfaces.
2. Clean the crankshaft and upper bearings (1) and lower bearings (2).
3. Install the bearings into the cylinder block and the bearing caps.
4. Install the crankshaft into the cylinder block.
5. Rotate the crankshaft approximately 30 degrees to seat the bearings.
6. Place the plastic gauge over the crankshaft journal across the full width of the bearing.
7. Install the crankshaft bearing caps.
8. Install the crankshaft bearing cap bolts.
9. Tighten the crankshaft bearing cap bolts in the proper sequence. 1st step 98 N.m (72 lb ft). 2nd step 132 N.m (97 lb ft). 3rd step 60 degrees using J 45059 meter.
10. Install the crankshaft bearing cap side bolts. Tighten the crankshaft bearing cap side bolts in the proper sequence to 70 N.m (52 lb ft).
11. Remove the crankshaft bearing cap bolts.
12. Remove the crankshaft bearing caps.
13. Compare the width of the plastic gauge with the scale printed on the plastic gauge container.
14. Select the crankshaft bearing grade that provides the proper oil clearances. The production specification for crankshaft bearing clearance is 0.039-0.070 mm (0.0015-0.0028 in) and the service limit is 0.014 mm (0.0055 in).

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer.
2. Inspect the crankshaft balancer for damage to belt drive surface and to crankshaft balancer hub.
3. Inspect the balancer hub groove for damage or wear.
4. Replace the crankshaft balancer if any concerns exist.

Engine Flywheel Cleaning and Inspection

1. Clean the flywheel assembly.
2. Inspect the flywheel assembly for cracks or excessive wear on the teeth.
3. Replace the flywheel assembly if any concerns exist.

Piston and Connecting Rod Disassemble

Tools Required

J 43654 Piston Pin Retainer Remover/Installer

1. Mark orientation of the piston to the connecting rod.
2. Remove the piston rings using a piston ring expander.
3. Remove the connecting rod bearing inserts.
4. Use J 43654 piston pin retainer remover/installer to remove the piston pin retainers.
5. Remove the piston pin. The pin is a full-floating style and should slide from the piston.
6. Remove the piston from the connecting rod.

Piston, Connecting Rod, and Bearing Cleaning and Inspection

1. Clean the deposits from the following components: Connecting rod and bearings Piston Piston pin
2. Inspect the piston for the following conditions: Scoring on the piston skirt (2) Scoring in the piston pin area (3) Cracks (1) Broken ring groove lands
3. Measure the piston ring end gap. Use a piston to square the piston ring near the top of the cylinder. Use a feeler gauge to measure the piston ring gap. The 1st compression ring production gap is 0.30-0.45 mm (0.0118-0.0177 in) and the service limit is 1.37 mm (0.0539 in). The 2nd compression ring production gap is 0.50-0.65 mm (0.0197-0.0256 in) and the service limit is 1.35 mm (0.0531 in). The oil ring production gap is 0.15-0.35 mm (0.0059-0.0138 in) and the service limit is 1.20 mm (0.0472 in). Replace the piston ring if the measured value exceeds the service limit.
4. Measure the piston ring to piston ring groove clearance. Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. The 1st compression ring production clearance is 0.08-0.17 mm (0.0030-0.0007 in) and the service limit is 0.26 mm (0.0102 in). The 2nd compression ring production clearance is 0.01-0.03 mm (0.0004-0.0012 in) and the service limit is 0.10 mm (0.0039 in). The oil ring production clearance is 0.01-0.03 mm (0.0004-0.0012 in) and the service limit is 0.12 mm (0.0047 in). Replace the piston ring if the measured value exceeds the service limit.
5. Measure the piston pin outside diameter. Measure the piston pin outside diameter at several points. The production value is 34.495-34.50 mm (1.3581-1.3563 in) and the service limit is 34.450 mm (1.3563 in). Replace the piston pin if the measured value is less than the service limit.
6. Measure the piston pin to piston pin bore clearance. Measure the piston pin bore. Subtract the piston pin measurement that was taken previously from the piston pin bore measurement. The difference between these two measurements will be the piston pin to piston pin bore clearance. The production clearance is 0.004-0.017 mm (0.0002-0.0007 in) and the service limit is 0.017 mm (0.0007 in). If the piston pin to piston pin bore clearance is beyond specifications then replace the piston.
7. Measure the piston pin to connecting rod small end clearance. Measure the inside diameter of the connecting rod small end. Subtract the piston pin measurement that was taken previously from the connecting rod small end measurement. The difference between these two measurements will be the piston pin to connecting rod clearance. The production clearance is 0.012-0.027 mm (0.0005-0.0011 in) and the service limit is 0.08 mm (0.0031 in). Replace the connecting rod if the piston pin to connecting rod small end clearance is beyond specifications. The connecting rod small end bushing is not serviceable.

Piston and Connecting Rod Assemble

Special Tools

J 43654 Piston Pin Retainer Remover/Installer

For equivalent regional tools, refer to Special Tools .

1. Apply engine oil to the connecting rod small end bushing and to the piston pin bore of the piston.
2. Install the piston pin into the piston and connecting rod.
3. Install the piston pin retaining rings.
4. Apply engine oil to the piston ring grooves.
5. Install the piston rings using a piston ring expander.
6. Install the piston rings so that the gaps are orientated as follows: The top compression ring (1) and second compression ring (2) gaps should be 180 degrees from each other. The inner oil ring expander ring (3) gap should be 180 degrees from the oil ring rail (4) gap. The ASSEMBLED oil ring gaps should be 90 degrees from the compression ring gaps.

Cylinder Head Disassemble

Tools Required

1. J 8062 Valve Spring Compressor
2. J 38820 Valve Stem Oil Seal Remover

1. Use the J 8062 valve spring compressor to compress the valve spring.
2. Remove the valve keys (1).
3. Remove the J 8062 valve spring compressor from the cylinder head.
4. Remove the valve spring upper seat (2).
5. Remove the valve spring (3).
6. Remove the valve (6).
7. Remove the valve stem seal (4) using J 38820 valve stem oil seal remover.
8. Remove the valve spring lower seat (5).

Cylinder Head Cleaning and Inspection

Special Tools

1. EN-28410 Gasket Remover
2. EN-47909 Injector Bore and Sleeve Cleaning Kit
3. J 9666 Valve Spring Tester

For equivalent regional tools, refer to Special Tools .

1. Clean the cylinder head of all foreign material.
2. Clean the threaded holes.
3. Clean the injector bores using EN-47909 injector bore and sleeve cleaning kit.
4. Clean the cylinder head gasket sealing surface. Use the EN-28410 remover or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) , wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding debris from building up and contaminating the oil and coolant cavities. Clean the head gasket surfaces with Brake Parts Cleaner, refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__adhesives-fluids-lubricants-and-sealers) , to remove any traces of oil or debris.
5. Inspect the cylinder head for the following: Damage to the gasket surfaces Damage to the threaded bolt holes Cracks in the exhaust ports External cracks in the water chamber Cracks between the valve seats Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted, damaged or leaking core plugs
6. Measure the cylinder head for warpage with a straight edge and a feeler gauge. A cylinder head block deck with warpage in excess of 0.1 mm (0.0039 in) must be replaced.
7. Measure the cylinder head exhaust manifold deck for warpage. A cylinder head exhaust manifold deck with warpage in excess of 0.1 mm (0.0039 in) within a 453 mm (17.83 in) area must be replaced.
8. Measure the cylinder head intake manifold deck for warpage. A cylinder head intake manifold deck with warpage in excess of 0.3 mm (0.011 in) within a 493 mm (19.41 in) area must be replaced.
9. Measure the valve spring tension using J 9666 valve spring tester. Replace the valve spring if the valve spring tension is less than 275 N (61.8 lb) at 41 mm (1.6142 in)
10. Measure the valve spring for squareness. Replace the valve spring if squareness is beyond 2.0 mm (0.0787 in).
11. Measure the valve spring free length. The production free length is 56.6 mm (2.2283 in).
12. Measure the valve stem to guide clearance. Set a dial indicator to the valve stem measuring point. Move the valve stem from side to side while reading the total movement on the dial indicator. If the measured valve exceeds 0.20 mm (0.0079 in), replace the cylinder head.
13. If the valve stem to guide clearance is over 0.25 mm (0.098 in) for the exhaust valve guides or 0.20 mm (0.0079 in) for the intake valve guides, the cylinder head must be replaced.
14. Inspect the valves for the following: Bent valve stem Scored valve stem Worn valve key grooves Pitted surfaces
15. Measure the valve margin. The intake valve production margin is 1.2 mm (0.0472 in) and the service limit is 0.88 mm (0.0346 in). The exhaust valve production margin is 1.0 mm (0.0394 in) and the service limit is 0.73 mm (0.0287 in). Replace the valve if the valve margin is below the service limit.
16. Measure the valve depression. Insert a new valve into the cylinder head (1). Use a depth gauge or a straight edge to measure the valve depression from the cylinder head gasket surface (2). The intake valve depression is 0.6 mm (0.0236 in) and the service limit is 2.5 mm (0.0984 in). The exhaust valve depression is 0.9 mm (0.0354 in) and the service limit is 2.0 mm (0.0787 in). Recondition the valve seat if the valve depression is above specifications.
17. Measure the valve contact width. Inspect the valve contact area for roughness or unevenness. The intake valve contact width is 2.1 mm (0.0827 in) and the service limit is 2.5 mm (0.0984 in). The exhaust valve contact width is 2.1 mm (0.0827 in) and the service limit is 2.5 mm (0.0984 in). Recondition the valve seats to bring the contact width into specifications.

Valve and Seat Grinding

1. Remove the carbon from the valve guide and valve seat surface.
2. Resurface the valve face to 45 degrees. If valve margin falls below specifications after resurfacing then discard valve.
3. Use a suitable tool to bring the valve contact width to the standard value. The valve seat angle is 45 degrees.
4. Apply valve lapping compound to the valve seat surface.
5. Insert the valve into the cylinder head.
6. Turn the valve back and forth in its seat to lap the valve face to the valve seat.

Cylinder Head Assemble

Special Tools

1. EN 49761 Valve Stem Seal Installer
2. J 8062 Valve Spring Compressor

For equivalent regional tools, refer to Special Tools .

1. Install the valves into the cylinder head.
2. Install the valve spring lower seat.
3. Install the valve stem seal using the EN 49761 installer. Tap the EN 49761 installer until it bottoms on the valve spring lower seat.
4. Install the valve spring with the painted end towards the cylinder head.
5. Install the valve spring upper seat.
6. Use the J 8062 compressor to compress the valve spring.
7. Install the valve keys.
8. Remove the J 8062 compressor from the cylinder head.
9. Measure the valve installed height using a ruler. Measure from the base of the valve spring to the top of the valve. Refer to «Engine Mechanical Specifications»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__engine-mechanical-specifications) .
10. Install the remaining valves, springs, and other components.

Valve Lifter Cleaning and Inspection

1. Push the roller towards the roller lifter body and measure the distance between the bottom of the roller and the roller lifter body. The production value is 0.989-1.0 mm (0.0389-0.0394 in) and the service limit is 0.9 mm (0.0354 in).
2. Replace the valve lifter if the measurement exceeds the service limit.
3. Inspect the valve lifters for the following: The valve lifter body for scuffing and wear The valve lifter roller assembly for wear The valve lifter roller for smooth rotation

Valve Rocker Arm and Shaft Cleaning and Inspection

1. Measure the rocker arm shaft outside diameter where the rocker arm is located. The production value is 21.979-22.0 mm (0.8653-0.8661 in) and the service limit is 21.85 mm (0.8602 in).
2. Replace the rocker arm shaft if the measured value is less than the service limit.
3. Measure the rocker arm inside diameter. The production value is 22.01-22.035 mm (0.8665-0.8675 in).
4. Calculate the rocker arm shaft to rocker arm clearance. Subtract the rocker arm shaft outside diameter from the rocker arm inside diameter. Replace the rocker arm if the rocker arm shaft to rocker arm clearance is over 0.2 mm (0.0079 in).
5. Inspect the valve lash adjusting screw and lock nut for damage. Replace the valve lash adjusting screw if any damage is found.
6. Measure the pushrods for warpage.
7. Replace the pushrod if the warpage exceeds 0.8 mm (0.031 in).

Piston Oil Nozzle Cleaning and Inspection

1. Inspect the piston oil cooling nozzle for damage.
2. Replace the piston oil cooling nozzle if any damage is found.

Oil Pump Cleaning and Inspection

1. Remove the oil pump gear cover bolts.
2. Remove the oil pump gear cover.
3. Use a feeler gauge to measure the clearance between the gear teeth and the oil pump housing. The production clearance is 0.125-0.221 mm (0.0049-0.0087 in) and the service limit is 0.221 mm (0.0087 in).
4. Replace the oil pump assembly if the clearance exceeds the service limit.
5. Use a feeler gauge and a straightedge to measure the clearance between the side of the gear and the cover. The production clearance is 0.064-0.109 mm (0.0025-0.0043 in) and the service limit is 0.109 mm (0.0043 in).
6. Replace the oil pump assembly if the clearance exceeds the service limit.
7. Calculate the driven gear shaft to bushing clearance. Measure the driven gear shaft outside diameter. The production specification is 19.947-19.960 mm (0.7853-0.7858 in) and the service limit is 19.86 mm (0.7819 in). Measure the driven gear bushing inside diameter. The production value is 20 mm (0.7874 in). Calculate the driven gear shaft to bushing clearance. The service limit is 0.14 mm (0.0055 in)
8. Replace the oil pump assembly if the clearance exceeds the service limit.
9. Install the oil pump gear cover to the oil pump assembly.
10. Install the oil pump gear cover bolts and tighten to 21 N.m (15 lb ft).

Engine Front Cover Cleaning and Inspection

1. Remove the O-ring (1) from the engine front cover.
2. Remove the oil pressure relief valve from the engine front cover.
3. Clean the engine front cover.
4. Clean the engine front cover mating surfaces.
5. Inspect the engine front cover mating surfaces for damage.
6. Inspect the engine front cover O-ring sealing surface for damage.
7. Inspect the crankshaft front oil seal bore for damage.
8. Replace the engine front cover if any damage is found.
9. Install the oil pressure relief valve with a new O-ring and tighten to 39 N.m (29 lb ft).

Lower Oil Pan Cleaning and Inspection

1. Remove the oil level sensor (1) and retaining clip (3).
2. Clean the lower oil pan (4). Remove any sludge or other deposits.
3. Clean the lower oil pan mating surface.
4. Inspect the lower oil pan (4) for dents or distortion.
5. Inspect the lower oil pan mating surface for damage.
6. Replace the lower oil pan (4) if any damage is found.
7. Install the oil level sensor (1) and retaining clip (3).

Valve Rocker Arm Cover Cleaning and Inspection - Lower

1. Remove the grommets.
2. Clean the lower valve rocker arm cover. Remove any sludge or other deposits.
3. Clean the lower valve rocker arm cover mating surfaces.
4. Inspect the lower valve rocker arm cover for cracks or other damage.
5. Inspect the lower valve rocker arm cover mating surfaces for damage.
6. Replace the lower valve rocker arm cover if any damage is found.
7. Inspect the grommets for damage.
8. Replace the grommets if any damage is found.
9. Install the grommets.

Valve Rocker Arm Cover Cleaning and Inspection - Upper

1. Clean the upper valve rocker arm cover (1). Remove any sludge or other deposits.
2. Clean the upper valve rocker arm cover mating surface.
3. Inspect the upper valve rocker arm cover for cracks or other damage.
4. Inspect the upper valve rocker arm cover mating surfaces for damage.
5. Replace the upper valve rocker arm cover if any damage is found.
6. Inspect the PCV oil separator (1) for damage.
7. Inspect the PCV oil separator O-ring seal for damage.
8. Replace the PCV oil separator if damage is found.

Intake Manifold Cleaning and Inspection

1. Clean the intake manifold crossover.
2. Clean the intake manifold mating surfaces.
3. Clean the intake manifolds.
4. Clean the intake manifold mating surfaces.
5. Inspect the intake manifolds for cracks.
6. Inspect the intake manifold mating surfaces for damage.
7. Replace the intake manifolds if any damage is found.

Oil Filter Adapter and Oil Cooler Assembly Cleaning and Inspection

1. Clean the coolant tube.
2. Inspect the coolant tube for cracks.
3. Inspect the coolant tube mating surfaces for damage.
4. Clean the oil filter adapter.
5. Inspect the oil filter adapter mating surfaces for damage.
6. Replace the O-rings.

Engine Coolant Thermostat Housing Cleaning and Inspection

1. Remove the fuel return hose bracket bolt (1).
2. Remove the fuel return hose bracket (2).
3. Remove the coolant temperature sensor (1).
4. Remove the engine coolant outlet pipe bolts (1).
5. Remove the engine coolant outlet pipe (2).
6. Remove the thermostats (3) and (4).
7. Clean the thermostat housing (1).
8. Clean the thermostat housing mating surfaces.
9. Inspect the thermostat housing for cracks.
10. Inspect the thermostat housing mating surfaces for damage.
11. Replace the thermostat housing if any damage is found.
12. Install the thermostats (1) and (2).
13. Ensure that the holes (3) in thermostat (2) are orientated as shown.
14. Install the engine coolant outlet pipe (2).
15. Install the engine coolant outlet pipe bolts (1) and tighten to 25 N.m (18 lb ft).
16. Install the engine coolant temperature sensor (1) and tighten to 20 N.m (15 lb ft).
17. Install the fuel return hose bracket (2).
18. Install the fuel return hose bracket bolt (1) and tighten to 25 N.m (18 lb ft).

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold.
2. Clean the exhaust manifold mating surfaces.
3. Inspect the exhaust manifold for cracks.
4. Inspect the exhaust manifold mating surfaces for damage.
5. Replace the exhaust manifold if any damage is found.
6. Measure the exhaust manifold flange for warpage with feeler gauge and a straightedge. Replace the exhaust manifold if the warpage is more than 0.3 mm (0.0118 in).
7. Install the exhaust manifold heat shield.
8. Install the exhaust manifold heat shield bolts and tighten to 8 N.m (71 lb in).

Exhaust Pipe Cleaning and Inspection

1. Clean the exhaust pipe.
2. Clean the exhaust pipe mating surfaces.
3. Inspect the exhaust pipe for dents or cracks.
4. Replace the exhaust pipe if any damage is found.

Exhaust Turbocharger Outlet Pipe Adapter Cleaning and Inspection

1. Clean the exhaust outlet.
2. Clean the exhaust outlet mating surfaces.
3. Inspect the exhaust outlet for dents or cracks.
4. Replace the exhaust outlet if any damage is found.

Fuel Injection Pump Cleaning and Inspection

1. Remove the fuel feed hose eye bolt (3).
2. Remove the fuel feed hose gasket (2).
3. Remove the fuel feed hose (1).
4. Remove and discard the fuel injection pump gear nut (1).
5. Remove the fuel injection pump gear (2).
6. Remove and discard the fuel injection pump adapter bolts (4).
7. Remove the fuel injection pump adapter (2).
8. Remove and discard the fuel injection pump O-ring seal (3).
9. Remove and discard the fuel injection pump adapter O-ring seal (1).
10. Clean the fuel injection pump adapter mating surfaces.
11. Clean the fuel injection pump mating surfaces.
12. Inspect the fuel injection pump, adapter and gear for damage.
13. Replace component if any damage is found.
14. Lubricate the O-rings with engine oil.
15. Install a NEW fuel injection pump O-ring seal (3).
16. Install a NEW fuel injection pump adapter O-ring seal (1).
17. Install the fuel injection pump adapter (2).
18. Install the NEW fuel injection pump adapter bolts (4) and hand tighten.
19. Tighten the fuel injection pump adapter bolts in the sequence shown. Tighten the M8 adapter bolts (1-2) a first pass to 8 N.m (71 lb in). Tighten the M6 adapter bolt (3) a first pass to 4 N.m (35 lb in). Tighten the M8 adapter bolts (1-2) a final pass to 25 N.m (18 lb ft). Tighten the M6 adapter bolts (3) a final pass to 15 N.m (11 lb ft).
20. Install the fuel injection pump gear (2).
21. Install the NEW fuel injection pump gear nut (1) and tighten to 78 N.m (58 lb ft).
22. Install the fuel feed hose (1).
23. Install the fuel feed hose gasket (2).
24. Install the fuel feed hose eye bolt (3) and tighten to 10 N.m (89 lb in).

Fuel Injector Cleaning and Inspection

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

Turbocharger Cleaning and Inspection

Completely inspect the turbocharger and all other engine components that may cause similar conditions before replacing the turbocharger.

Use the following information to diagnose problems caused by the turbocharger.

The turbocharger is serviced as a complete unit.

1. Remove the turbocharger cooler return pipe nut (1).
2. Remove the turbocharger cooler return pipe eye bolt (4) and gasket (3). Discard the gasket (3).
3. Remove the turbocharger cooler return pipe (2).
4. Remove the turbocharger cooler feed pipe bolt (4).
5. Remove the turbocharger cooler feed pipe eye bolt (3) and gasket (2). Discard the gasket (2).
6. Remove the turbocharger cooler feed pipe (1).
7. Remove the turbocharger oil return pipe bolts (1).
8. Remove the turbocharger oil return pipe (2) and gasket (3). Discard the gasket (3).
9. Clean mating surfaces.
10. Inspect for damage to the compressor wheel, compared to a normal compressor wheel.
11. Inspect for damage to the compressor wheel, by a soft object.
12. Inspect for damage to the compressor wheel, by a hard object.
13. Inspect compressor blades for heavy rubbing. Ensure that the following conditions do not exist on the compressor wheel blades: Cracks Bends Erosion of the blades Broken blades
14. Check the housing for signs of rubbing.
15. Install the turbocharger oil return pipe (2) and NEW gasket (3).
16. Install the turbocharger oil return pipe bolts (1) and tighten to 21 N.m (15 lb ft).
17. Inspect the coolant outlet lines for damage.
18. Install the turbocharger cooler feed pipe (1).
19. Install the turbocharger cooler feed pipe eye bolt (3) and NEW gasket (2) and tighten to 35 N.m (26 lb ft).
20. Install the turbocharger cooler feed pipe bolt (4) and tighten to 10 N.m (89 lb in).
21. Install the turbocharger cooler return pipe (2).
22. Install the turbocharger cooler return pipe eye bolt (4) and NEW gasket (3) and tighten to 35 N.m (26 lb ft).
23. Install the turbocharger cooler return pipe nut and tighten to 10 N.m (89 lb in).
24. Clean the turbocharger inlet duct (1).
25. Clean the turbocharger inlet duct mating surfaces.
26. Inspect the turbocharger inlet duct for cracks.
27. Inspect the turbocharger inlet duct mating surfaces for damage.
28. Replace the turbocharger inlet duct if any damage is found.

Positive Crankcase Ventilation System Cleaning and Inspection

1. Remove the O-ring seals and discard.
2. Clean the sealing surfaces (2).
3. Inspect the sealing surfaces (2) for damage. Replace the affected component if damage is found.
4. Inspect the clamped hose connections (1) for looseness or damage. Repair or replace as necessary.

Flywheel Housing Cleaning and Inspection

1. Remove the O-rings from the flywheel housing and discard.
2. Clean the flywheel housing.
3. Clean the flywheel housing mating surfaces.
4. Clean the flywheel housing O-ring sealing area.
5. Inspect the flywheel housing for cracks.
6. Inspect the flywheel housing mating surfaces for damage.
7. Inspect the crankshaft rear oil seal bore for damage.
8. Replace the flywheel housing if any damage is found.

Water Pump Cleaning and Inspection

1. Clean the water pump assembly (1).
2. Clean the water pump mating surfaces.
3. Inspect the water pump impeller for damage.
4. Inspect the water pump mating surfaces for damage.
5. Inspect the water pump shaft for looseness.
6. Inspect the water pump assembly for damage.
7. Replace the water pump if any damage is found.

Exhaust Gas Recirculation Valve Cooler Cleaning and Inspection (LGH)

1. Remove the heater inlet hose connector (2).
2. Remove the heater hose (1).
3. Remove the exhaust gas recirculation (EGR) valve assembly bolts (1).
4. Remove the EGR valve assembly (2).
5. Remove and discard the EGR valve assembly gasket (3).
6. Clean the EGR valve assembly (1) and EGR cooler (2).
7. Clean and inspect the EGR valve assembly gasket sealing surfaces.
8. Inspect the EGR valve assembly and EGR cooler for damage.
9. Replace the EGR valve assembly or EGR cooler if damage is found.
10. Install a NEW EGR valve assembly gasket (3).
11. Install the EGR valve assembly (2).
12. Install the EGR valve assembly bolts (1) and tighten to 25 N.m (18 lb ft).
13. Install the heater hose (1).
14. Install the heater inlet hose connector (2).

Thread Repair

General purpose thread repair kits are available commercially.

1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.

Scheme 87

The torque of a fuel line fitting is critical to prevent fuel leaks in a high pressure direct injection fuel system. The preferred method is through the use of a flare nut socket. With the use of a flare nut socket, the torque wrench can be set to the listed torque specification. Refer to Fastener Tightening Specifications .

If a crows foot is used to torque the fuel lines, then special attention to the position of the crows foot in relation to the torque wrench is required.

1. If the crows foot is kept perpendicular (90 degrees) to the torque wrench during the entire tightening procedure, then the torque wrench can be set to the listed torque specification. Refer to «Fastener Tightening Specifications»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__fastener-tightening-specifications) .
2. If the crows foot is positioned straight with the torque wrench, then the torque setting needs to be corrected to compensate for the increased leverage.
3. If the crows foot is held at any position other than 90 degrees or inline to the wrench, more complex corrections of the torque setting are required, and therefore, positioning the crows foot in this manner is not recommended.

If it is necessary to position a crows foot in line with the torque wrench, the procedure for adjusting the torque specification is as follows

1. Measure the distance between the center of the crows foot wrench end to the center of the square drive hole.
2. Measure the length of the torque wrench from the center of the square drive to the center of the handle.
3. Divide the measurement of the crows foot length by the torque wrench length. This figure is the percentage of additional torque, over the torque wrench setting, that will be applied to the fitting.
4. Subtract the results of step 3 from the number 1. This figure is the percentage of the listed torque specification that the torque wrench should be set to.
5. Multiply the results of step 4 by the listed torque setting. Refer to «Fastener Tightening Specifications»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__fastener-tightening-specifications) . This figure is the proper setting the torque wrench should be set at when using a crows foot in line with the torque wrench.

Example

1. Crows foot measurement = 25 mm (1.0 in)
2. Torque wrench measurement = 355 mm (14.0 in)
3. 25 mm / 355 mm (1.0 in / 14.0 in) = 0.07, or 7 %
4. 1 - 0.07 = 0.93, or 93 %
5. 0.93 x 41 N.m (30 lb ft) = 38 N.m (28 lb ft)

Service Prior to Assembly

1. Dirt will cause premature wear of the rebuilt engine. Clean all the components.
2. Use the proper tools to measure the components when checking for excessive wear. Components not within the manufacturer's specification must be repaired or replaced.
3. When the components are reinstalled into an engine, return the components to their original location, position, and direction.
4. During assembly, lubricate all the moving parts with clean engine oil (unless otherwise specified). This will provide initial lubrication when the engine is first started.

Crankshaft and Bearing Installation

Special Tools

J 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Install the upper crankshaft bearings into the cylinder block. The bearing halves to be inserted into the crankshaft main bearing saddle have a wide groove and oil hole in the center of the bearing (1).
2. Install the lower crankshaft bearings into the crankshaft bearing caps. The bearing halves to be inserted into the crankshaft main bearing caps do NOT have an oil hole or groove in the bearing (2).
3. Install the upper thrust bearings to the cylinder block. There are 2 thrust bearings (1 and 3) in the cylinder block and one lower thrust bearing in the No. 5 crankshaft bearing cap (2).
4. Lubricate the crankshaft bearing surfaces with engine oil.
5. Install the crankshaft into the cylinder block.
6. Install the No. 5 crankshaft bearing cap with the lower thrust bearing (2).
7. Install the remaining 4 crankshaft bearing caps.
8. Install the NEW crankshaft bearing cap bolts.
9. Tighten the NEW crankshaft bearing cap bolts in the proper sequence. 1st step 98 N.m (72 lb ft). 2nd step 132 N.m (97 lb ft). 3rd step 60 degreesusing J 45059 meter.
10. Clean the crankshaft bearing side cap bolt threads, sealing flange and mounting holes with GM P/N 12377981 (Canadian P/N 10953463) or equivalent. Dry the bolts and mounting holes with compressed air.
11. Apply GM P/N 12346004 (Canadian P/N 10953480) to the threads and sealing flange of the bolts.
12. Install the ten bolts and tighten to 70 N.m (52 lb ft).
13. Install the oil pressure sensor and tighten to 41 N.m (30 lb ft).

Camshaft Installation

Special Tools

J 7872 Dial Indicator Set

For equivalent regional tools, refer to Special Tools .

1. Install the camshaft thrust plate (4) to the camshaft.
2. Install the camshaft driven gear (3).
3. Install the camshaft washer (2) and a NEW camshaft driven gear bolt (1). Leave the bolt finger tight.
4. Install the camshaft and gear assembly into the cylinder block, aligning the camshaft gear to the crankshaft gear as shown.
5. Install the camshaft thrust plate bolts (1) and tighten to 22 N.m (16 lb ft).
6. Remove the exciter ring bolt that was installed to hold the spring tension of the two piece cam gear.
7. Install the camshaft position sensor exciter ring (2) to the camshaft gear.
8. Install the camshaft position sensor exciter ring bolts (1).
9. Tighten the camshaft position sensor exciter ring bolts in sequence to 12 N.m (9 lb ft).
10. Block the crankshaft from turning using a wooden handle (2).
11. Install the new camshaft gear bolt and tighten to 234 N.m (173 lb ft).
12. Measure the camshaft end play with J 7872 set. The production value is 0.050-0.114 mm (0.0020-0.0045 in) and service limit is 0.2 mm (0.0079 in). Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the service limit.

Piston, Connecting Rod, and Bearing Installation

Special Tools

1. J 8037 Piston Ring Compressor
2. J 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

1. Select the connecting rod bearing according to the «Connecting Rod Bearings Selection Specifications»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications) chart.
2. Position the crankshaft so the connecting rod journal is opposite the piston and connecting rod assembly being installed.
3. Install the connecting rod bearing inserts.
4. Lubricate the cylinder wall and piston rings with engine oil.
5. Install the J 8037 compressor to the piston to compress the piston rings.
6. Orientate the piston front mark and the piston inside mark to the engine block.
7. Push the piston and connecting rod assembly into the engine.
8. Install the gauging plastic onto the connecting rod journal. Install the gauging plastic the full width of the journal.
9. Install the connecting rod cap with its stamped cylinder number aligned with the stamped cylinder number on the connecting rod.
10. Install the original connecting rod cap bolts for the plastic gauging. NEW bolts will be used for final assembly.
11. Tighten the bolts in three steps. 1st step 64 N.m (47 lb ft) 2nd step 30 degreesusing J 45059 meter 3rd step 30 degreesusing J 45059 meter
12. Remove the connecting rod cap bolts.
13. Compare the width of the gauging plastic with the scale printed on the gauging plastic container. The connecting rod bearing clearance should be 0.10 mm (0.0039 in).
14. Discard the original connecting rod bolts once the plastic gauging is completed. NEW connecting rod bolts will be used for final assembly.
15. Carefully clean the gauging plastic from the bearing surface and the crankpin.
16. Lubricate the connecting rod bearing inserts with engine oil.
17. Install the connecting rod caps with the stamped cylinder number aligned with the stamped cylinder number on the connecting rods.
18. Install NEW connecting rod cap bolts.
19. Tighten the NEW connecting rod cap bolts in three steps. 1st step 64 N.m (47 lb ft) 2nd step 30 degreesusing J 45059 meter 3rd step 30 degreesusing J 45059 meter

Piston Oil Nozzle Installation

1. Install the piston oil cooling nozzle.
2. Install the piston oil cooling nozzle bolt and tighten to 21 N.m (15 lb ft).

Oil Pump Installation

1. Install a new O-ring to the engine block.
2. Lubricate the O-ring with engine oil.
3. Install the oil pump.
4. Install the oil pump bolts and tighten to 21 N.m (15 lb ft).
5. Install the oil pump drive gear and crank sensor reluctor assembly.
6. Install the oil pump driven gear.
7. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the oil pump driven gear nut to 100 N.m (74 lb ft).

Oil Pump Suction Pipe and Screen Assembly Installation

1. Install the NEW oil pump pipe and screen seal (1).
2. Install the oil pump pipe and screen (2).
3. Install the oil pump pipe and screen assembly bolts (3) and (4) and tighten to 25 N.m (18 lb ft).

Engine Front Cover Installation

1. Install the relief valve O-ring (1) 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 (1).
5. Install the engine wiring harness clip (2).
6. Install the engine front cover bolts (3) and (4).
7. Tighten the engine front cover bolts (1) and (2) in sequence to 25 N.m (18 lb ft).
8. Install a NEW O-ring to the crankshaft position sensor spacer.
9. Lubricate the O-ring with engine oil.
10. Install the crankshaft position sensor spacer (4).
11. Install the crankshaft position sensor spacer bolts (3). Tighten the crankshaft position sensor spacer bolts to 10 N.m (89 lb in).
12. Install a NEW O-ring to the crankshaft position sensor.
13. Lubricate the O-ring with engine oil.
14. Install the crankshaft position sensor (2).
15. Install the crankshaft position sensor bolt (1). Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).

Crankshaft Front Oil Seal Installation

Tools Required

J 44645 Crankshaft Front Oil Seal Installer

1. Lubricate the crankshaft sealing surface with engine oil.
2. Place the crankshaft front oil seal onto the crankshaft.
3. Install the J 44645 crankshaft front oil seal installer to the crankshaft.
4. Press the crankshaft front oil seal onto the crankshaft with the J 44645 crankshaft front oil seal installer until the tool bottoms out.
5. Remove the J 44645 crankshaft front oil seal installer.

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. 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 NEW (4) engine coolant pipe gasket.
3. Install the NEW (3) water pump seal.
4. Install the water pump (2). Be sure the water pump studs align with the coolant tube.
5. Install the water pump bolts (1) and (5), and nut (6) and tighten to 25 N.m (18 lb ft).
6. Install the water pump to coolant tube nuts Tighten the water pump to coolant tube nuts to 25 N.m (18 lb ft).

Fuel Injection Pump Installation

1. Rotate the crankshaft to align the camshaft gear timing marks with the center of the inspection hole.
2. Lubricate the O-ring on the fuel injection pump adapter with engine oil.
3. Install the fuel injection pump and adapter assembly (4) so that the timing mark on the fuel pump gear (5) is aligned with the timing marks on the camshaft gear (6).
4. Install the turbocharger cooler return pipe bracket (3).
5. Install the fuel injection pump bolts (1) and (2) and tighten 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 11 N.m (97 lb in).

Cylinder Head Gasket Selection

Special Tools

J 7872 Dial Indicator Set

For equivalent regional tools, refer to Special Tools .

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 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/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications) to determine what gasket to use for each bank of cylinders.
3. Be sure the piston and cylinder deck are free of carbon, gasket material, or other objects that may give you an erroneous measurement.
4. Use J 7872 indicator 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.
5. Calculate the average value of piston projection for each cylinder.
6. Obtain the maximum piston projection value for that bank of cylinders.
7. Determine the gasket grade by the maximum piston projection value using the chart.
8. 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.

Cylinder Head Installation - Left Side

Special Tools

J 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

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/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-off-vehicle__cylinder-head-gasket-selection) .
3. Install the left cylinder head.
4. Install the NEW M12 cylinder head bolts. Tighten the NEW M12 cylinder head bolts in four steps: 1st step 50 N.m (37 lb ft) 2nd step 80 N.m (59 lb ft) 3rd step tighten 60 degreesusing J 45059 meter 4th step tighten 60 degreesusing J 45059 meter
5. Reuse the M8 bolts. Install the M8 bolts and tighten the M8 cylinder head bolts to 25 N.m (18 lb ft).

Cylinder Head Installation - Right Side

Special Tools

J 45059 Angle Meter

For equivalent regional tools, refer to Special Tools .

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/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-off-vehicle__cylinder-head-gasket-selection) .
3. Install the right cylinder head.
4. Install the NEW M12 cylinder head bolts. Reuse the M8 bolts. Tighten the NEW M12 cylinder head bolts in four steps: 1st step 50 N.m (37 lb ft) 2nd step 80 N.m (59 lb ft) 3rd step tighten 60 degreesusing J 45059 meter 4th step tighten 60 degreesusing J 45059 meter
5. Install the M8 bolts. 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 the exhaust manifold bolts and nuts to 57 N.m (42 lb ft) in the proper sequence. 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 and tighten to 10 N.m (89 lb in).

Scheme 88

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and nuts. Tighten the exhaust manifold bolts and nuts to 57 N.m (42 lb ft) in the proper sequence. 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 and tighten 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 the rocker arm shaft assembly bolts in the proper sequence. Tighten the rocker arm shaft bolts to 41 N.m (30 lb ft).
6. Install the valve rocker arm shaft oil deflector (1).
7. Install the valve rocker arm shaft oil deflector bolts (2) and tighten to 10 N.m (89 lb in).

Valve Clearance 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/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__valve-clearance-adjustment-specifications) to determine which valves that can be adjusted when the engine is at Top Dead Center. 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/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-specifications__valve-clearance-adjustment-specifications) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 N.m (16 lb ft).

Lower Intake Manifold Cover 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 (1, 2, 3).
3. Install the intake manifold bolts and nuts and tighten to 25 N.m (18 lb ft).

Lower Intake Manifold Cover 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 and tighten to 25 N.m (18 lb ft).

Valve Rocker Arm Cover Installation - Lower Left Side

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

Valve Rocker Arm Cover Installation - Lower Right Side

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

Valve Rocker Arm Cover Installation - Upper Left Side

1. Install the NEW valve rocker arm cover gasket (1).
2. Install the NEW valve rocker arm cover grommets (3).
3. Install the upper valve rocker arm cover (2).
4. Install the upper valve rocker arm cover bolts (4).
5. Tighten the upper valve rocker arm cover bolts in sequence to 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Upper Right Side

1. Install the NEW valve rocker arm cover gasket (1).
2. Install the NEW valve rocker arm cover grommets (3).
3. Install the upper valve rocker arm cover (2).
4. Install the upper valve rocker arm cover bolts (4).
5. Tighten the upper valve rocker arm cover bolts in sequence to 10 N.m (89 lb in).

Fuel Injector Installation

1. Install a NEW O-ring seal (3) onto the fuel injector.
2. Lubricate the O-ring seal with engine oil.
3. Install a NEW copper washer to the fuel injector.
4. Install the fuel injector bracket pin (2).
5. Install the fuel injector with fuel injector bracket (1).
6. Install the fuel injector bracket bolt (1) and tighten to 30 N.m (22 lb ft).
7. Repeat steps 1-6 to install the remaining injectors.

Fuel Feed Pipe and Fuel Rail Installation

1. Install the left fuel rail (1).
2. Install the left fuel rail bolt (2) and tighten to 25 N.m (18 lb ft).
3. Install the intake manifold heat shield (2).
4. Install the intake manifold heat shield bolts (1) and stud (3) and tighten to 25 N.m (18 lb ft).
5. Install the right fuel rail (1).
6. Install the right fuel rail bolts (2) and tighten to 25 N.m (18 lb ft).
7. Install the left fuel injector pipes (2) and tighten to 30 N.m (22 lb ft).
8. Install the left fuel injector pipe bolts (1) and tighten to 10 N.m (89 lb in).
9. Install the right fuel injector pipes (2) and tighten to 30 N.m (22 lb ft).
10. Install the left right injector pipe bolts (1) and tighten to 10 N.m (89 lb in).
11. Install the exhaust gas recirculation (EGR) valve bracket (1).
12. Install the EGR valve bracket bolt and tighten to 25 N.m (18 lb ft).
13. Install the fuel feed pipe clip bracket (1).
14. Install the fuel feed pipe clip bracket bolt (1) and tighten to 25 N.m (18 lb ft).
15. Install the high pressure fuel rail crossover pipe (4) and tighten to 30 N.m (22 lb ft).
16. Install the high pressure fuel rail crossover pipe bolts (1) and (3) and tighten to 10 N.m (89 lb in).
17. Install the high pressure fuel rail crossover pipe bolt (2) and tighten to 25 N.m (18 lb ft).
18. Install the fuel return hose (2).
19. Install the fuel feed hose (1).
20. Install the high pressure fuel rail pipe (2). Tighten the high pressure fuel rail pipe nut - fuel rail side to 30 N.m (22 lb ft). Tighten the high pressure fuel rail pipe nut - high pressure pump side to 38 N.m (28 lb ft).
21. Install the high pressure fuel rail pipe bolt (1) and tighten to 10 N.m (89 lb in).
22. Install the fuel feed hose bolt (1) and tighten to 25 N.m (18 lb ft).
23. Install the indirect fuel injector assembly (5) and fuel feed pipe assembly (2).
24. Install the indirect fuel injector feed pipe bracket bolts (3) and tighten to 25 N.m (18 lb ft).
25. Install the indirect fuel injector feed pipe clip bolts (4) and tighten to 10 N.m (89 lb in).
26. Install the fuel pipe bracket bolt (1) and tighten to 25 N.m (18 lb ft).
27. Install the indirect fuel injector feed pipe eye bolt (6) and washers (7) and tighten to 10 N.m (89 lb in).
28. Install the fuel return pipe (3).
29. Install the fuel return pipe nut (2) and tighten to 25 N.m (18 lb ft).
30. Install the fuel return hose (1).
31. Install the fuel pipe brackets (2) and (4).
32. Install the fuel pipe bracket bolt (1) and tighten to 25 N.m (18 lb ft).
33. Install the fuel pipe bracket bolt (3) and tighten to 10 N.m (89 lb in).
34. Install the fuel feed pipe (2).
35. Install the fuel feed pipe bolt (3) and tighten to 10 N.m (89 lb in).
36. Install the fuel feed pipe nut (1) and tighten to 25 N.m (18 lb ft).
37. Install the fuel injector fuel return line assembly (1).
38. Inspect the O-rings (1) for damage. Replace if necessary.
39. Inspect the fuel return line locking tabs (2) for damage. Replace the fuel return line assembly if necessary.
40. With the cylindrical locking sleeve (3) released in the upward position, install the fuel return line to the fuel injector.
41. Press down on the locking sleeve (3) to secure the connection.
42. Repeat steps 37-40 for the remaining injectors.
43. Install the engine fuel vacuum switch bracket (4).
44. Install the engine fuel vacuum switch bracket bolt (3) and tighten to 25 N.m (18 lb ft).
45. Install the engine fuel vacuum switch (2) and tighten to 25 N.m (18 lb ft).
46. Install the fuel pressure regulator vacuum tube (1).

Intake Manifold Installation

1. Install the intake manifold studs (5) and tighten to 6 N.m (53 lb in).
2. Install the intake manifold gaskets (1).
3. Install the intake manifold (3).
4. Install the intake manifold nuts (4) and tighten to 10 N.m (89 lb in).
5. Install the intake manifold bolts (2) and tighten to 10 N.m (89 lb in).
6. Install the fuel return pipe bolt (1) to the top of the intake manifold and tighten to 10 N.m (89 lb in).

Turbocharger Installation

1. Install the turbocharger air inlet adapter (1).
2. Tighten the turbocharger air inlet adapter holding clamp (2) to 10 N.m (89 lb in).
3. Install the turbocharger oil feed pipe (3).
4. Install the turbocharger oil feed pipe eye bolt (1) and washers (2). Tighten the eye bolt to 35 N.m (26 lb ft).
5. Install the turbocharger lower heat shield (1).
6. Install the turbocharger assembly (2) with the oil feed pipe, oil return pipe and cooling return pipe.
7. Install the turbocharger mounting bolts (1) and tighten to 78 N.m (58 lb ft).
8. Install the turbocharger cooling return pipe bolt (3) and tighten to 25 N.m (18 lb ft).
9. Install the turbocharger cooling feed pipe (2) and the turbocharger cooling feed tubes (1) and (3).
10. Install the turbocharger cooling feed pipe bolt (4) and tighten to 25 N.m (18 lb ft).
11. Install the turbocharger cooling return pipe (2) and the turbocharger cooling return hose (1).
12. Install the turbocharger cooling return pipe bolts (3) and (4) and tighten to 25 N.m (18 lb ft).
13. Install the turbocharger oil feed pipe eye bolt (1) and washers (2). Tighten the eye bolt to 50 N.m (37 lb ft).
14. Install the turbocharger heat shield (2).
15. Install the turbocharger upper heat shield bolts (1) and tighten to 10 N.m (89 lb in).
16. Install the CDR valve, separator and hose (4) as an assembly.
17. Install the CDR valve, separator and hose bolts (1-3) and tighten to 10 N.m (89 lb in).

Positive Crankcase Ventilation Oil Separator Installation

Special Tools

EN-50956 Tamper Proof Drive Bit

For equivalent regional tools, refer to Special Tools .

1. Install the Positive Crankcase Ventilation (PCV) oil separator and crankcase depression regulator (CDR) assembly (2).
2. Install the CDR bolts (1) and tighten to 10 N.m (89 lb in).
3. Using EN 50596 drive bit, install NEW tamper-resistant PCV oil separator bolts (3) and tighten to 10 N.m (89 lb in).
4. Install the PCV oil separator drain hose (6) and connect the PCV oil separator drain hose clamp (7).
5. Using EN 50596 drive bit, install a NEW tamper-resistant PCV oil separator drain hose bolt (5) and tighten to 10 N.m (89 lb in).
6. Install the PCV oil separator drain hose bracket bolt (4) and tighten to 10 N.m (89 lb in).

Exhaust Gas Recirculation Valve and Cooler Installation

1. Install the exhaust gas recirculation (EGR) cooler bracket (1).
2. Install the EGR cooler bracket bolts (2) and tighten to 50 N.m (37 lb ft).
3. Install the EGR valve and cooler (2).
4. Install the EGR valve and cooler bolts (1) and tighten to 50 N.m (37 lb ft).
5. Install the EGR valve and cooler bolt (3) and tighten to 25 N.m (18 lb ft).
6. Install the EGR valve temperature sensor (1) and tighten to 44 N.m (32 lb ft).
7. Install the intake manifold tube seal (3) and gaskets (4).
8. Install the intake manifold tube (1).
9. Install the intake manifold tube bolts (2) and tighten to 25 N.m (18 lb ft).
10. Install the EGR valve bracket (3).
11. Install the EGR valve bracket bolts (1) and (2) and tighten to 25 N.m (18 lb ft).
12. Install the manifold absolute pressure (MAP) sensor (2).
13. Install the MAP sensor bolt (1) and tighten to 10 N.m (89 lb in).
14. Install the intake heater gasket (1).
15. Install the intake heater (2).
16. Install the throttle body (3).
17. Install the throttle body bolts (4) and tighten to 10 N.m (89 lb in).

Engine Wiring Harness Assembly Installation

1. Install the turbocharger vane position sensor connector bracket (2).
2. Install the turbocharger vane position sensor connector bracket bolt (1) and tighten to 25 N.m (18 lb ft).
3. Install the engine wiring harness bracket (2).
4. Install the engine wiring harness bracket bolt (1) and tighten to 25 N.m (18 lb ft).
5. Install the engine wiring harness bracket (4).
6. Install the engine wiring harness bracket bolts (3) and tighten to 10 N.m (89 lb in).
7. Install the right side glow plugs (1).
8. Install the left side glow plugs (1).
9. Install the glow plug controller bracket (2).
10. Install the glow plug controller bracket bolts (1) and tighten to 25 N.m (18 lb ft).
11. Install the fuel feed return pipe clip (1).
12. Install the fuel feed return pipe clip bolt (2) and tighten to 10 N.m (89 lb in).
13. Install the glow plug controller (2).
14. Install the glow plug controller bolts (1) and tighten to 10 N.m (89 lb in).
15. Install the engine wiring harness (1).
16. Install the left side glow plug connector nuts (1) and tighten to 3 N.m (26 lb in).
17. Connect the left side fuel injector electrical connectors (1).
18. Connect the left side fuel rail fuel pressure sensor electrical connector (1).
19. Connect the glow plug controller electrical connector (3).
20. Connect the fuel pressure sensor electrical connector (2).
21. Connect the fuel temperature sensor electrical connector (1).
22. Connect the EGR valve electrical connector (1).
23. Connect the intake heater electrical connector (1).
24. Connect the throttle body electrical connector (2).
25. Connect the manifold absolute pressure (MAP) sensor electrical connector (1).
26. Connect the turbocharger control solenoid valve electrical connector (1).
27. Install the right side glow plug connector nuts (1) and tighten to 3 N.m (26 lb in).
28. Connect the hydrocarbon injector (HCI) electrical connector (1).
29. Connect the right side fuel injector electrical connectors (1).
30. Connect the exhaust gas recirculation (EGR) valve temperature sensor electrical connector (1).
31. Connect the crankshaft position sensor electrical connector (1).
32. Install the engine wiring harness ground bolt (1) and tighten to 41 N.m (30 lb ft).
33. Install the right side engine wiring harness bolt (1) and tighten to 10 N.m (89 lb in).
34. Install the left side engine wiring harness bolt (1) and tighten to 25 N.m (18 lb ft).
35. Install the left side engine wiring harness bolts (2) and tighten to 10 N.m (89 lb in).

Engine Coolant Thermostat Housing Installation

1. Install the thermostat bypass pipe O-ring seal (1).
2. Install the thermostat bypass pipe (2).
3. Install the thermostat housing studs (3) and tighten to 8 N.m (71 lb in).
4. Install the thermostat housing gaskets (2) and thermostat bypass pipe O-ring seal (6).
5. Install the thermostat housing (4).
6. Install the thermostat housing bolts (5) and nuts (1) and tighten to 25 N.m (18 lb ft).
7. Install the thermostat bypass pipe bolts (7) and tighten to 25 N.m (18 lb ft).
8. Connect the engine coolant temperature sensor (1) and the turbocharger coolant feed hose (2).
9. Install the turbocharger coolant return hose (1).
10. Install the fuel pipe bracket (4).
11. Install the fuel pipe bracket bolts (3) and tighten to 25 N.m (18 lb ft).
12. Install the fuel feed manifold assembly (2).
13. Install the fuel feed manifold assembly bolt (1) and tighten to 25 N.m (18 lb ft).
14. Install the oil fill tube O-ring seal (3).
15. Install the oil fill tube (1).
16. Install the oil fill tube bolts (2) and tighten to 25 N.m (18 lb ft).
17. Install and connect the turbocharger vane position sensor (1).

Generator and Drive Belt Tensioner Bracket Installation

1. Install the generator and drive belt tensioner mounting bracket studs (2) and tighten to 10 N.m (89 lb in).
2. Install the generator and drive belt tensioner mounting bracket (3).
3. Install the generator and drive belt tensioner mounting bracket bolt (4) and nuts (1) and tighten to 50 N.m (37 lb ft).
4. Install the drive belt tensioner (2).
5. Install the drive belt tensioner bolt (1) and tighten to 50 N.m (37 lb ft).
6. Install the upper intake manifold brace (2).
7. Install the upper intake manifold brace bolts (1) and tighten to 25 N.m (18 lb ft).

Power Steering Pump Mounting Bracket Installation

1. Install the power steering pump mounting bracket studs (2) and tighten to 10 N.m (89 lb in).
2. Install the power steering pump mounting bracket (3).
3. Install the power steering pump mounting bracket bolts (4) and nuts (1) and tighten to 50 N.m (37 lb ft).

Fan Pulley Installation

1. Lubricate the camshaft position sensor O-ring with engine oil.
2. Install the camshaft position sensor.
3. Install the camshaft position sensor retaining bolt and tighten to 10 N.m (89 lb in).
4. Install the cooling fan pulley studs (4) and tighten to 20 N.m (15 lb ft).
5. Install the cooling fan pulley spacer (5) and the cooling fan pulley (1).
6. Install the cooling fan pulley bolts (2) and nuts (3).
7. Tighten the cooling fan pulley bolts (1) and nuts (2) in sequence to 50 N.m (37 lb ft).
8. Connect the camshaft position sensor connector.

Engine Removal from Stand

Special Tools

EN 49397 Engine Lift Bracket Set

For equivalent regional tools, refer to Special Tools .

1. Install EN 49397 lift bracket (1) to the right side exhaust manifold.
2. Install EN 49397 lift bracket (2) to the power steering pump mounting bracket.
3. Lift the engine and the engine stand with a suitable hoist.
4. Remove the engine stand from the engine adapter.
5. Lower the engine to the floor. Support the engine with blocks.
6. Remove the engine adapter.

Flywheel Housing Installation

1. Install the oil cooler adapter (3) with gaskets (1) and (4) to the oil cooler.
2. Install the oil cooler adapter to oil cooler bolts (2) and tighten to 25 N.m (18 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 (1) to the cylinder block.
5. Install the flywheel housing bolts (2) and (3).
6. Tighten the flywheel housing bolts (1) and (2) in sequence to 95 N.m (70 lb ft).
7. Install the oil cooler adapter studs (2) and tighten to 8 N.m (71 lb in).
8. Install the oil cooler adapter nuts (1) and tighten to 25 N.m (18 lb ft).
9. Install a new gasket to the turbocharger oil return pipe.
10. Install the turbocharger oil return pipe to flywheel housing studs (2) and tighten to 8 N.m (71 lb in).
11. Install the turbocharger oil return pipe nuts (1) and tighten to 25 N.m (18 lb ft).

Upper Oil Pan Installation

1. Apply a 2-3 mm wide by 0.5-1.5 mm bead of GM P/N 12378521 (Canadian P/N 88901148) sealant to the upper oil pan mating surfaces.
2. Install the upper oil pan to the engine block.
3. Install the wiring harness clips (3).
4. Install the upper oil pan bolts (2) and (4).
5. Tighten the upper oil pan bolts (1) and (2) in sequence to 21 N.m (15 lb ft).
6. Install the two flywheel housing to upper oil pan bolts (1) and tighten to 50 N.m (37 lb ft).
7. Install the oil level indicator tube (1).
8. Install the oil level indicator tube bracket bolt (3) and tighten to 25 N.m (18 lb ft).
9. Install the oil level indicator tube bracket stud (2) and tighten to 10 N.m (18 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 (1).
3. Install the lower oil pan nuts (2) and bolts (3).
4. Tighten the lower oil pan bolts and nuts (1) in sequence to 10 N.m (89 lb in).
5. Connect the oil level sensor (1, 2).

Exhaust Pipe Installation - Left Side

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

Exhaust Pipe Installation - Right Side (LGH)

1. Install the exhaust pipe gaskets (2), exhaust pipe (1), and exhaust pipe bracket (3).
2. Install the exhaust pipe nuts and bolts.
3. Tighten the exhaust pipe nuts (1) and bolts (2-3) in the sequence shown. Tighten the exhaust pipe nuts (1) to 25 N.m (18 lb ft). Tighten the exhaust pipe bolts (2) to 25 N.m (18 lb ft). Tighten the exhaust pipe nuts (3) to 53 N.m (39 lb ft).
4. Install the exhaust gas recirculation (EGR) sensor (1) and tighten to 44 N.m (32 lb ft).
5. Install the exhaust pipe heat shield (1).
6. Install the exhaust pipe heat shield bolts and tighten to 6 N.m (53 lb in).

Exhaust Gas Recirculation Manifold Cooling Feed Pipe Installation

1. Install the exhaust gas recirculation (EGR) manifold cooling feed pipe O-ring seal (3).
2. Install the EGR manifold cooling feed pipe (2).
3. Install the EGR manifold cooling feed pipe bolts (1) and tighten to 25 N.m (18 lb ft).

Exhaust Turbocharger Outlet Pipe Adapter Installation

1. Install the exhaust adapter (2) and exhaust adapter clamp (1) and tighten to 10 N.m (89 lb in).
2. Install the indirect fuel injector (4).
3. Install the indirect fuel injector retainer (3) into the fitting.
4. Install the indirect fuel injector bolts (1) and tighten to 25 N.m (18 lb ft).
5. Install the fuel feed pipe clip bolts (2) and tighten to 25 N.m (18 lb ft).
6. Tighten the indirect fuel injector to exhaust outlet adapter fitting to 45 N.m (33 lb ft).
7. Install the exhaust temperature sensor (1) and tighten to 19 N.m (14 lb ft).
8. Install the NOx sensor (1) and tighten to 45 N.m (33 lb ft).
9. Install the exhaust adapter to right exhaust pipe bracket bolt (1) and tighten to 34 N.m (25 lb ft).
10. Install the exhaust adapter heat shield (2).
11. Install the exhaust adapter heat shield bolts (1) and tighten to 10 N.m (89 lb in).

Crankshaft Rear Oil Seal Installation

Tools Required

J 44642 Crankshaft Rear Oil Seal Installer

1. Place the crankshaft rear oil seal onto the crankshaft.
2. Install the J 44642 crankshaft rear oil seal installer to the crankshaft.
3. Press the crankshaft rear oil seal into position using the J 44642 crankshaft rear oil seal installer. The J 44642 crankshaft rear oil seal installer will bottom out when the seal reaches the proper depth.
4. Remove the J 44642 crankshaft rear oil seal installer.

Engine Flywheel Installation (Automatic Transmission)

Special Tools

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

For equivalent regional tools, refer to Special Tools .

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

Crankshaft Balancer Installation

Special Tools

J 44643 Flywheel Hold Tool

For equivalent regional tools, refer to Special Tools .

1. Install the J 44643 tool (1, 2) to lock the flywheel.
2. Lightly lubricate the crankshaft balancer internal hub with engine oil.
3. Install the crankshaft balancer (3) to the crankshaft.
4. Lightly lubricate the NEW crankshaft balancer bolt (1) with engine oil.
5. Install the NEW crankshaft balancer bolt (1) and washer (2). Tighten the NEW bolt to 100 N.m (74 lb ft)on the first pass. Tighten the NEW bolt an additional 90 degrees.
6. Remove the J 44643 tool.

Starter Installation

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

Engine Prelubing

Special Tools

J 45299 Engine Preluber

For equivalent regional tools, refer to Special Tools .

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

See also:
• Special Tools
• Adhesives, Fluids, Lubricants, and Sealers
• Fastener Caution
• Crankshaft Bearing Selection Specifications
• Engine Mechanical Specifications
• Safety Glasses Warning
• Fastener Tightening Specifications
• Connecting Rod Bearings Selection Specifications
• Valve Clearance Adjustment Specifications
• Cylinder Head Gasket Selection