Engine Controls and Fuel - 6.6l (Lgh) - Repair Instructions Chevrolet Express G3500

Brake Pedal Position Sensor Learn

Note. Brake system does not use a brake switch, stoplight switch or brakelight switch. System uses a Brake Pedal Position Sensor to control these functions.

Brake Pedal Position Sensor Learn is a procedure for the ECM to determine the position of the brake pedal position sensor when the brake pedal is in the released position.

1. An Engine Control Module Replacement
2. A BPP Sensor Replacement
3. Any repair procedure that effects the brake pedal position sensor alignment

1. Install a scan tool.
2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
3. Navigate to the scan tool Brake Pedal Position Sensor Learn command by selecting the following: Module Diagnosis Engine Control Module Configuration/Reset Functions Learn Functions Brake Pedal Position Sensor Learn
4. Ignition ON, Engine OFF, transmission in Park, brake pedal in the fully released position, select Learn.
5. Verify Brake Pedal Position Sensor and Brake Pedal Position Sensor Learned Home Position are within .1 Volts.
6. Select Exit.
7. Perform the body control module (BCM) brake pedal position sensor calibration. Refer to «Brake Pedal Position Sensor Calibration»(/chevrolet/express-g3500/2013-2013/remont/exterior-lights/#lighting-system__brake-pedal-position-sensor-calibration) .

Engine Control Module Replacement

Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM.

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

Scheme 85

1. Using a scan tool, capture the ECM data.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Reposition the master cylinder without disconnecting the brake lines. Refer to «Master Cylinder Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
4. Remove the ECM mounting bolts (1).
5. Release the ECM upper retaining tabs (2).
6. Disconnect the ECM electrical connectors (3).
7. Remove the ECM (4) from the bracket.

Installation Procedure

1. Place the bottom edge of the ECM into the bracket lower retainers.
2. Push the ECM (4) towards the bracket until the upper edge of the ECM snaps into place.
3. Install the ECM mounting bolts (1).
4. Connect the ECM electrical connectors (3).
5. Install the master cylinder. Refer to «Master Cylinder Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
7. If a NEW ECM was installed, program the ECM. Refer to «Control Module References»(/chevrolet/express-g3500/2013-2013/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .
8. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__turbocharger-learn) .
9. Perform the crankshaft position reluctor wheel learn procedure. Refer to «Crankshaft Position Reluctor Wheel Learn»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Circuit/System Description

The engine control module (ECM) monitors the crankshaft position (CKP) sensor signal under specific conditions to calculate errors caused by slight build tolerance variations in the crankshaft, reluctor wheel, CKP sensor, CKP sensor location, and other related components. The calculated error allows the engine control module (ECM) to accurately compensate for reference period variations. The ECM stores the Crankshaft Position Reluctor Wheel Learn values after a Learn procedure has been performed. If the actual crankshaft position variation is not learned in a given time DTC P0315 will set.

The Crankshaft Position Reluctor Wheel Learn feature is used to enable the ECM's quick learn of build tolerance variations. The stored values are cleared and the ECM stores the newly learned variation values after a Crankshaft Position Reluctor Wheel Learn procedure has been successfully performed.

Diagnostic Aids

1. CKP Pos. Reluctor Wheel Learn - Command: ON; clears the ECM's learn variation values. Press the ON button once during a Learn procedure.
2. CKP Zone 1 Variation Learn Status and CKP Zone 2 Variation Learn Status parameters display: Not Learned - until the ECM attempts to calculate the variation value for the respective RPM range. Active - when the ECM is calculating the variation value for the following engine speeds: Zone 1 - 900 to 1,449 RPM Zone 2 - 1,450 to 1,900 RPM Complete - when the ECM has successfully finished calculating the variation value for the respective RPM ranges. Fail - when the ECM has un-successfully finished calculating the variation value for the respective RPM ranges. More than 1 attempt during an ignition cycle may be needed for the ECM to successfully finish calculating the values.
3. A damaged or defective CKP sensor reluctor /exciter ring may prevent the ECM from successfully completing the Crankshaft Position Reluctor Wheel Learn procedure.
4. Debris between the CKP sensor and the CKP sensor reluctor /exciter ring may prevent the ECM from successfully completing the Crankshaft Position Reluctor Wheel Learn procedure.
5. Monitor the Diesel Particulate Filter (DPF) Regeneration Status parameter, it should remain Inactive when the using the scan tool CKP Pos. Reluctor Wheel Learn procedure.
6. Placing the transmission selector in 4th, 5th, or 6th gear may assist in completing the Learn procedure.
7. The engine RPM will increase when the torque converter clutch (TCC) is un-applied or unlocked.

Note. The Crankshaft Position Reluctor Wheel Learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement An ECM replacement An ECM "box swap" with another like vehicle A crankshaft harmonic balancer replacement A crankshaft replacement A flywheel replacement An oil pump drive gear replacement A CKP sensor reluctor /exciter ring replacement A CKP sensor replacement Any engine repairs which disturb the crankshaft to CKP sensor relationship

Note. The Crankshaft Position Reluctor Wheel Learn procedure may have to be performed up to 4 times before the procedure completes successfully. Cycle the ignition to insure the ECM enters a new ignition cycle.

1. Ignition OFF. Verify all vehicle systems are OFF. This may take up to 2 minutes.
2. Ignition ON, engine at idle speed. Observe the DTC information with a scan tool. If a DTC, other than P0300-P0308, P0315, P0263, P0266, P0269, P0272, P0275, P0278, P0281, P0284, or P12B3-P12C1 is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) . If DTC P0315 is set, clear the DTC using a scan tool.
3. Select the CKP Pos. Reluctor Wheel Learn procedure with a scan tool.
4. Use the scan tool to: Command On - CKP Pos. Reluctor Wheel Learn procedure. Command State: On
5. Monitor the following parameters with a scan tool. Verify both parameters display: Not Learned. CKP Zone 2 Variation Learn Status CKP Zone 1 Variation Learn Status If both parameters do not display the indicated status, return to step1.
6. Select a smooth section of roadway to safely perform the following steps.
7. Safely maintain about 2,500 RPM.
8. When traffic conditions permit, release the accelerator pedal. APP SIGNAL parameter equals 0 %.
9. Verify the scan tool CKP Zone 2 Variation Learn Status parameter displays: Active.
10. Verify the scan tool CKP Zone 2 Variation Learn Status parameter displays: Complete. If the CKP Zone 2 Variation Learn Status parameter does not display the indicated status, repeat steps 7 - 10, up to 3 more times.
11. Safely maintain about 1,700 RPM.
12. When traffic conditions permit, release the accelerator pedal. APP SIGNAL parameter equals 0 %.
13. Verify the scan tool CKP Zone 1 Variation Learn Status parameter displays: Active.
14. Verify the following scan tool parameters display: Complete. If the CKP Zone 1 Variation Learn Status parameter does not display the indicated status, repeat steps 11 - 14, up to 3 more times. If both CKP Zone 1 Variation Learn Status AND CKP Zone 2 Variation Learn Status parameters do not display the indicated status after completing steps 7 - 10 and 11 - 14 a total of 4 times, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for DTC P0315 for further diagnosis.
15. Engine idling, transmission in Park or Neutral.
16. If you were directed to perform this procedure because DTC P0315 failed, verify that DTC P0315 ran and passed. If DTC P0315 failed or did not run, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for DTC P0315.
17. Ignition OFF. Verify all vehicle systems are OFF. This may take up to 2 minutes.
18. Perform the «Diagnostic Repair Verification»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-repair-verification) after completing the procedure.

Before Programming a Control Module

Note. DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors service bulletin. Programming a control module at any other time will not permanently correct a customer's concern.

Ensure the following conditions are met before programming a control module

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

High Idle Switch Programming

1. Using the scan tool, select High Idle Speed Configuration
2. Select desired settings
3. Turn OFF the ignition until communication with the ECM is lost, as indicated on the scan tool.
4. Start the vehicle and confirm the new settings by operating the high idle switch.

Description

The engine control module (ECM) has the ability to learn injector timing performance. With the engine at operating temperature and in closed throttle decel mode, the ECM will pulse each injector individually and measure the changes in rotational speed of the crankshaft using the input from the crankshaft position sensor (CPS). The ECM will run this diagnostic under three different fuel rail pressures for each injector. The ECM will adjust the timing of fuel delivered by each injector to obtain the desired RPM increase. The ECM stores the injector timing value required to increase the crankshaft speed by the desired RPM. If the ECM cannot control an increase in RPM for a given injector the appropriate code will set for that injector. The Fuel Injector Correction Reset must be performed anytime a fuel injector is replaced or an ECM is replaced and the values cannot be transferred from the old ECM.

Conditions for Running the Fuel Injector Correction Reset

Ignition ON, engine OFF.

Reset Procedure

1. Ignition ON, engine OFF, perform the Fuel Injector Correction Reset with a scan tool for each fuel injector that was replaced.
2. Clear the DTCs and return to the diagnostic that referred you here.

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

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

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

Note. DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors service bulletin. Programming a control module at any other time will not permanently correct a customers concern.

Ensure the following conditions are met before programming a control module

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

Circuit/System Verification

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

Circuit/System Testing

Note. If the flow rate number is not available in either control module, the numbers will need to be retrieved from each individual injector.

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

Note. The ECM and the GPCM must be allowed to completely power down after programming is complete.

1. Install any components or connectors that have been removed or replaced during diagnosis.
2. Perform any adjustment, programming or setup procedures that are required when a component or module is removed or replaced.
3. Turn ON the ignition, with the engine OFF, and clear the DTCs.
4. Disconnect the scan tool and turn OFF the ignition for 2 minutes.
5. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) and perform the appropriate diagnostic procedure. OR If the repair was symptom related, duplicate the conditions under which the customer concern occurred to verify the repair. If the customer concern reoccurs, return to «Symptoms - Vehicle»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) and perform the appropriate symptom diagnostic.

The Engine Control Module (ECM) monitors the correction values for the energizing time of each cylinder.

A correction value for the energizing time is learned for each cylinder at two different rail pressure operating points. The energizing time of the pilot injection is adapted at two calibrated rail pressure points. The Fuel Injector Timing Learn must be performed anytime an Injector Timing or Injector Exceeded Learning Limit DTC is cleared and is being revaluated.

Conditions for Running the Fuel Injector Timing Learn

1. Ambient air temperature is above -7°C (19°F).
2. Fuel temperature is between 0-80°C (32-176°F).
3. Engine temperature is greater than 70° (158°F).
4. Battery voltage is greater than 10v.
5. Diesel particulate filter (DPF) regeneration is not active.
6. Engine speed is between 950-1850 RPM.
7. Vehicle speed is between 64-113 km/h (40-70 mph).
8. Ambient pressure is above 75 kPa (11 psi).
9. No other DTCs are present.

1. Clear all DTCs using the scan tool.
2. Drive vehicle for 10 minutes to warm engine and exhaust.
3. Operate vehicle in deceleration with no accelerator pedal input following the conditions for running the Fuel Injector Timing Learn.
4. Run 20 deceleration cycles to complete the injection timing learn.
5. When completed return to the diagnostic that referred you here.

A service regeneration of the diesel particulate filter (DPF) is required when the scan tool DPF Accumulation Status parameter displays 30 grams or more of accumulated soot. When commanded, the engine control module (ECM) controls the service regeneration as follows

1. The exhaust system is warmed up for about 8 minutes. Engine speed is slowly increased to 2,000 RPM and then to 2,500 RPM.
2. Once the DPF reaches its calibrated regeneration temperature, the ECM maintains engine speed between 2,000-2,500 RPM for about 20 minutes until regeneration is complete, is cancelled by the technician, or is aborted due to abnormal conditions.
3. The ECM then slowly decreases engine speed to 1600 RPM, then to 800 RPM, and finally to normal idle speed over a 5 minute period. This is done to allow the DPF to cool down.

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

1. DTCs P2463 is the only active DTC.
2. The battery voltage is greater than 10 V.
3. The engine speed is between 500-2,700 RPM.
4. The vehicle speed is 0.
5. The transmission is not in Drive or Reverse
6. The exhaust gas temperature (EGT) sensors 1 is between 20-500°C (68-932°F).
7. The exhaust gas temperature (EGT) sensors 3 is between 20-735°C (68-1,355°F).
8. The engine coolant temperature (ECT) sensor is greater than 70°C (158°F).
9. The fuel temperature is less than 150°C (302°F).
10. The BARO pressure is greater than 40 kPa (5.8 psi)
11. The APP sensor is less than 1 percent.
12. The diesel exhaust fluid temperature is greater than -7°C ( +19°F).
13. The diesel exhaust fluid tank is not empty.
14. The brake pedal and accelerator pedal are in the released position.
15. The transmission is in Park or Neutral.

The DPF Service Regeneration will be terminated if any of the following conditions occur

1. The DPF Service Regeneration is commanded OFF using the scan tool.
2. The scan tool is disconnected from the vehicle.
3. The vehicle is shifted out or Park or Neutral.
4. The brake or accelerator pedal is applied.

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

Service Regeneration Unsuccessful

Reference Information

Description and Operation

Exhaust Aftertreatment System Description

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

DPF Service Regeneration

Note. If you were not referred to this procedure from another diagnostic, DO NOT perform the Service Regeneration. Do not refuel the vehicle during DPF Service Regeneration. The scan tool must remain connected to the data communication link (DCL) during the entire service regeneration procedure. Do not perform the DPF Service Regeneration if the diesel exhaust fluid temperature (DEF) is less than -7°C (+19°F). Fuel level should be greater 15% to ensure a successful regeneration.

1. Ignition ON.
2. Clear all DTCs with a scan tool before proceeding with DPF Service Regeneration.
3. Park the vehicle outside the repair facility and away from any obstacles.
4. With the vehicle in Park, use the throttle to increase the engine speed to 3000 RPM while looking for the speedometer to move slightly (greater than 1 mph). If this signal noise exists, inch the vehicle forward, place in park and repeat until there is no response seen from the speedometer. This will avoid a vehicle speed based interrupt of the service regeneration.
5. Place the transmission in Park and apply the parking brake.
6. Clear the DTCs with a scan tool before commanding a DPF Service Regeneration.
7. Observe the scan tool DPF Regenerations Completed parameter and record the value.
8. Open the hood.
9. Check the following fluid levels before and after this procedure: Reductant Engine oil Engine coolant Power steering Transmission
10. Perform the Ambient Air Temperature Reset with a scan tool if the vehicle has been driven in an outside temperature below -5°C (+23°F).
11. Select the DPF Service Regeneration in the Output Controls menu and follow the instruction on the scan tool.
12. Command the DPF Service Regeneration ON with a scan tool. If the service regeneration failed to start, repair the vehicle for the condition indicated by the scan tool DPF Regen Inhibit Reason parameter. Refer to the Service Regeneration Unsuccessful table.
13. When the service regeneration is complete, the DPF Regeneration Status parameter will display Complete and the DPF Regenerations Completed parameter will increment by 1 from the value previously recorded. If the service regeneration failed to start, repair the vehicle for the condition indicated by the scan tool DPF Regen Inhibit Reason parameter. Refer to the Service Regeneration Unsuccessful table.
14. Allow the engine to cool by idling for an additional 15 minutes. Command the Reductant Injector ON and OFF several times with a scan tool.
15. Clear the DTCs with a scan tool.
16. Ignition OFF for 90 s.

Perform the Diagnostic Repair Verification .

Exhaust Particulate Filter Replacement (LGH-35 Series) , Exhaust Particulate Filter Replacement (LGH) .

Diesel Particulate Filter (DPF) Regeneration Enable

Note. The DPF Regeneration Enable is required when specific service procedures have been performed. Do not perform a DPF Regeneration Enable unless instructed to in the Repair Instruction section of the service procedure. After the system is repair, perform the following to avoid possible damage to the DPF.

1. Ignition ON, clear the DTCs with a scan tool.
2. Select DPF Regeneration Enable with a scan tool.
3. Select ON. The DPF Regeneration Reason parameter should display DLC Override.
4. Exit the Special Function menu. Remove the scan tool.

Scheme 86

Engine Coolant Temperature Sensor Replacement

Scheme 87

Charge Air Temperature Sensor Replacement (Outlet Pipe)

Scheme 88

Charge Air Temperature Sensor Replacement (Turbocharger)

Scheme 89

Mass Airflow Sensor with Intake Air Temperature Sensor Replacement

Humidity Sensor With Intake Air Temperature Sensor 1 Replacement

Note. 8-pin Humidity Sensor is placed in the air stream ahead of the (5 Pin) Mass Air Flow/Intake Air Temperature (IAT sensor 2). IAT sensor 1 is integrated within the humidity sensor.

Scheme 90

Humidity Sensor Replacement

Intake Air Temperature (IAT) Sensor 2 Replacement

Note. Conflicting OE information provides separate IAT sensor 2 replacement procedure. Wiring shows it built into MAF sensor. This may be in error and just a carryover from previous design.

Scheme 91

Intake Air Temperature (IAT) Sensor 2 Replacement

Scheme 92

1. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (2) from the throttle body.
3. Remove the throttle body bolts and throttle body.

1. Position thethrottle body to the intake air heater and install the throttle body bolts and tighten to 20 N.m (15 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the throttle body.
3. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Scheme 93

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Disconnect the engine wiring harness electrical connector (1) from the intake air heater (IAH).
4. Disconnect the engine wiring harness electrical connector (2) from the intake air valve.
5. Remove the nut and the positive battery cable from the IAH.
6. Remove the throttle body assembly. Refer to «Throttle Body Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
7. Remove the IAH and remove and discard the IAH gasket.

1. Position a NEW IAH gasket to the intake manifold tube and position the IAH to the intake manifold tube.
2. Install the throttle body assembly. Refer to «Throttle Body Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) . .
3. Install the positive battery cable and nut to the IAH and tighten to 4 N.m (34 lb in) .
4. Connect the engine wiring harness electrical connector (2) to the intake air valve.
5. Connect the engine wiring harness electrical connector (1) from IAH.
6. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .

Scheme 94

Manifold Absolute Pressure Sensor Replacement

Scheme 95

Nitrogen Oxide Sensor Replacement - Position 1

Scheme 96

Nitrogen Oxide Sensor Replacement - Position 2

Accelerator Pedal Position Sensor Replacement

Note. Brake system does not use a brake switch, stoplight switch or brakelight switch. System uses a Brake Pedal Position Sensor to control these functions.

Removal Procedure

Scheme 97

1. Remove the connector position assurance (CPA) retainer.
2. Disconnect the electrical connector from the accelerator pedal position (APP) sensor.
3. Remove the accelerator pedal bolt (1).
4. Remove the accelerator pedal assembly (1) from the dash panel.

1. Install the accelerator pedal assembly (1) to the dash panel.
2. Install the accelerator pedal bolt (1) and tighten to 33 N.m (24 lb ft) .
3. Connect the electrical connector to the APP sensor.
4. Install the CPA retainer.
5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
7. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.

Metal Collar Quick Connect Fitting Service

Special Tools

1. J 43178 Fuel Line Disconnect Tool
2. J 44581 Fuel Line Disconnect Tool

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the fuel fill cap.
3. Remove the retainers from the fuel feed and return pipe quick connect fittings.
4. Using compressed air, blow any dirt or debris from around the fitting.
5. Using the correct end of J 44581 Fuel Line Disconnect Tool for the size of the fitting. Insert J 44581 Fuel Line Disconnect Tool into the female connector, then push inward in order to release the locking tabs.
6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 Fuel Line Disconnect Tool in order to release the quick connect fittings at the sending unit.
7. Pull the connection apart.
8. Use a clean shop towel in order to wipe off the male end. CAUTION: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.
9. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the fittings together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the connections in order to make sure the connection is secure.
4. Install the retainers to the fuel feed/return pipes.
5. Install the fuel fill cap.
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .

Disconnect Procedure

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Using compressed air, blow any dirt or debris from around the connection.
3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs.
4. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting.
6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction.
7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow.
8. Pull the connection apart.

Connect Procedure

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.
4. Install the fuel fill cap.
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .

Fuel System Priming

1. Prior to priming the engine, ensure that the following has been completed: There is fuel in the fuel tank. The fuel filter has been installed and properly tightened. The fuel lines are properly connected. The fuel filter is cool to the touch. Any dirt or debris has been removed from the fuel filter head and vent valve.
2. Turn the ignition key on for two minutes. The fuel pump will be operating and starting the priming process. Do not start the engine during the first two minutes.
3. After completing the initial prime in step 2, turn the ignition off, then back to start and crank the engine for 15 seconds.
4. If the engine does not start, repeat steps 2 and 3 until the engine starts.
5. If the engine does not run after repeating steps 2 and 3 three times, turn the ignition key OFF for 60 seconds, allowing the electronic control module (ECM) to reset.
6. Repeat the above steps until the engine starts.
7. If the engine runs, but does not run smoothly, increase the engine speed slightly by pressing the accelerator pedal. This will help to force out air through the system.
8. If the engine starts and runs but stalls again, turn the ignition key OFF for 60 seconds to reset the ECM and repeat the steps above.
9. Start the engine and allow it to idle for a few minutes.
10. Check the filter for leaks.

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__water-in-fuel-draining) .
2. Remove the water in fuel sensor. Refer to «Water in Fuel Indicator Sensor Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Unscrew the fuel filter housing (1) and remove the fuel filter.

1. Clean the fuel filter sealing surface.
2. Install the filter.
3. Install the fuel filter housing (1).
4. Install the water in fuel sensor. Refer to «Water in Fuel Indicator Sensor Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
5. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
6. Start the engine and check for leaks.

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__water-in-fuel-draining) .
2. Remove the fuel filter assembly from the bracket and secure out of the way. Refer to «Fuel Filter Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Remove the fuel pump assembly from the bracket and secure out of the way. Refer to «Fuel Pump Replacement (Secondary)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , «Fuel Pump Replacement (Primary)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove the fuel pump and filter bracket fasteners (1) and remove the bracket (2) from the frame.

1. Install the fuel pump and filter bracket (2) to the frame and tighten the fasteners (1) to 25 N.m (18 lb ft).
2. Install the fuel pump assembly to the bracket. Refer to «Fuel Pump Replacement (Secondary)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , «Fuel Pump Replacement (Primary)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Install the fuel filter assembly to the bracket. Refer to «Fuel Filter Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
5. Start the engine and check for leaks.

Scheme 98

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the electrical connector (1).
3. Disconnect the rubber drain hose.
4. Remove the water in fuel indicator sensor (2) and o-ring (3) from the fuel filter (4).

1. Install the water in fuel indicator sensor (2) and tighten 180° after the o-ring seal (3) makes contact with the filter housing (4).
2. Install the rubber drain hose to the sensor.
3. Connect the electrical connector (1).
4. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
5. Start the engine and check for leaks.

1. Remove the diesel fuel strainer bowl (1).
2. Remove the fuel pump (2) pre-filter and o-rings.

1. Clean the strainer bowl (1) sealing surface, the pre-filter and o-rings. Inspect for damage and replace if necessary.
2. Install the fuel pump (2) pre-filter and o-rings.
3. Install the diesel strainer bowl.
4. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
5. Start the engine. If the engine stalls, repeat the above step.
6. Once the engine starts, inspect for fuel leaks.

Water-in-Fuel Draining

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
2. Attach a small piece of hose to the drain cock (1) onto the water-in-fuel sensor.
3. Place an approved fuel-resistant container under the fuel filter (2).
4. Open the drain cock 3 or 4 turns or until the water contaminated fuel seeps from the drain cock.
5. Prime the fuel system until only diesel fuel is visible. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
6. Tighten the drain cock.
7. Remove the container and hose.

Fuel Tank Draining

Special Tools

CH 45004 Fuel Tank Siphon Hose

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the fuel fill cap.
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
4. Insert the CH 45004 hose into the tank.
5. Attach the CH 45004 hose to a hand or air operated pump device.
6. Using a hand or air operated pump drain as much fuel from the tank as possible.

Fuel Tank Draining (Emission Reduction Fluid)

1. Ensure the ignition is OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
3. Using only a Low pressure clean water hose, spray the upper surfaces of the Diesel Exhaust Fluid (DEF) Tank and pump supply module, the injection hose, and the fill hose assembly, to remove all dirt and debris.
4. Using only a Low pressure air wand or air gun, direct air along the same surfaces to both dry and remove any further contaminants.
5. Using a clean white shop towel, carefully dry connections and joints by hand to ensure dryness and cleanliness.
6. Collapse the spring clamp (1) and disconnect the filler hose.
7. Insert the hose from the pump devise into the DEF tank.
8. Using a hand or air operated pump device, drain as much DEF from the tank as possible into an approved container and dispose of propertly.
9. Align the DEF fill hose to the DEF tank and install the hose into position. Secure the spring clamp (1) into position on the hose.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining) , «Fuel Tank Draining (Emission Reduction Fluid)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining-emission-reduction-fluid) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
4. Disconnect the fuel fill hose (1) from the fuel tank.
5. Disconnect the fuel fill vent hose (2) from the fuel filler neck and cut the tie straps.
6. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
7. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__metal-collar-quick-connect-fitting-service) .
8. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__metal-collar-quick-connect-fitting-service) .
9. Disconnect the auxiliary heater fuel feed pipe.
10. With the aid of an assistant, support the fuel tank.
11. Remove the attaching bolts (4) from the fuel tank strap. Discard attaching bolts.
12. Remove the fuel tank straps (3).
13. Carefully lower the fuel tank.
14. Disconnect the fuel sender harness connector.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-sender-assembly-replacement) .
18. On all models, remove the fuel fill hose from the fuel tank.
19. Remove the fuel tank from the fuel tank shield.

1. Install the fuel tank insulators (3).
2. Install the fuel tank into the fuel tank shield.
3. Install the fuel fill hose to the fuel tank. Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
4. Install the (EVAP) hoses to the fuel tank and (EVAP) canister.
5. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-sender-assembly-replacement) .
6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the fuel sender harness connector.
9. Raise the tank fully.
10. Install the fuel tank straps (3).
11. Install the new attaching bolts (4) to the fuel tank straps and tighten to 52 N.m (39 lb ft).
12. Connect the auxiliary heater fuel feed pipe.
13. Connect the rear fuel feed pipe to the chassis fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__metal-collar-quick-connect-fitting-service) .
14. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__metal-collar-quick-connect-fitting-service) .
15. Connect the fuel fill vent hose (2) to the filler neck.
16. Connect the fuel fill hose (1) to the fuel fill pipe and tighten to 2.75 N.m (24 lb in).
17. Lower the vehicle.
18. Refill the fuel tank.
19. Tighten the fuel filler cap.
20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system)
21. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .

1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-sender-assembly-replacement) .
2. Disconnect the fuel level sensor electrical connector (1).
3. Remove the sensor retaining clip (3).
4. Squeeze the locking tangs (2) and remove the fuel level sensor.

1. Install the fuel level sensor.
2. Install the sensor retaining clip (3).
3. Connect the sensor electrical connector (1).
4. Install the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-sender-assembly-replacement) .

Scheme 99

Fuel Pump Replacement (Secondary)

1. Relieve the fuel pressure.
2. Disconnect the electrical connectors from the fuel pump assembly.
3. Disconnect the fuel lines (2) from the fuel pump assembly (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove fuel pump assembly fasteners (1) and remove the fuel pump assembly from the bracket.

1. Install the fuel pump assembly (3) to the bracket and tighten the fasteners (1) to 20 N.m (15 lb ft).
2. Connect the fuel lines (2) to the fuel pump assembly (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Connect the electrical connectors.
4. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
5. Start the vehicle and inspect for leaks.

Fuel Tank Fuel Pump Module Replacement

Special Tools

CH-45722 Fuel Tank Sender Wrench

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Disconnect the fuel feed and return pipes (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Using the CH-45722 wrench , remove the cam lock ring (1) by turning counter-clockwise.
4. Remove the fuel sender assembly (1) and O-ring (2).

1. Install the fuel sender assembly (1) and O-ring (2).
2. Using the CH-45722 wrench , install the cam lock ring (1) by turning clockwise.
3. Connect the fuel feed and return pipes (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Fuel Sender Assembly Replacement

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Use the J 45722 wrench and a long breaker-bar in order to unlock the fuel sender lock ring. Turn counter-clockwise.
3. Remove the sending unit and seal. Discard the seal.
4. Clean the sending unit sealing surfaces.
5. If replacing the sender assembly, remove the fuel level sensor. Refer to «Fuel Level Sensor Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the fuel level sensor, if necessary. Refer to «Fuel Level Sensor Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Install the sending unit and a NEW seal.
3. Use the J 45722 wrench in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
4. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
4. Disconnect the fuel lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__metal-collar-quick-connect-fitting-service)
5. Remove the fuel line bracket fastener.
6. Remove the fasteners (1).
7. Compress the spring clamps (2) and disconnect the hoses.
8. Remove the fuel feed pipe (3).

1. Install the fuel feed pipe (3).
2. Compress the spring clamps (2) and connect the hoses.
3. Install the fasteners (1) and tighten to 25 N.m (18 lb ft).
4. Install the fuel line bracket fastener and tighten to 25 N.m (18 lb ft).
5. Connect the fuel feed and return pipes.
6. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
7. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
8. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
9. Start the engine. If the engine does not start, repeat the above step.
10. Inspect the fuel system for fuel leaks.
11. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
4. Disconnect the fuel lines. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__metal-collar-quick-connect-fitting-service)
5. Remove the fuel line bracket fastener.
6. Remove the fasteners (1).
7. Compress the spring clamps (2) and disconnect the hoses.
8. Remove the fuel return pipe (3).

1. Install the fuel return pipe (3).
2. Compress the spring clamps (2) and install the hoses.
3. Install the fasteners (1) and tighten to 25 N.m (18 lb ft).
4. Install the fuel line bracket fastener and tighten to 25 N.m (18 lb ft).
5. Connect the fuel feed and return pipes.
6. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
7. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
8. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
9. Start the engine. If the engine does not start, repeat the above step.
10. Inspect the fuel system for fuel leaks.
11. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Remove the charge air inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove the generator. Refer to «Generator Replacement (Diesel)»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Remove the A/C compressor bolts and reposition the A/C compressor.
6. Disengage the fuel return line by pulling upward on the cylindrical locking sleeve (1).
7. Remove the fuel return line (2) from the fuel injector (3).
8. Repeat steps 6-7 for the remaining injectors.
9. Remove the fuel return pipe bracket bolt from left valve cover.
10. Disconnect the fuel return hose vacuum line.
11. Remove the fuel return hose clip from back of A/C compressor bracket.
12. Disconnect the fuel return hose from the fuel feed pipe.
13. Remove the return hose from fuel return clip.
14. Remove the fuel return hose vacuum valve from bracket.
15. Remove the fuel injector fuel return line assembly (1).

1. Install the fuel injector fuel return line assembly (1).
2. Inspect the O-rings (1) for damage. Replace if necessary.
3. Inspect the fuel return line locking tabs (2) for damage. Replace the fuel return line assembly if necessary.
4. With the cylindrical locking sleeve (3) released in the upward position, install the fuel return line to the fuel injector.
5. Press down on the locking sleeve (3) to secure the connection.
6. Repeat steps 2-5 for the remaining injectors.
7. Install the fuel return hose vacuum valve to bracket.
8. Install the return hose to fuel return hose clip.
9. Connect the fuel return hose to fuel feed pipe.
10. Install the fuel return hose clip to back of A/C compressor bracket.
11. Connect the fuel return hose vacuum line.
12. Install the fuel return pipe bracket bolt to left valve cover.
13. Install the A/C compressor and bolts.
14. Install the generator. Refer to «Generator Replacement (Diesel)»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
15. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
16. Install the charge air inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
17. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Remove the exhaust gas recirculation (EGR) cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the indirect fuel injector. Refer to «Indirect Fuel Injector Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__indirect-fuel-injector-replacement) .
3. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
4. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
5. Remove the fuel pipe bracket fasteners (1) and fuel injector pipes (2).

1. Install the fuel injector pipes (2). Tighten the fittings to 30 N.m (22 lb ft).
2. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
3. Install the fuel pipe bracket fasteners (1) and tighten to 10 N.m (89 lb in).
4. Remove the indirect fuel injector. Refer to «Indirect Fuel Injector Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__indirect-fuel-injector-replacement) .
5. Remove the EGR cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Inspect the fuel system for fuel leaks.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. If equipped, remove the auxiliary generator. Refer to «Auxiliary Generator Replacement»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the glow plug module bracket. Refer to «Glow Plug Control Module Bracket Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove the positive crankcase ventilation (PCV) oil separator. Refer to «Positive Crankcase Ventilation Oil Separator Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
5. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
6. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
7. Remove the fuel pipe bracket fasteners (1) and pipes (2).

1. Install the fuel injector pipes (2). Tighten the fittings to 30 N.m (22 lb ft).
2. Install the fuel pipe bracket fasteners (1) and tighten to 10 N.m (89 lb in).
3. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
4. Install the positive PCV oil separator. Refer to «Positive Crankcase Ventilation Oil Separator Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
5. Install the glow plug module bracket. Refer to «Glow Plug Control Module Bracket Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
6. Install the auxiliary generator. Refer to «Auxiliary Generator Replacement»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
7. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
8. Start the engine. If the engine stalls, repeat the above step.
9. Inspect the fuel system for fuel leaks.
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Remove the high pressure fuel pipe fastener (1).
2. Remove the high pressure fuel pipe fitting (2).
3. Remove the turbo charger assembly. Refer to «Turbocharger Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
4. Remove the high pressure fuel pipe fasteners (1).
5. Remove the high pressure fuel pipe fitting (2).
6. Remove the high pressure fuel pipe (3).

1. Install the high pressure fuel pipe fitting (2) and tighten to 30 N.m (22 lb ft).
2. Install the high pressure fuel pipe fasteners (1) and tighten to 10 N.m (89 lb in).
3. Install the high pressure fuel pipe fitting (2) and tighten to 30 N.m (22 lb ft).
4. Install the high pressure fuel fastener (1) and tighten to 10 N.m (89 lb in).
5. Install the turbo charger assembly. Refer to «Turbocharger Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
6. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
7. Start the engine. If the engine does not start, repeat the above step.
8. Inspect the fuel system for leaks.

1. Remove the high pressure fuel pipe fastener (1).
2. Remove the high pressure fuel pipe fitting (2).
3. Remove the turbo charger assembly. Refer to «Turbocharger Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
4. Remove the high pressure fuel pipe fitting (1).
5. Remove the high pressure fuel pipes (2) as an assembly.

1. Install the high pressure fuel pipe fitting (1) and tighten to 38 N.m (28 lb ft).
2. Install the high pressure fuel pipe fitting (2) and tighten to 30 N.m (22 lb ft).
3. Install the high pressure fuel fastener (1) and tighten to 10 N.m (89 lb in).
4. Install the turbo charger assembly. Refer to «Turbocharger Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
5. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
6. Start the engine. If the engine does not start, repeat the above step.
7. Inspect the fuel system for leaks.

1. Drain the fuel below the fuel fill neck. Refer to «Fuel Tank Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining) , «Fuel Tank Draining (Emission Reduction Fluid)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining-emission-reduction-fluid) .
2. Remove the filler housing fasteners (1).
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
4. Remove the filler hose ground fastener (1).
5. Loosen the bottom filler hose clamp (1).
6. Disconnect the vent tube (2) from the fuel sender. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
7. Remove the fuel tank filler hose (3).

1. Install the fuel tank filler hose (3).
2. Connect the vent tube (2) to the fuel sender. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Tighten the bottom filler pipe hose clamp (1) to 6 N.m(53 lb in).
4. Tighten the filler hose ground fastener (1) to 10 N.m(89 lb in).
5. Tighten the filler housing fasteners (1) to 10 N.m (89 lb in).
6. Fill the fuel to the previous level.

Scheme 100

Engine Fuel Vacuum Switch Replacement

Fuel System Cleaning

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

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

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

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

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

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

Remove and inspect the fuel filter element.

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

Cleaning Water from the Fuel System

1. Disconnect the negative battery. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-sender-assembly-replacement) .
3. Inspect the fuel tank and the fuel sender for rust, fungi or bacteria. If there is rust, replace the rusted components.
4. Clean the inside of the fuel tank and the fuel sender with hot water.
5. Use compressed air in order to dry the fuel tank and the fuel sender.
6. Disconnect the ends of the following lines: The fuel filter inlet line (both ends) The transfer pump pressure line and suction line (if applicable) The fuel filter outlet line (both ends) The fuel filter drain The fuel return line (both ends)
7. Inspect each of the pipes and lines.
8. Replace any rusted pipes.
9. Clean the inside of the fuel filter housing.
10. Dry the fuel filter housing with compressed air.
11. Dry the inside of each line with low pressure air.
12. Disconnect the crankshaft position (CKP) sensor. Refer to «Crankshaft Position Sensor Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
13. Install a new fuel filter. Refer to «Fuel Filter Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
14. Install the sending unit. Refer to «Fuel Sender Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-sender-assembly-replacement) .
15. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
16. Reconnect the following lines: The fuel filter inlet line The fuel filter outlet line The transfer pump pressure and suction (both ends) lines The fuel return line (tank end)
17. Connect the batteries.
18. Install a hose on the fuel return line near the glow plug relay, and insert other end into a 7.6 liters (2 gallon) metal container.
19. Turn ignition on with the engine OFF. Allow the fuel pump to run until the cycle ends or until 3.8 liters (1 gallon) of fuel has passed into the container.
20. Turn the ignition OFF.
21. Connect the fuel return line.
22. Clean any fuel spillage from the engine.
23. Reconnect the CKP sensor.
24. Start and run the engine.
25. Stop the engine.
26. Check for oil leaks.
27. Fill the fuel tank and add a biocide, if needed.

Cleaning Gasoline from the Fuel System

1. Drain the fuel tank.
2. Fill the fuel tank to 1/4 full.
3. Disconnect the CKP sensor. Refer to «Crankshaft Position Sensor Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Install a hose on the fuel return line near the glow plug relay, and insert the other end into a 7.6 liters (2 gallon) metal container.
5. Turn the ignition ON with the engine OFF. Allow the fuel pump to run until the cycle ends or until 3.8 liters (1 gallon) of fuel has passed into the container.
6. Reconnect the fuel return line.
7. Clean any fuel spillage from the engine.
8. Reconnect the CKP sensor.
9. Attempt to start and run the engine for 15 minutes. If the engine does not start, cycle the ignition and allow the fuel pump to run until the cycle ends.
10. Start the engine.
11. Stop the engine.
12. Check for fuel leaks.
13. Clear the engine of any diagnostic trouble codes (DTCs).

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Remove the exhaust gas recirculation valve cooler assembly. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the right fuel injector feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Right Side»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove the fuel high pressure pipes - pump to rail. Refer to «Fuel High Pressure Pipe Replacement - Pump to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
5. Remove the fuel high pressure pipes - rail to rail. Refer to «Fuel High Pressure Pipe Replacement - Rail to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
6. Disconnect the high pressure fuel pipes (1).
7. Remove the fuel rail fasteners (1) and fuel injection fuel rail assembly (2).

1. Position the fuel injection fuel rail assembly (2) and install the fuel rail fasteners (1). Tighten to 25 N.m (18 lb ft)
2. Install the fuel rail feed pipe fittings (1) and tighten to 30 N.m (22 lb ft).
3. Install the fuel high pressure pipes - rail to rail. Refer to «Fuel High Pressure Pipe Replacement - Rail to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Install the fuel high pressure pipes - pump to rail. Refer to «Fuel High Pressure Pipe Replacement - Pump to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
5. Install the right fuel injector feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Right Side»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
6. Install the exhaust gas recirculation valve cooler assembly. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
8. Start the engine. If the engine does not start, repeat the above step.
9. Inspect the fuel system for leaks.
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Remove the air conditioning (A/C) compressor. Refer to «Air Conditioning Compressor Replacement (6.6L)»(/chevrolet/express-g3500/2013-2013/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the left fuel injector feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Left Side»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove the fuel high pressure pipes - rail to rail. Refer to «Fuel High Pressure Pipe Replacement - Rail to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
5. Disconnect the fuel pressure relief valve electrical connector (1).
6. Remove the high pressure fuel pipe (2).
7. Collapse the spring clamp and disconnect the fuel return hose (1).
8. Disconnect the fuel pressure sensor electrical connector (1).
9. Remove the fuel rail heat shield fasteners (1).
10. Remove the fuel injection rail fasteners (1).
11. Remove the heat shield (2) and fuel injection fuel rail assembly (3).

1. Install the fuel injection fuel rail assembly (3) and heat shield (2).
2. Install the fuel injection rail fasteners (1) and tighten to 25 N.m(18 lb ft).
3. Install the fuel rail heat shield fasteners (1) and tighten to 25 N.m(18 lb ft).
4. Connect the fuel pressure sensor electrical connector (1).
5. Collapse the spring clamp, and connect the fuel return hose (1).
6. Connector the fuel pressure relief valve electrical connector (1).
7. Install the fuel high pressure pipes - rail to rail. Refer to «Fuel High Pressure Pipe Replacement - Rail to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
8. Install the high pressure fuel pipe (2) and tighten to 30 N.m(22 lb ft).
9. Install the left fuel injector feed pipes. Refer to «Fuel Injection Fuel Feed Pipe Replacement - Left Side»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
10. Install the A/C compressor. Refer to «Air Conditioning Compressor Replacement (6.6L)»(/chevrolet/express-g3500/2013-2013/remont/manual-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
12. Start the engine. If the engine does not start, repeat the above step.
13. Inspect the fuel system for fuel leaks.
14. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

Scheme 101

Fuel Pressure Regulator Replacement

Scheme 102

Fuel Pressure Relief Valve Replacement (Fuel Pressure Regulator Valve 2)

1. Remove the center intake manifold. Refer to «Center Intake Manifold Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
2. Remove the high pressure fuel pipes from the fuel injection pump. Refer to «Fuel High Pressure Pipe Replacement - Rail to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , and «Fuel High Pressure Pipe Replacement - Pump to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Disconnect the electrical connectors (1).
4. Collapse the hose clamps and remove the fuel return and fuel feed hoses (2).
5. Remove the engine cooling crossover housing «Thermostat Housing Crossover Replacement (LGH)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Remove the camshaft gear access hole plug (1).
7. Rotate the crankshaft until the fuel injection pump gear timing marks are aligned with camshaft gear timing marks.
8. Remove the fuel injection pump bolts (1) and (2).
9. Remove the turbocharger cooler return pipe bracket (3).
10. Remove the fuel injection pump (4).
11. Remove the fuel pressure regulator and inspect for metal debris on the end of the regulator tip.

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).
6. Install the camshaft gear access hole plug (1) and tighten to 75 N.m (55 lb ft).
7. Connect the electrical connectors (1).
8. Collapse the hose clamps and install the fuel return and fuel feed hoses (2).
9. Install the engine cooling crossover housing «Thermostat Housing Crossover Replacement (LGH)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Install the high pressure fuel pipes from the fuel injection pump. Refer to «Fuel High Pressure Pipe Replacement - Rail to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , and «Fuel High Pressure Pipe Replacement - Pump to Rail»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
11. Install the center intake manifold. Refer to «Center Intake Manifold Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .

Fuel Injector Replacement (Left Side)

Special Tools

1. EN-47909 Injector Bore and Sleeve Cleaning Kit
2. EN-49774 Fuel Injector Puller

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

Scheme 103

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Diesel)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. If equipped, remove the auxiliary generator. Refer to «Auxiliary Generator Replacement»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the glow plug module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Remove the injector/glow plug wire harness retaining bolt at lower upper valve cover.
5. Disconnect the left engine wiring harness connector.
6. Remove the engine wiring harness bracket fasteners (1) and reposition the wiring harness.
7. Disconnect the fuel injector electrical connectors (1).
8. Disconnect and reposition the fuel return pipes (1).
9. Remove the fuel pipe bracket fasteners (1) and fuel injector pipes (2).
10. Remove the fuel injector bracket bolts (1).
11. Install EN-49774 puller into the bolt hole in the fuel injector bracket.
12. Install a flare nut wrench onto EN 49774 puller , and work the tool outward until the injector releases from its seat.
13. Remove the EN-49774 puller.
14. Remove the fuel injectors (1) with brackets (2).
15. Remove and discard the copper washer from the fuel injector bore.
16. Remove and discard the fuel injector O-ring from the injector.

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 re-installation.
2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat.
3. Replace the injector if any damage is found.
4. Clean the fuel injector high pressure line.
5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found.

Injector Bore Cleaning

1. Install the EN-47909-2 brush to the EN-47909-1 handle.
2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole.
3. Using compressed air, evacuate any debris from the injector bore.
4. Remove the radial brush from the handle assembly.
5. Install the EN-47909-3 brush to the EN-47909-1 handle.
6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore.
7. Using compressed air, evacuate any debris from the injector bore.
8. Lightly dampen EN-47909-20 swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore.
9. Inspect the injector bore for any deposits and repeat brushing if necessary.
10. If necessary, crank the engine in order to expel any solvent before starting the engine. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , and/or «Glow Plug Replacement - Bank 2»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) . Disable the fuel system. Disconnect the crankshaft position (CKP) sensor electrical connector. Crank the engine in order to expel any excessive solvent. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris. Connect the CKP sensor electrical connector. Enable the fuel system. Reinstall the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , and/or «Glow Plug Replacement - Bank 2»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

1. Install a NEW copper washer to the fuel injector bore.
2. Install a NEW fuel injector O-ring to the injector.
3. Install the fuel injectors (1) with brackets (2).
4. Install the fuel injector bracket fasteners (1) and tighten to 30 (22 lb ft).
5. Install the left fuel injector pipes (2) and tighten to 30 (22 lb ft).
6. Install the fuel pipe bracket fasteners (1) and tighten to 10 (89 lb in).
7. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
8. Reposition and connect and the fuel return pipes (1).
9. Connect the fuel injector electrical connectors (1).
10. Position the engine wiring harness, and install the engine wiring harness bracket fasteners (1) and tighten to 21 (15 lb ft).
11. Install the glow plug module and bracket. Refer to «Glow Plug Control Module Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
12. If equipped, install the auxiliary generator. Refer to «Auxiliary Generator Replacement»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
13. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Diesel)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
14. If the fuel injectors were replaced, refer to «Fuel Injector Flow Rate Programming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
15. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
16. Start the engine. If the engine stalls, repeat the above step.
17. Once the engine starts, inspect for fuel leaks.
18. If any or all fuel injectors were replaced, perform the fuel injector correction reset. Refer to «Fuel Injector Correction Reset»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Fuel Injector Replacement (Right Side)

Special Tools

1. EN-47909 Injector Bore and Sleeve Cleaning Kit
2. EN-49774 Fuel Injector Puller

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Remove the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Diesel)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the exhaust gas recirculation bracket. Refer to «Exhaust Gas Recirculation Valve Bracket Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Disconnect the fuel injector electrical connectors (1).
4. Disconnect and reposition the fuel return pipes (1).
5. Remove the fuel pipe bracket fasteners (1) and fuel injector pipes (2).
6. Remove the fuel injector bracket bolts (1).
7. Install EN-49774 puller into the bolt hole in the fuel injector bracket.
8. Install a flare nut wrench onto EN-49774 puller , and work the tool outward until the injector releases from its seat.
9. Remove the EN-49774 puller.
10. Remove the fuel injectors (1) with brackets (2).
11. Remove and discard the copper washer from the fuel injector bore.
12. Remove and discard the fuel injector O-ring from the injector.

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

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

1. Install the EN-47909-2 brush to the EN-47909-1 handle.
2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole.
3. Using compressed air, evacuate any debris from the injector bore.
4. Remove the radial brush from the handle assembly.
5. Install the EN-47909-3 brush to the EN-47909-1 handle.
6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore.
7. Using compressed air, evacuate any debris from the injector bore.
8. Lightly dampen EN-47909-20 swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore.
9. Inspect the injector bore for any deposits and repeat brushing if necessary.
10. If necessary, crank the engine in order to expel any solvent before starting the engine. Remove the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , and/or «Glow Plug Replacement - Bank 2»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) . Disable the fuel system. Disconnect the crankshaft position (CKP) sensor electrical connector. Crank the engine in order to expel any excessive solvent. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris. Connect the CKP sensor electrical connector. Enable the fuel system. Reinstall the glow plugs. Refer to «Glow Plug Replacement - Bank 1»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) , and/or «Glow Plug Replacement - Bank 2»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

1. Install a NEW copper washer to the fuel injector bore.
2. Install a NEW fuel injector O-ring to the injector.
3. Install the fuel injectors (1) with brackets (2).
4. Install the fuel injector bracket fasteners (1) and tighten to 30 (22 lb ft).
5. Install the left fuel injector pipes (2) and tighten to 30 (22 lb ft).
6. Install the fuel pipe bracket fasteners (1) and tighten to 10 (89 lb in).
7. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
8. Reposition and connect and the fuel return pipes (1).
9. Position the engine wiring harness, and install the engine wiring harness bracket fasteners (1) and tighten to 21 (15 lb ft).
10. Install the exhaust gas recirculation bracket. Refer to «Exhaust Gas Recirculation Valve Bracket Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
11. Install the upper fan shroud. Refer to «Engine Coolant Fan Upper Shroud Replacement (Diesel)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
12. If the fuel injectors were replaced, refer to «Fuel Injector Flow Rate Programming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
13. Prime the fuel system. Refer to «Fuel System Priming»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-system-priming) .
14. Start the engine. If the engine stalls, repeat the above step.
15. Once the engine starts, inspect for fuel leaks.
16. If any or all fuel injectors were replaced, perform the fuel injector correction reset. Refer to «Fuel Injector Correction Reset»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Scheme 104

Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement

Indirect Fuel Injector Replacement

Special Tools

CH 49736 Hydrocarbon Injector Quick Connect Release Tool

For equivalent regional tools, refer to Special Tools .

Scheme 105

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Remove the indirect fuel injector fasteners (1) and (2).
3. Remove the indirect injector fitting from the turbocharger exhaust pipe.
4. Relieve the fuel pressure.
5. Remove the indirect fuel injector line retainer from the fitting.
6. Remove the indirect fuel injector line (1) using the CH 49736 tool.
7. Remove the injector (2).

1. Install the indirect fuel injector line retainer to the fitting.
2. Install the indirect fuel injector (2) and tighten the fitting to 30 N.m (22 lb ft).
3. Install the indirect fuel injector fasteners (1) and (2) to 25 N.m (18 lb ft).
4. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
5. Perform the Diesel Particulate Filter Regeneration. Refer to «Diesel Particulate Filter (DPF) Regeneration Enable»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__diesel-particulate-filter-dpf-regeneration-enable) .

Scheme 106

Fuel Temperature Sensor Replacement (Fuel Return Rail)

Scheme 107

Fuel Temperature Sensor Replacement (Injection Pump)

Scheme 108

Glow Plug Control Module Bracket Replacement

Scheme 109

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. If necessary, remove the left front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
4. Remove the wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g3500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Remove the glow plug harness nut(s).
6. Remove the harness from the glow plug(s).
7. Remove the glow plug(s).

1. Install the glow plug(s) and tighten to 18 N.m (13 lb ft).
2. Install the harness to the glow plug(s).
3. Install the glow plug harness nut(s) and tighten to 1.7 N.m (15 lb in).
4. Install the left front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
6. Install the wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g3500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. If necessary, remove the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
4. Remove the wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g3500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Remove the glow plug harness nut(s).
6. Remove the harness from the glow plug(s).
7. Remove the glow plug(s).

1. Install the glow plug(s) and tighten to 18 N.m (13 lb ft).
2. Install the harness to the glow plug(s).
3. Install the glow plug harness nut(s) and tighten to 1.7 N.m (15 lb in).
4. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g3500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
5. Install the wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g3500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
7. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

Scheme 110

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
3. Disconnect the engine wiring harness electrical connector (1) from the glow plug control module.
4. Disconnect the positive battery cable (1) from the glow plug control module.
5. Remove the glow plug control module bolts (1).
6. Remove the glow plug control module (2).

1. Position the glow plug control module (2).
2. Install the glow plug control module bolts (1) and tighten to 10 N.m (89 lb in).
3. Connect the positive battery cable (1) to the glow plug control module.
4. Connect the engine wiring harness electrical connector (1) to the glow plug control module.
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
6. If a NEW glow plug control module was installed, program the module. Refer to «Control Module References»(/chevrolet/express-g3500/2013-2013/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .
7. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

Cleaning Procedure

1. Ensure the ignition is OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
3. Using only a Low pressure clean water hose, spray the upper surfaces of the Diesel Exhaust Fluid (DEF) Tank (1) and pump supply module, the injection hose, and the fill hose assembly, to remove all dirt and debris.
4. Using only a low pressure air wand or air gun, direct air along the same surfaces to both dry and remove any further contaminants.
5. Using a clean white shop towel, carefully dry connections and joints by hand to ensure dryness and cleanliness.

1. Drain the emission reduction fluid tank. Refer to «Fuel Tank Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining) , «Fuel Tank Draining (Emission Reduction Fluid)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining-emission-reduction-fluid) .
2. Remove the DEF tank. Refer to «Emission Reduction Fluid Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Scheme 111

1. Remove the DEF supply pump module insulators.
2. Note the routing of the DEF wiring jumper harness
3. Disconnect the DEF wiring jumper harness connectors from the pump (1), pressure sensor (2), and reverting valve (3).
4. Remove the 3 DEF supply pump module retaining bolts (1).
5. Carefully lift the DEF supply pump module (2) to remove from the reservoir cover.
6. Carefully remove & discard the supply pump to reservoir cover o-ring seals (1). The seals will typically remain in the reservoir cover, but may be on the underside of the supply pump.
7. Wipe away any dried DEF crystallization residue from the reservoir cover supply pump ports (2).

1. Carefully install the new supply pump to reservoir cover o-ring seals. Position the smaller o-ring seal (1) over the port on the underside of the supply pump, and position the larger o-ring seal (2) into the port on the reservoir cover.
2. Position the supply pump module (2) onto the reservoir cover and carefully press down into place.
3. Install the 3 supply pump module retaining bolts (1), and tighten the bolts to 5 N.m (3.7 lb in) .
4. Connect the DEF wiring jumper harness connectors to the pump (1), pressure sensor (2), and reverting valve (3).
5. Install the DEF supply pump module insulators.
6. Install the DEF tank. Refer to «Emission Reduction Fluid Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
7. Fill the DEF tank with approved DEF fluid.
8. With system operational, inspect for DEF fluid leaks.

Scheme 112

Emission Reduction Fluid Injector Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information)
2. Disconnect the urea pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions)
3. Disconnect the electrical connector (2).
4. Release the plastic retainers (1).
5. Release the plastic retainers (1).
6. Release the plastic retainers (1).
7. Disconnect the urea pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions)

1. Connect the urea pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions)
2. Fasten the plastic retainers (1).
3. Fasten the plastic retainers (1).
4. Connect the electrical connector (2).
5. Connect the urea pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the emission reduction fluid tank opening filler fasteners (1).
3. Remove the emission reduction fluid tank opening filler clamp (1).
4. Remove the emission reduction fluid tank opening filler quick disconnect (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
5. Remove the emission reduction fluid tank opening filler (3).

1. Install the emission reduction fluid tank opening filler (3).
2. Install the emission reduction fluid tank opening filler quick disconnect (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Install the emission reduction fluid tank opening filler clamp (1).
4. Install the emission reduction fluid tank opening filler fasteners (1) and tighten to 10 N.m 89 lb in.
5. Lower the vehicle.

Scheme 113

Level and Temperature Emission Reduction Fluid Tank Module Replacement

Emission Reduction Fluid Tank Reservoir Replacement

Special Tools

CH-38879-B Fuel Pump Module Wrench

1. Ensure the ignition is OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
3. Using only a Low pressure clean water hose, spray the upper surfaces of the Diesel Exhaust Fluid (DEF) Tank and pump supply module, the injection hose, and the fill hose assembly, to remove all dirt and debris.
4. Using only a Low pressure air wand or air gun, direct air along the same surfaces to both dry and remove any further contaminants.
5. Using a clean white shop towel, carefully dry connections and joints by hand to ensure dryness and cleanliness.

1. Drain the emission reduction fluid tank. Refer to «Fuel Tank Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining) , «Fuel Tank Draining (Emission Reduction Fluid)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining-emission-reduction-fluid) .
2. Remove the DEF tank. Refer to «Emission Reduction Fluid Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Place the DEF tank assembly in a suitable, clean work area.
4. Remove the DEF tank supply pump module. Refer to «Emission Reduction Fluid Supply Pump Module Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Disassembly Procedure

1. Disconnect the DEF wiring jumper harness connectors from the control module assembly (1), and from the reservoir heater connector (2).
2. Release the jumper harness retaining clips from the supply module lock ring (2). Release the clip retaining tab (1) and slide the clip upward to remove.
3. Remove the jumper harness.
4. Release the reservoir heater connector (1) from the retainer on the DEF tank. Carefully depress the lock tab (2) of the tank retainer, while sliding the connector forward.
5. Release the control module assembly (1) from the retainer on the DEF tank. Carefully depress the lock tab (2) on the underside of the control module, while sliding the module sideways away from the supply pump.
6. Carefully remove & discard the supply pump to reservoir cover o-ring seals (1). The seals will typically remain in the reservoir cover, but may be on the underside of the supply pump.
7. Wipe away any dried DEF crystallization residue from the reservoir cover supply pump.
8. Rotate the reservoir vent (1) inward.
9. Position the CH-38879-B Fuel Pump Module Wrench (3), DEF supply pump module wrench, onto the supply module lock ring (4). Ensure the posts of the tool are positioned to fit securely onto opposing ribs of the lock ring.
10. Plug the reservoir cover to supply pump ports (1,2) to protect from dirt & debris.
11. Using a breaker bar attached to CH-38879-B Fuel Pump Module Wrench loosen the lock ring. Reposition CH-38879-B Fuel Pump Module Wrench as necessary to prevent damage to the reservoir level sensor and heater wiring.
12. Carefully remove the lock ring over the reservoir wiring.
13. Carefully lift the reservoir cover (1) up just enough to free it from the seal (2).
14. Carefully work the reservoir seal (1) up and out of the neck of the DEF tank.
15. Carefully remove the seal (1) from around the reservoir cover and the reservoir wiring.
16. Using finger pressure only to rotate the reservoir assembly, position fingers against the level sensor bulkhead (1) and the ledge opposite the bulkhead (2).
17. Rotate the reservoir assembly (1) counterclockwise to release the lock tabs (2) at the bottom of the DEF tank, then lift the reservoir (3) out of the tank.
18. If the reservoir assembly is to be reused, inspect the DEF filter (1) at the bottom of the reservoir for damage, and for dirt and debris, other than dried DEF crystallization residue.
19. To remove dried DEF crystallization residue, use only a Low pressure clean water hose to spray the applicable surfaces of the reservoir assembly. Dried DEF crystallization residue will flush away with clean water.
20. Replace the DEF filter as necessary.
21. Wipe away any dried DEF crystallization residue from the tank seal.
22. Inspect the lower portion of the tank seal for deformity; taking a deeper set shape to the reservoir step (1), rather than returning to a mild shape for the reservoir step (1). Replace the seal if it is deformed.
23. Inspect the bottom of the DEF tank (1) for the presence of dirt and debris, and dried DEF crystallization residue.
24. If dirt and debris - other than dried DEF crystallization - are present inside the DEF tank, and if the reservoir is to be reused, replace the DEF filter at the bottom of the reservoir.
25. If dirt, debris, and/or dried DEF crystallization residue are present inside the DEF tank; using only a Low pressure clean water hose, spray the applicable surfaces inside the DEF tank. Dried DEF crystallization residue will flush away with clean water.
26. Using a suitable Clean, blunt object, carefully depress and hold open, the flapper valve (1) at the back of the DEF tank fill port.
27. While keeping the fill port open, pour out the contents of the tank into a suitable container for disposal.
28. Repeat steps 25-27 until the inside of the DEF tank is free of dirt, debris, and/or dried DEF crystallization residue.

Assembly Procedure

1. Align the reservoir lock tabs (1) to the reservoir retainer at the bottom of the DEF tank, and carefully lower the reservoir (2) into position.
2. Using finger pressure only to rotate the reservoir assembly, position fingers against the level sensor bulkhead (1) and the ledge opposite the bulkhead (2).
3. Rotate the reservoir clockwise to secure the lock tabs (1) at the bottom of the DEF tank. An audible "click" noise will be heard when the lock position is reached.
4. Carefully slide the seal (1) over the reservoir wiring and around the reservoir cover.
5. Carefully work the reservoir seal (1) down into the neck of the DEF tank, while simultaneously working the seal lower lip around the outside of the reservoir.
6. Inspect to ensure the seal is fully seated and to ensure the lower lip of the seal (1) is positioned correctly around the outside of the reservoir (2).
7. Carefully position the reservoir cover (1) to the tank seal (2).
8. Position the reservoir cover so that the cover alignment mark arrow (1) will be centered between the 2 long alignment marks (2) on the top of the tank.
9. Carefully slide the lock ring over the reservoir wiring.
10. Remove the plugs from the supply ports (1,2).
11. Hand tighten the reservoir lock ring only until snug.
12. Position the CH-38879-B Fuel Pump Module Wrench (3), DEF supply pump module wrench, onto the supply module lock ring (4). Ensure the posts of the tool are positioned to fit securely onto opposing ribs of the lock ring.
13. Using a torque wrench attached to CH-38879-B Fuel Pump Module Wrench tighten the lock ring. Reposition CH-38879-B Fuel Pump Module Wrench as necessary to prevent damage to the reservoir level sensor and heater wiring. Tighten the lock ring to 85 Nm (63 lb ft) .
14. Rotate the reservoir vent (1) outward.
15. Carefully install the new supply pump to reservoir cover o-ring seals. Position the smaller o-ring seal (1) over the port on the underside of the supply pump, and position the larger o-ring seal (2) into the port on the reservoir cover.
16. Install the DEF tank supply pump module. Refer to «Emission Reduction Fluid Supply Pump Module Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
17. Align the control module assembly (1) retaining slots to the mating slots on the retainer. Slide the module sideways toward the pump to secure the lock tab (2) on the underside of the module.
18. Align the reservoir heater connector (1) retaining slots to the mating slots on the retainer. Slide the connector into place to secure the lock tab (2) of the tank retainer.
19. Install the DEF wiring jumper harness into position as noted prior to removal.
20. Secure the jumper harness retaining clips to the supply module lock ring in the locations noted prior to removal. Slide the clip (2) downward to secure the clip retaining tab (1).
21. Connect the DEF wiring jumper harness connectors to the pump (1), pressure sensor (2), reverting valve (3), control module assembly (4), and to the reservoir heater connector (5).

1. Install the DEF tank (1). Refer to «Emission Reduction Fluid Tank Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Install the DEF line (2).
3. Fill the DEF tank with approved DEF fluid.
4. With system operational, inspect for DEF fluid leaks.

1. Ensure the ignition is OFF.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
3. Using only a Low pressure clean water hose, spray the upper surfaces of the Diesel Exhaust Fluid (DEF) Tank and pump supply module, the injection hose, and the fill hose assembly, to remove all dirt and debris.
4. Using only a Low pressure air wand or air gun, direct air along the same surfaces to both dry and remove any further contaminants.
5. Using a clean white shop towel, carefully dry connections and joints by hand to ensure dryness and cleanliness.
6. Drain the emission reduction fluid tank. Refer to «Fuel Tank Draining»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining) , «Fuel Tank Draining (Emission Reduction Fluid)»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__fuel-tank-draining-emission-reduction-fluid) .
7. Disconnect the filler pipe and vent pipe from the tank. Refer to «Emission Reduction Fluid Tank Opening Filler Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
8. Cap both the vent hose and filler hose. Also cap the filler ports to prevent possible contamination.
9. Support the tank with a suitable jack. Remove the fuel tank strap fasteners (1) and remove the tank straps (2).
10. Lower the tank enough to access and disconnect the electrical connectors (1) and the injection hose port (2) by squeezing both sides.
11. Cap both the injection hose fitting and the port of the supply pump.
12. Lower the tank (1) with a suitable jack.

1. Install the tank (1) with a suitable jack.
2. Raise the tank enough to access and connect the electrical connectors (1) and the injection hose port (2).
3. Remove the caps for the injection hose fitting and the port of the supply pump.
4. Install the fuel tank strap fasteners (1) and tighten to 22 N.m (16 lb ft).
5. If the emission reduction tank was replaced or serviced, perform the scan tool Reductant System Reset procedure to reset the tank level sensor calibration.
6. In order to clear the DEF lamp, allow the engine to reach normal operating temperature. Drive the vehicle to 32-48 km/h (20-30 mph) until the DEF lamp turns OFF automatically.

Scheme 114

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Remove the CKP sensor bolt .
5. Remove the CKP sensor.
6. If necessary, remove the CKP sensor spacer bolts.
7. If necessary, remove the CKP sensor spacer.

1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil.
2. If necessary, install the NEW O-ring to the CKP sensor spacer.
3. If necessary, install the CKP sensor spacer.
4. If necessary, install the CKP sensor spacer bolts and tighten to 10 N.m (89 lb in).
5. Install the CKP sensor.
6. Install the CKP sensor bolt and tighten to 10 N.m (89 lb in).
7. Connect the CKP sensor electrical connector.
8. Lower the vehicle.
9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-g3500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
10. Perform the crankshaft position reluctor wheel learn procedure. Refer to «Crankshaft Position Reluctor Wheel Learn»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Scheme 115

Camshaft Position Sensor Replacement

Scheme 116

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) , «Cooling System Draining and Filling (Static Fill Diesel)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the turbocharger air inlet adapter. Refer to «Turbocharger Air Inlet Adapter Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
4. Remove the exhaust gas recirculation valve temperature sensor - 1. Refer to «Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
5. Disconnect both exhaust gas recirculation coolant hoses from the exhaust gas recirculation valve cooler.
6. If equipped, remove the exhaust outlet pipe heat shield bolts (3) and remove the exhaust outlet pipe heat shield (4).
7. Remove the exhaust outlet pipe to exhaust gas recirculation valve cooler fasteners (1).
8. Remove the rear exhaust gas recirculation valve cooler bolts (3).
9. Remove the front exhaust gas recirculation valve cooler bolt (1).
10. Disconnect the exhaust gas recirculation valve electrical connector (2).
11. Carefully remove the exhaust gas recirculation valve assembly (1) from the engine.
12. Remove the exhaust gas recirculation valve to exhaust gas recirculation valve cooler bolts (3).
13. Separate the exhaust gas recirculation valve (2) from the exhaust gas recirculation valve cooler (1).
14. Discard the gasket.

1. Connect the exhaust gas recirculation valve (2) to the exhaust gas recirculation valve cooler(1) using a NEW gasket.
2. Install the exhaust gas recirculation valve to exhaust gas recirculation valve cooler bolts (3) and tighten to 25 (18 lb ft).
3. Carefully Install the exhaust gas recirculation valve assembly (1) to the engine.
4. Connect the exhaust gas recirculation valve electrical connector (2).
5. Install the front exhaust gas recirculation valve cooler bolt (1) and tighten to 25 (18 lb ft).
6. Install the rear exhaust gas recirculation valve cooler bolts (3) and tighten to 50 (37 lb ft).
7. Install the exhaust outlet pipe to exhaust gas recirculation valve cooler fasteners (1) and tighten to 53 (39 lb ft).
8. If equipped, Install the exhaust outlet pipe heat shield (4), washers (2) and tighten the bolts to 10 (89 lb in).
9. Connect both exhaust gas recirculation coolant hoses from the exhaust gas recirculation valve cooler.
10. Install the exhaust gas recirculation valve temperature sensor - 1. Refer to «Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
11. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement»(/chevrolet/express-g3500/2013-2013/remont/mechanical/#engine-mechanical-66l-lgh-repair-instructions-on-vehicle) .
12. Install the turbocharger air inlet adapter. Refer to «Turbocharger Air Inlet Adapter Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
13. Refill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) , «Cooling System Draining and Filling (Static Fill Diesel)»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 117

Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1

Scheme 118

Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2

Scheme 119

Exhaust Gas Recirculation Valve Bracket Replacement

Scheme 120

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the engine wiring harness electrical connector (1) from the exhaust differential pressure sensor.
3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (1).
4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor.
5. Remove the exhaust differential pressure sensor bracket bolt (2).
6. Remove the exhaust differential pressure sensor.

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

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .
2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3).
3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor.
4. Remove the exhaust differential pressure sensor pipe assembly fittings (2).
5. Remove the exhaust differential pressure sensor bracket bolts (1).
6. Remove the exhaust differential pressure sensor pipe assembly.

1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
2. Position and install the exhaust differential pressure sensor pipe assembly.
3. Loosely install the exhaust differential pressure sensor bracket bolts (1).
4. Install the exhaust differential pressure sensor pipe assembly fittings (2). Tighten the exhaust differential pressure sensor pipe fittings to 45 N.m (33 lb ft). Tighten the exhaust differential pressure sensor bracket bolts to 9 N.m (80 lb in).
5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor.
6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3).
7. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g3500/2013-2013/remont/hoistjack/#general-information) .

Scheme 121

Exhaust Temperature Sensor Replacement - Position 1

Scheme 122

Exhaust Temperature Sensor Replacement - Position 2

Scheme 123

Exhaust Temperature Sensor Replacement - Position 3

Scheme 124

Exhaust Temperature Sensor Replacement - Position 4

Scheme 125

1. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the turbocharger oil feed pipe banjo bolt and washer.
3. Reposition the oil feed pipe out of the way.
4. Disconnect the turbocharger vane control solenoid valve electrical connector.
5. Remove the vane control solenoid valve bracket bolt and bracket.
6. Remove the turbocharger vane control solenoid valve from the turbocharger.

1. Install the turbocharger vane control solenoid valve to the turbocharger.
2. Install the vane control solenoid valve bracket and bolt and tighten to 23 N.m (17 lb ft).
3. Connect the turbocharger vane control solenoid valve electrical connector.
4. Position the oil feed pipe to the turbocharger.
5. Install a NEW turbocharger oil feed pipe washer and the banjo bolt and tighten to 34 N.m (25 lb ft).
6. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(/chevrolet/express-g3500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__turbocharger-learn) .

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Disconnect the turbocharger vane position sensor electrical connector.
3. Remove the turbocharger vane position sensor connector from the bracket on the LH valve cover.
4. Remove the turbocharger vane position sensor from the turbocharger.

Scheme 126

1. CAUTION: Refer to «Fastener Caution»(/chevrolet/express-g3500/2013-2013/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) . Install the turbocharger vane position sensor to the turbocharger and tighten to 23 N.m (17 lb ft).
2. Install the turbocharger vane position sensor connector to the bracket located on the LH valve cover.
3. Connect the turbocharger vane position sensor electrical connector.
4. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions__turbocharger-learn) .

Turbocharger Learn

The engine control module (ECM) performs the turbocharger (TC) learn procedure automatically when the engine coolant temperature (ECT) is least 72°C (162°F). After each ignition cycle, and before the enable criteria have been met, the ECM will use the previously learned value. If the ECM does not have a previously learned value, it will default to a stored calibrated value. The ECM will use this value until the enable criteria have been met. It will then perform this procedure to learn the new value. If the ECM attempts to perform the TC Learn procedure and fails, DTC P003A, P2598 or P2599 may set.

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

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

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

Learn Procedure With the Tech 2

Note. Once the enable conditions have been met the throttle must remain at idle. Do not change the accelerator pedal position (APP) during this procedure.

1. The following conditions must be met for the ECM to perform the turbocharger learn procedure: The air conditioning (A/C) system is OFF. The vehicle is in Park or Neutral. Start and idle the engine. The ECT is greater than 40°C (104°F).
2. After the enable conditions have been met and the engine idle is stabilized, enter the TC Learn Output function from the Module Setup Menu. Command the TC Learn ON for at least 5 s, then command it OFF. The system should have learned the new turbocharger position. The TC Vane Position Learn Status parameter should have toggled from In Progress to TC Learned.

1. Remove 3 air cleaner cover bolts.
2. Remove the air cleaner cover.
3. Remove the air cleaner element.

1. Install the air cleaner element.
2. Install the air cleaner cover.
3. Install the air cleaner cover bolts and tighten to 4 N.m (35 lb in).

1. Disconnect the mass air flow (MAF) harness connector.
2. Remove the air cleaner assembly hold down screw.
3. Loosen the air cleaner outlet duct hose clamp.
4. Remove the air cleaner assembly.

1. Install the air cleaner assembly.
2. Tighten the air cleaner outlet duct hose clamp to 4 N.m (35 lb in).
3. Install the air cleaner assembly hold down screw.
4. Connect the MAF harness connector.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
3. Loosen the air intake duct to turbo clamp.
4. Remove the intake air duct.

1. Install the intake air duct.
2. Tighten the intake air duct to turbo clamp to 8 N.m (71 lb in).
3. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Scheme 127

Turbocharger Air Inlet Adapter Replacement

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .
2. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
3. Loosen the inlet pipe clamp (1).
4. Loosen the inlet pipe clamp (1) and remove the inlet pipe (2).

1. Install the inlet pipe (1) and tighten to 6 N.m (53 lb in)
2. Tighten the inlet pipe clamp (1) to 6 N.m (53 lb in)
3. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g3500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-g3500/2013-2013/remont/testing-diagnostics/#engine-controls-and-fuel-66l-lgh-repair-instructions) .

Scheme 128

Charge Air Cooler Outlet Pipe Replacement

See also:
• Diagnostic Trouble Code (DTC) List - Vehicle
• Brake Pedal Position Sensor Calibration
• Control Module References
• Battery Negative Cable Disconnection and Connection
• Master Cylinder Replacement
• Fastener Caution
• Diagnostic Repair Verification
• Symptoms - Vehicle
• Exhaust Aftertreatment System Description
• Exhaust Particulate Filter Replacement (LGH-35 Series)
• Cooling System Draining and Filling (Static Fill)
• Cooling System Draining and Filling (Vac N Fill)
• Engine Cover Replacement
• Adhesives, Fluids, Lubricants, and Sealers
• Lifting and Jacking the Vehicle
• Safety Glasses Warning
• Fuel Pipe Fitting Warning
• Battery Disconnect Warning
• Relieving Fuel Pressure Warning
• Special Tools (Diagnostic Tools)
• Gasoline/Gasoline Vapors Warning
• Intake Manifold Tube Replacement
• Air Conditioning Compressor Replacement (6.6L)
• Engine Coolant Thermostat Housing Removal
• Component Fastener Tightening Caution
• Special Tools
• Tire and Wheel Removal and Installation (6-Lug Wheel)
• Wheelhouse Splash Shield Replacement
• Exterior Trim Emblem Removal Caution
• Transmission Fluid Filler Tube and Seal Replacement
• Turbocharger Learn
• Crankshaft Position Reluctor Wheel Learn
• Water-in-Fuel Draining
• Fuel System Priming
• Fuel Tank Draining
• Fuel Tank Draining (Emission Reduction Fluid)
• Metal Collar Quick Connect Fitting Service
• Fuel Sender Assembly Replacement
• Indirect Fuel Injector Replacement
• Diesel Particulate Filter (DPF) Regeneration Enable