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Engine Controls - 6.6L (LB7) (Introduction): Removal & Installation Chevrolet Silverado 3500

Testing & Diagnostics 1 illustration ~21453 words

Engine Control Module (ECM) 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.

Removal Procedure

IMPORTANTTo prevent internal ECM damage, the ignition switch must be OFF when disconnecting or connecting power to the ECM. Remove any debris from the ECM connector surfaces before servicing the ECM. Inspect the ECM module connector gaskets when diagnosing or replacing the ECM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the ECM. The replacement ECM must programmed.
  1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. If equipped with the Allison transmission regular production option (RPO) M74, remove the engine harness clip from the ECM cover.
  4. Release the ECM cover mounting tabs.
  5. Release the ECM cover from the mounting bracket.
  6. Remove the ECM cover.
  7. Loosen the ECM electrical connector bolts (2).
  8. Disconnect the ECM electrical connectors (3).
  9. Release the spring latch from the ECM.
  10. Release the ECM mounting tabs from the ECM.
  11. Remove the ECM.

Installation Procedure

  1. Install the ECM. Ensure that the mounting tabs are engaged.
  2. Secure the spring latch to the ECM.
  3. Connect the ECM electrical connectors (3).
  4. Tighten the ECM electrical connector bolts (2). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  5. Install the ECM cover.
  6. If equipped with the Allison transmission RPO M74, install the engine harness clip to the ECM cover.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  8. If a NEW ECM was installed, program the ECM. Refer to «Service Programming System (SPS)»(ref-184120-S18443623862005082200000) in Programming.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Unsnap the positive battery cable cap.
  3. Loosen the positive battery cable bolt.
  4. Remove the positive battery cable.
  5. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  6. Remove the fuel fill cap in order to relieve the fuel pressure.
  7. Cut and discard the large tie straps from the control module (6) and harness.
  8. Remove the fuel line bolts (4) from the control module (6).
  9. Remove the control module bolts (1, 5).
  10. Remove the control module insulators (2) between the module and bracket.
  11. Disconnect the control module electrical connectors (2).
  12. Remove the fuel lines (2) from the control module (1) and discard washers.
  13. Remove the control module (1) from the bracket.
  1. Install the insulators (2) to the control module (6).
  2. Install the control module.
  3. Install by hand the fuel lines (2) and bolts with new washers to the control module (1).
  4. Install the control module bolts (1, 5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  5. Connect the control module electrical connectors (2).
  6. Install the fuel line bolts (4) to the control module (6).
  7. Tighten the eye bolts (4). Tighten: Tighten the bolts to 35 N.m (26 lb ft).
  8. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  9. Install the positive battery cable.
  10. Tighten the positive battery cable bolt. Tighten: Tighten the bolt to 17 N.m (13 lb ft).
  11. Snap the positive battery cable cap closed.
  12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  13. Install the fuel fill cap.
  14. Depress the fuel manager primer button 30 times.
  15. Start the engine. If the engine stalls, repeat steps 13 and 15.
  16. Inspect for fuel leaks.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) .
  3. Disconnect the fuel injection control module electrical connectors (1).
  4. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Disconnect the following electrical connectors: Water-in-fuel sensor (1) Fuel heater (2)
  7. Disconnect the right rear fuel injector electrical connector (1).
  8. Disconnect the exhaust gas recirculation (EGR) valve solenoid electrical connector (1).
  9. Disconnect the EGR valve vent solenoid electrical connector (1).
  10. Disconnect the EGR valve vacuum sensor electrical connector (1).
  11. Disconnect the EGR throttle valve solenoid electrical connector.
  12. Remove the right side glow plug electrical nuts.
  13. Remove the right side engine harness from the glow plug (1).
  14. Disconnect the right front fuel injector electrical connector (1).
  15. Disconnect the turbocharger boost sensor electrical connector (1).
  16. Remove the sight shield hold-down bolt and bracket (1).
  17. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  18. Reposition the turbocharger water inlet hose clamp.
  19. Remove the turbocharger water inlet hose.
  20. Remove the turbocharger coolant bypass valve.
  21. Remove the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  22. Disconnect the engine harness electrical connectors.
  23. Remove the bulk connector bolts from the bracket (1).
  24. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  25. Remove the charged air cooler inlet duct from the turbocharger.
  26. Reposition the positive crankcase ventilation (PCV) hose clamp.
  27. Remove the PCV hose from the left valve cover.
  28. Disconnect the left front fuel injector electrical connector (1).
  29. Disconnect the left rear fuel injector electrical connector (1).
  30. Disconnect the fuel rail temperature sensor electrical connector (1).
  31. Disconnect the glow plug controller electrical connectors (1).
  32. Remove the fuel pipe retainer nut at the valve cover.
  33. Remove the fuel pipe retainer (2).
  34. Remove the left front wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  35. Remove the left side glow plug electrical nuts.
  36. Remove the left side engine harness from the glow plugs (1).
  37. Disconnect the oil level electrical connector (1).
  38. Disconnect the barometric pressure (BARO) sensor electrical connector (1).
  39. Disconnect the fuel rail pressure sensor electrical connector (1).
  40. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  41. Remove the engine shield bolts and shield.
  42. Disconnect the crankshaft position (CKP) sensor electrical connector.
  43. Disconnect the camshaft position (CMP) sensor electrical connector (1).
  44. Remove the engine harness ground bolts (1).
  45. Lower the vehicle.
  46. Unroute and lift up the engine wiring harness for access to fuel pressure regulator.
  47. Disconnect the fuel pressure regulator electrical connector (1).
  48. Remove the engine wiring harness.
  1. Install the engine wiring harness.
  2. Connect the fuel pressure regulator electrical connector (1).
  3. Route the engine wiring harness to the engine.
  4. Raise the vehicle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  5. Install the engine wiring harness ground bolts (1). Tighten: Tighten the bolts to 34 N.m (25 lb ft).
  6. Connect the CMP sensor electrical connector (1).
  7. Connect the CKP sensor electrical connector.
  8. Install the engine shield and bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  9. Lower the vehicle.
  10. Connect the fuel rail pressure sensor electrical connector (1).
  11. Connect the BARO sensor electrical connector (1).
  12. Connect the oil level sensor electrical connector (1).
  13. Install the left side engine harness to the glow plugs (1).
  14. Install the glow plug electrical nuts. Tighten: Tighten the nuts to 2 N.m (18 lb in).
  15. Install the left inner wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  16. Install the fuel pipe retainer (2).
  17. Install the fuel pipe retainer nut at the valve cover. Tighten: Tighten the nut to 8 N.m (70 lb in).
  18. Connect the glow plug controller electrical connectors (1).
  19. Connect the fuel rail temperature sensor electrical connector (1).
  20. Connect the left rear fuel injector electrical connector (1).
  21. Connect the left front fuel injector electrical connector (1).
  22. Install the PCV hose to valve cover.
  23. Position the PCV hose clamp.
  24. Install the charged air cooler inlet duct to the turbocharger.
  25. Align the mark on the duct (2) with the mark on the turbocharger.
  26. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  27. Install the bulk connector bolts (1) to the bracket. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  28. Connect the engine harness electrical connectors.
  29. Install the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  30. Install the turbocharger coolant bypass valve. Tighten: Tighten the valve to 60 N.m (44 lb ft).
  31. Install the turbocharger water inlet hose.
  32. Position the turbocharger water inlet hose clamp.
  33. Connect the ECT sensor electrical connector (1).
  34. Install the engine sight shield hold-down bracket (1) and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  35. Connect the turbocharger boost sensor electrical connector (1).
  36. Connect the right front fuel injector electrical connector (1).
  37. Install the right side engine harness to the glow plugs (1).
  38. Install the right side glow plug electrical nuts. Tighten: Tighten the nuts to 2 N.m (18 lb in).
  39. Connect the EGR throttle valve solenoid electrical connector (1).
  40. Connect the EGR vacuum sensor electrical connector (1).
  41. Connect the EGR vent solenoid electrical connector (1).
  42. Connect the EGR valve solenoid electrical connector (1).
  43. Connect the right rear fuel injector electrical connector (1).
  44. Connect the following electrical connectors: Water-in-fuel sensor (1) Fuel heater (2)
  45. Install the charged air cooler outlet duct to the intake.
  46. Tighten the charged air cooler outlet duct clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
  47. Connect the fuel injection control module electrical connectors (1).
  48. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) .
  49. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the ECT sensor electrical connector (1).
  3. Remove the ECT sensor (1).

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the ECT sensor (1). Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  3. Connect the ECT sensor electrical connector (1).
  4. Fill the cooling system, if necessary. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (1).
  2. Remove the MAF/IAT sensor screws.
  3. Remove the MAF/IAT sensor (1).
  1. Install the MAF/IAT sensor (1). NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the MAF/IAT sensor screws. Tighten: Tighten the screws to 8 N.m (70 lb in).
  3. Connect the MAF/IAT sensor electrical connector (1).
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
  4. Remove the intake air heater (IAH) nut.
  5. Remove the IAH wire.
  6. Remove the IAH.
  1. Install the IAH. Tighten: Tighten the IAH to 50 N.m (37 lb ft).
  2. Install the IAH wire.
  3. Install the IAH nut. Tighten: Tighten the nut to 5 N.m (44 lb in).
  4. Install the upper intake manifold cover.
  5. Install the upper intake manifold cover to the outlet duct.
  6. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
IMPORTANTThe intake air heater (IAH) relay is part of the glow plug controller on vehicles equipped with federal emissions.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Loosen the outlet duct clamp at the upper intake manifold.
  3. Remove the upper intake manifold cover from the outlet duct.
  4. Remove the upper intake manifold cover.
  5. Using a flat bladed screwdriver, disengage the glow plug controller cover clips.
  6. Remove the glow plug controller cover.
  7. Remove the glow plug controller nuts.
  8. Lift the glow plug controller off the studs.
  9. Separate the intake heater relay from the glow plug controller housing by inserting a small screwdriver between them while prying the relay assembly outward.
  10. Slide the intake heater relay outward to disengage it from the glow plug controller housing.
  11. Using a flat bladed screwdriver, disengage the intake heater relay clip.
  12. Remove the intake heater relay.
  1. Install the intake heater relay.
  2. Slide the intake heater relay inward to engage it to the glow plug controller housing.
  3. Place the glow plug controller onto the studs.
  4. Install the glow plug controller nuts. Tighten: Tighten the nuts to 42 N.m (31 lb ft).
  5. Install the glow plug controller cover.
  6. Install the upper intake manifold cover.
  7. Install the upper intake manifold cover to the outlet duct.
  8. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  9. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Loosen the outlet duct clamp at the upper intake manifold.
  3. Remove the upper intake manifold cover from the outlet duct.
  4. Remove the upper intake manifold cover.
  5. Disconnect the engine harness electrical connector (2).
  6. Disconnect the intake air heater (IAH) relay electrical connector (3).
  7. Reposition the battery cable boots (1).
  8. Remove the battery cable nuts and cables from the IAH relay controller. Reposition the cables.
  9. Remove the IAH relay controller bolts (2).
  10. Remove the IAH relay controller.
  11. Remove the IAH relay controller cover.
  12. Remove the IAH relay controller nuts and washers.
  13. Using 2 screwdrivers, disengage the IAH relay assembly from the controller housing.
  14. Remove the IAH relay assembly from the housing.
  15. Remove the IAH relay.
  1. Install the IAH relay.
  2. Install the IAH relay assembly to the housing.
  3. Install the IAH relay controller nuts and washers. Tighten: Tighten the nuts to 5 N.m (44 lb in).
  4. Install the IAH relay controller cover.
  5. Install the IAH relay controller.
  6. Install the IAH relay controller bolts (2). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  7. Install the battery cables and nuts to the IAH relay controller. Tighten: Tighten the nuts to 5 N.m (44 lb in).
  8. Reposition the battery cable boots (1).
  9. Connect the IAH relay electrical connector (3).
  10. Connect the engine harness connector (2).
  11. Install the upper intake manifold cover.
  12. Install the upper intake manifold cover to the outlet duct.
  13. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  14. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the barometric pressure (BARO) sensor electrical connector (1).
  2. Bend the tabs (2), located on the bracket, away from the sensor, enough so that the sensor can be removed.
  3. Pull the BARO sensor (3) downward in order to remove it from the bracket.
  1. Install the BARO sensor (3) to the bracket.
  2. Bend the tabs (2) inward to hold the sensor.
  3. Connect the BARO sensor electrical connector (1).
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  2. Disconnect the boost sensor electrical connector (2).
  3. Remove the boost sensor bracket nut (4).
  4. Lift the coolant tube (1) off of the stud and move it out of the way.
  5. Remove the boost sensor (2) with bracket (1).
  6. Remove the sensor from the bracket.
  7. Inspect the boost sensor seal for damage, replace as necessary.
  1. Position the sensor (2) onto the bracket (1).
  2. Install the bracket (with sensor) over the stud.
  3. Position the coolant tube (1) over the stud. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the boost sensor bracket nut (4). Tighten: Tighten the nut to 9 N.m (80 lb in).
  5. Connect the boost sensor electrical connector (2).
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
  4. Disconnect the boost sensor electrical connector (1).
  5. Remove the boost sensor bracket bolt (4).
  6. Disconnect the vacuum line from the sensor.
  7. Remove the boost sensor and bracket.
  8. Remove the bracket from the sensor.
  9. Inspect the boost sensor seal for damage, replace as necessary.
  1. Install the sensor to the bracket.
  2. Install the bracket (with sensor).
  3. Connect the vacuum line to the sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the boost sensor bracket bolt (4). Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. Connect the boost sensor electrical connector (1).
  6. Install the upper intake manifold cover.
  7. Install the upper intake manifold cover to the outlet duct.
  8. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).

Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

  1. Remove the connector position assurance (CPA) retainer.
  2. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  3. Reposition the carpet to access the lower nut.
  4. Remove the accelerator pedal nuts.
  5. Remove the accelerator pedal assembly.
  1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Cautions and Notices.
  2. Install the accelerator pedal nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
  3. Connect the APP sensor electrical connector.
  4. Reposition the carpet.
  5. Install the CPA retainer.
  6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between closed a closed throttle and a wide open throttle (WOT).
  8. 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.
  9. Inspect the carpet fit under the accelerator pedal.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the fuel fill cap.
  3. Remove the fuel feed/return pipe retainers.
  4. Blow any dirt out of the fitting using compressed air. NOTE: 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.
  5. Choose the correct end of J 44581 for the size of the fitting. Insert J 44581 into the female connector, then push inward in order to release the locking tabs.
  6. Pull the connection apart.
  7. Use a clean shop towel in order to wipe off the male end.
  8. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
CAUTIONIn order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
  1. Apply a few drops of clean engine oil to the male end.
  2. Push both fittings together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides to ensure the connection is secure.
  4. Install the fuel feed/return pipe retainers.
  5. Install the fuel fill cap.
  6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove fuel fill cap.
  3. Using compressed air, blow any dirt out of the quick-connect fitting.
  4. Squeeze the plastic retainer release tabs.
  5. Pull the connection apart.
  1. Apply a few drops of clean engine oil to the male end.
  2. Push both sides together in order to cause the retaining tabs to snap into place.
  3. Once installed, pull on both sides to ensure the connection is secure.
  4. Install the fuel fill cap.
  5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining Procedure»(ref-184139-S19144488272005082200000) .
  2. Disconnect the water-in-fuel sensor electrical connector (1).
  3. Unscrew the fuel filter (2) from the fuel filter adapter (1).
  4. Remove the water-in-fuel sensor (3) from the fuel filter (2).
  1. Install the water-in-fuel sensor (3) to the NEW fuel filter (2). IMPORTANT: Inspect the fuel heater element housing for contamination. Contamination on the fuel heater element housing may cause leakage at the fuel filter. Coat the fuel filter seal with clean engine oil.
  2. Install the fuel filter (2) to the fuel filter adapter (1).
  3. Connect the water-in-fuel sensor electrical connector (1).
  4. Prime the fuel system.
  5. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) .
  6. Start the engine and inspect for fuel leaks.
  1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining Procedure»(ref-184139-S19144488272005082200000) .
  2. Disconnect the water-in-fuel sensor electrical connector (1).
  3. Remove the water-in-fuel sensor (3) from the fuel filter (2).
IMPORTANTThe water-in-fuel sensor must ONLY be tightened by hand.
  1. Install the water-in-fuel sensor (3) to the fuel filter (2).
  2. Connect the water-in-fuel sensor electrical connector (1).
  1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining Procedure»(ref-184139-S19144488272005082200000) .
  2. Disconnect the following electrical connectors: Water-in-fuel sensor (1) Fuel heater (2)
  3. Reposition the fuel hose clamps.
  4. Remove the fuel hoses from the fuel filter/heater element housing.
  5. Disconnect the electrical and vacuum lines from the following: The exhaust gas recirculation (EGR) valve vent solenoid The EGR valve vacuum sensor The EGR valve solenoid
  6. Remove the fuel filter bracket bolts.
  7. Remove the fuel filter/heater element housing.
  8. Remove the fuel filter bracket from the fuel filter/heater element housing.
  9. Remove the fuel filter from the fuel filter/heater element housing.
  10. Inspect the fuel filter, replace if necessary.
  1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel filter bracket to the fuel filter/heater element housing. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  3. Install the fuel filter bracket bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  4. Connect the electrical and vacuum to the following: The EGR valve vent solenoid The EGR valve vacuum sensor The EGR valve solenoid
  5. Connect the fuel hoses to the fuel filter/heater element housing.
  6. Reposition the fuel hose clamps.
  7. Prime the fuel system.
  8. Connect the following electrical connectors: Water-in-fuel sensor (1) Fuel heater (2)
  9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) .
  10. Start the engine and inspect for fuel leaks.
  1. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184139-S16015704432005082200000) .
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  3. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
  4. Loosen the clamp at the fuel inlet neck.
  5. Remove the fuel fill hose from the inlet neck.
  6. Remove the fuel system cooler. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184139-S29599247742005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184139-S07102381542005082200000) .
  7. Remove the fuel tank shield bolts, if equipped.
  8. Remove the fuel tank shield, if equipped.
  9. Disconnect the fuel feed and return pipes from the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  10. Cap the fuel pipes in order to prevent possible fuel system contamination.
  11. Place a suitable adjustable jack under the fuel tank.
  12. Remove the fuel tank strap bolts. NOTE: Refer to «Fuel Tank Strap Fastener Notice»(ref-184123-S27170260212005082200000) in Cautions and Notices.
  13. Remove the fuel tank straps.
  14. Remove the fuel tank.
  15. Lower the fuel tank until the electrical connector is accessible.
  16. Disconnect the sending unit electrical connector.
  17. With the aid of an assistant, place the fuel tank in a suitable work area.
  18. If necessary, loosen the fuel inlet hose clamp at the tank.
  19. If necessary, remove the fuel inlet hose from the tank.
  20. Disconnect and remove the fuel feed and return pipes from the sending unit (1) and retaining clips (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  21. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  2. Install and connect the fuel feed and return pipes to the sending unit (1) and retaining clips (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  3. If necessary, install the fuel inlet hose to the tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. If necessary, tighten the fuel inlet hose clamp at the tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  5. With the aid of an assistant, place the fuel tank on the jack.
  6. Raise the fuel tank until the electrical connector is accessible.
  7. Connect the sending unit electrical connector.
  8. Install the fuel tank.
  9. Install the fuel tank straps.
  10. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  11. Remove the jack from under the fuel tank.
  12. Remove the caps from the fuel pipes.
  13. Connect the fuel feed and return pipes from the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  14. Install the fuel tank shield, if equipped.
  15. Install the fuel tank shield bolts, if equipped. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  16. Install the fuel system cooler. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184139-S29599247742005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184139-S07102381542005082200000) .
  17. Install the fuel fill hose to the inlet neck.
  18. Tighten the clamp at the fuel inlet neck. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  19. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  20. Lower the vehicle.
  21. Fill the fuel tank.
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  24. Prime the fuel system.
  25. Start the engine and test for fuel leaks.
  1. Disconnect the fuel feed and pressure balance rear pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  2. Loosen the fuel fill and vent hose clamps at the fuel tank.
  3. Remove the fuel fill pipe and vent hose from the tank.
  4. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184139-S16015704432005082200000) .
  5. Disconnect the sending unit electrical connector.
  6. Disconnect the fuel feed/return pipes from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  7. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  8. Remove the fuel tank shield bolts.
  9. Remove the fuel tank shield.
  10. Place a suitable adjustable jack under the fuel tank.
  11. Remove the fuel tank strap bolts. NOTE: Refer to «Fuel Tank Strap Fastener Notice»(ref-184123-S27170260212005082200000) in Cautions and Notices.
  12. Remove the fuel tank straps (1).
  13. Lower the fuel tank.
  14. With the aid of an assistant, place the fuel tank in a suitable work area.
  15. Cap the fuel pipes on the vehicle in order to prevent possible fuel system contamination.
  16. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  2. Remove the caps from the fuel pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps (1). NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  10. Lower the vehicle.
  11. Connect the fuel feed/return pipes at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  12. Connect the sending unit electrical connector.
  13. Install the fuel fill pipe and vent hose to the tank.
  14. Tighten the fuel fill and vent hose clamps at the fuel tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  15. Connect the fuel feed and pressure balance rear pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  16. Fill the fuel tank.
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  19. Prime the fuel system.
  20. Start the engine and test for fuel leaks.
  1. Loosen the fuel fill and vent hose clamps at the tank.
  2. Remove the fuel fill and vent hose from the tank.
  3. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184139-S16015704432005082200000) .
  4. Disconnect the sending unit electrical connector (2).
  5. Disconnect the fuel feed/return pipes from the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  7. Remove the fuel tank shield bolts.
  8. Remove the fuel tank shield.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts. NOTE: Refer to «Fuel Tank Strap Fastener Notice»(ref-184123-S27170260212005082200000) in Cautions and Notices.
  11. Remove the fuel tank straps.
  12. Lower the fuel tank.
  13. With the aid of an assistant, place the fuel tank in a suitable work area.
  14. Cap the fuel pipes in order to prevent possible fuel system contamination.
  15. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  2. Remove the caps from the fuel pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  10. Lower the vehicle.
  11. Connect the fuel feed/return pipes to the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  12. Connect the sending unit electrical connector (2).
  13. Install the fuel fill and vent hose to the tank.
  14. Tighten the fuel fill and vent hose clamps at the tank. Tighten: Tighten the hose clamps to 2.5 N.m (22 lb in).
  15. Fill the fuel tank.
  16. Install the fuel fill cap.
  17. Install the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  18. Command the fuel transfer pump on with a scan tool.
  19. Test for fuel leaks.
  1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184139-S23623806752005082200000) .
  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»(ref-184139-S23623806752005082200000) .
  1. Loosen the fuel fill cap to relieve the fuel system pressure.
  2. Disconnect the fuel pump electrical connector (1).
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  4. Clean the fuel pipe connections and surrounding areas at the pump before disconnecting to avoid possible fuel system contamination.
  5. Disconnect the fuel pipes from the pump.
  6. Slide the pump out of the bracket.
  7. Cap the fuel pipes.
  1. Remove the caps from the fuel pipes.
  2. Install the NEW fuel pipe O-rings.
  3. Position the new pump in the pump bracket.
  4. Connect the fuel pipes to the fuel pump. Use a backup wrench to prevent the pump from turning. Tighten: Tighten the fittings to 30 N.m (22 lb ft).
  5. Lower the vehicle.
  6. Connect the fuel pump electrical connector (1).
  7. Install the fuel fill cap.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  2. Disconnect the fuel pipes from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  3. Using J 44402 , remove the sending unit lock ring.
  4. Remove the sending unit and seal. Discard the seal.
  5. Clean the sending unit sealing surfaces.
  1. Install the sending unit and a NEW seal.
  2. Using J 44402 , install the sending unit lock ring.
  3. Connect the fuel pipes to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  5. Remove the fuel feed front connector pipe bolt from the fuel injector control module (FICM).
  6. Reposition the fuel feed hose clamps.
  7. Remove the fuel hose (1) from fuel feed front connector pipe.
  8. Remove the fuel hose (1) from fuel feed front pipe.
IMPORTANTAlways install new fuel line gaskets when servicing the fuel lines.
  1. Install the fuel hose (1) to fuel feed front pipe.
  2. Install the fuel hose (1) to fuel feed front connector pipe.
  3. Reposition the fuel feed hose clamps. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel feed front connector pipe bolt to the FICM. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  5. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Loose the fuel fill cap in order to relieve the fuel pressure.
  2. Remove air cleaner outlet duct. Refer «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct.
  5. Reposition the fuel hose clamps.
  6. Remove the fuel hose from the fuel injector control module (FICM).
  7. Remove the fuel hose from fuel filter.
  1. Install the fuel hose to fuel filter.
  2. Install the fuel hose to the FICM.
  3. Reposition the fuel hose clamps.
  4. Install the charged air cooler outlet duct to the intake. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  5. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  6. Install air cleaner outlet duct. Refer «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  7. Install the fuel fill cap.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  5. Remove the exhaust gas recirculation (EGR) valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-184139-S37431876232005082200000) .
  6. Reposition the fuel hose clamps.
  7. Remove the fuel hose (1) from the fuel filter/heater element housing.
  8. Remove the fuel hose (1) from the fuel feed block.
  1. Install the fuel hose (1) to the fuel feed block.
  2. Install the fuel hose (1) to the fuel filter/heater element housing.
  3. Position the fuel hose clamps.
  4. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-184139-S37431876232005082200000) .
  5. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  9. Remove the Schrader valve nuts (1) and bracket (2).
  10. Reposition the fuel hose clamps.
  11. Remove the fuel hose (1) from the fuel feed block.
  12. Remove the Schrader valve and fuel hose from the engine.
  13. Remove the fuel hose from valve.
  1. Install the fuel hose to the valve.
  2. Install the Schrader valve and fuel hose to engine.
  3. Install the fuel hose (1) to fuel feed block.
  4. Reposition the fuel hose clamps.
  5. Install the Schrader valve bracket (2) and nuts (1). Tighten: Tighten the nuts to 20 N.m (15 lb ft).
  6. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  7. Install the charged air cooler inlet duct to the turbocharger.
  8. Align the mark on the duct (2) with the mark on the turbocharger.
  9. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  10. Install the charged air cooler outlet duct to the intake.
  11. Align the mark on the duct (3) with the mark on the intake.
  12. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  13. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  15. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Loosen the charged air cooler outlet duct to intake clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  9. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  10. Reposition the fuel hose clamps.
  11. Remove the fuel hose from the fuel return rear pipe.
  12. Remove the fuel hose from the fuel injection pump.
  1. Install the fuel hose to the fuel injection pump.
  2. Install the fuel hose to the fuel return rear pipe.
  3. Position the fuel hose clamps.
  4. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  5. Install the charged air cooler inlet duct to the turbocharger. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  8. Install the charged air cooler outlet duct to the intake.
  9. Align the mark on the duct (3) with the mark on the turbocharger.
  10. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  13. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct.
  5. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  6. Remove the charged air cooler inlet duct from the turbocharger.
  7. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  8. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  9. Reposition the fuel hose clamps.
  10. Remove the fuel hose from the fuel injection pump.
  11. Remove the fuel hose from the fuel feed block.
  1. Install the fuel hose to the fuel feed block.
  2. Install the fuel hose to the injection pump.
  3. Position the fuel hose clamps.
  4. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  5. Install the charged air cooler inlet duct to the turbocharger. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  8. Install the charged air cooler outlet duct to the intake.
  9. Align the mark on the duct (3) with the mark on the turbocharger.
  10. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  13. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Disconnect the fuel feed and return pipes from the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  2. Remove the fuel bundle bracket nut.
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  4. Remove the fuel bundle clips (2) from the transmission brackets (1).
  5. Disconnect the chassis harness from the retaining clips.
  6. Remove the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184139-S29599247742005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184139-S07102381542005082200000) .
  7. Disconnect the chassis fuel pipes from the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  8. Remove the fuel bundle nuts from the chassis.
  9. Loosen the electronic brake control module (EBCM) bracket bolts (4).
  10. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
  11. Remove the fuel bundle using the following procedure: Guide the fuel bundle (2) pipes towards the rear of vehicle to clear the engine. Lower the fuel bundle while moving it foreword and out.
  1. Install the fuel pipe bundle using the following procedure: Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel bundle nuts to the chassis. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  3. Connect the chassis fuel pipes to the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  4. Install the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184139-S29599247742005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184139-S07102381542005082200000) .
  5. Connect the fuel bundle clips (2) to the transmission brackets (1).
  6. Tighten the EBCM bracket bolts (4). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  7. Lower the vehicle.
  8. Install the fuel bundle bracket.
  9. Install the fuel bundle bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  10. Connect the fuel feed and return pipes to the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  11. Purge the air from the fuel system.
  1. Disconnect the fuel feed and return pipes from the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  2. Remove the fuel bundle bracket nut.
  3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  4. Remove the fuel bundle clips (2) from the transmission brackets (1).
  5. Disconnect the chassis harness from the retaining clips.
  6. Remove the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184139-S29599247742005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184139-S07102381542005082200000) .
  7. Disconnect the chassis fuel pipes from the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  8. Remove the fuel bundle nuts from the chassis.
  9. Loosen the electronic brake control module (EBCM) bracket bolts (4).
  10. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
  11. Remove the fuel bundle using the following procedure: Guide the fuel bundle (2) pipes towards the rear of vehicle to clear the engine. Lower the fuel bundle while moving it foreword and out.
  1. Install the fuel pipe bundle using the following procedure: Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel bundle nuts to the chassis. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  3. Connect the chassis fuel pipes to the fuel tank pipes. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  4. Install the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184139-S29599247742005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184139-S07102381542005082200000) .
  5. Connect the fuel bundle clips (2) to the transmission brackets (1).
  6. Tighten the EBCM bracket bolts (4). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  7. Lower the vehicle.
  8. Install the fuel bundle bracket.
  9. Install the fuel bundle bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
  10. Connect the fuel feed and return pipes to the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  11. Purge the air from the fuel system.
  1. Remove the front fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  2. Remove the auxiliary fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  3. Disconnect the pressure balance pump electrical connector (1).
  4. Remove the fuel pipes bundle nuts.
  5. Remove the fuel pipes bundle.
  1. Install the fuel pipes bundle. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel pipes bundle nuts. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
  3. Connect the pressure balance pump electrical connector (1).
  4. Install the auxiliary fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  5. Install the front fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  2. Disconnect the fuel lines from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  3. Disconnect and remove the fuel lines from the clips (3) on the fuel tank.
  1. Install and connect the fuel lines to the clips (3) on the fuel tank.
  2. Connect the fuel lines to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184139-S04349655082005082200000) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184139-S25222812662005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184139-S15896634012005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184139-S14458213192005082200000) .
  1. Remove the lower valve cover. Refer to «Valve Rocker Arm Cover Replacement - Lower Left»(ref-184191-S40011019652005082200000) in Engine Mechanical - 6.6L.
  2. Remove the fuel return pipe bolts.
  3. Remove the fuel injector return pipe.
  4. Remove and discard the return pipe gaskets.
IMPORTANTAlways install NEW copper gaskets onto the fuel injector fuel return pipe.
  1. Install the NEW gaskets onto fuel injector return pipe.
  2. Install the fuel injector return pipe. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel injector return pipe bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
  4. Install the lower valve cover. Refer to «Valve Rocker Arm Cover Replacement - Lower Left»(ref-184191-S40011019652005082200000) in Engine Mechanical - 6.6L.
  1. Remove the upper valve cover. Refer to «Valve Rocker Arm Cover Replacement - Lower Right»(ref-184191-S15957937092005082200000) in Engine Mechanical - 6.6L.
  2. Remove the fuel return pipe bolts.
  3. Remove the fuel injector return pipe.
  4. Remove and discard the return pipe gaskets.
IMPORTANTAlways install NEW copper gaskets onto the fuel injector fuel return pipe.
  1. Install the NEW gaskets onto fuel injector return pipe.
  2. Install the fuel injector return pipe. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel injector return pipe bolts. Tighten: Tighten the bolts to 16 N.m (12 lb ft).
  4. Install the upper valve cover. Refer to «Valve Rocker Arm Cover Replacement - Lower Right»(ref-184191-S15957937092005082200000) in Engine Mechanical - 6.6L.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct.
  5. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  6. Remove the charged air cooler inlet duct from the turbocharger.
  7. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  8. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  9. Disconnect the fuel feed and return pipes from the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  10. Remove the air conditioning (A/C) compressor/power steering pump bracket. Refer to «Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement»(ref-184191-S09647890492005082200000) in Engine Mechanical - 6.6L.
  11. Remove the heater pipe bolt and pipe.
  12. Remove the fuel pipe clip bolt and clip.
  13. Remove the fuel pipe clip bolts and clips on the intake.
  14. Remove the fuel feed front pipe bracket nuts.
  15. Remove the fuel feed front hose from the fuel feed front pipe.
  16. Remove the fuel feed front pipe (1).
  1. Install the fuel feed front pipe (1).
  2. Install the fuel feed front hose to the fuel feed front pipe.
  3. Install the fuel feed front pipe bracket nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  4. Install the fuel pipe clips and bolts to the intake. Tighten: Tighten the bolts to 16 N.m (11 lb ft).
  5. Install the fuel pipe clip and bolt. Tighten: Tighten the bolt to 16 N.m (11 lb ft).
  6. Install the heater pipe and bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  7. Install the A/C compressor/power steering pump bracket. Refer to «Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement»(ref-184191-S09647890492005082200000) in Engine Mechanical - 6.6L.
  8. Connect the fuel feed and return pipes from the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  9. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  10. Install the charged air cooler inlet duct to the turbocharger.
  11. Align the mark on the duct (2) with the mark on the turbocharger.
  12. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  13. Install the charged air cooler outlet duct to the intake.
  14. Align the mark on the duct (3) with the mark on the turbocharger.
  15. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  16. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  9. Remove the fuel feed front pipe bracket nut.
  10. Remove the fuel feed front pipe (1).
  11. Reposition the fuel injection fuel feed front hose clamps.
  12. Remove the fuel injection fuel feed front hose.
  13. Remove the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  14. Remove the fuel return rear pipe bolt (2) from the cylinder head.
  15. Remove the fuel pipe clip bolt and clip.
  16. Remove the fuel return rear pipe bolt and pipe.
  17. Remove and discard the return pipe gaskets.
IMPORTANTAlways install NEW copper gaskets onto the fuel injector fuel return pipe.
  1. Install NEW the return pipe gaskets. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel return rear pipe and bolt. Tighten: Tighten the bolt to 27 N.m (19 lb ft).
  3. Install the fuel pipe clip and bolt. Tighten: Tighten the bolt to 16 N.m (11 lb ft).
  4. Install the fuel return rear pipe bolt (2) to the cylinder head. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  5. Install the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  6. Install the fuel injection fuel feed front hose.
  7. Reposition the fuel injection fuel feed front hose clamps.
  8. Install the fuel feed front pipe (1).
  9. Install the fuel feed front pipe bracket nut. Tighten: Tighten the nut to 8 N.m (70 lb in).
  10. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  11. Install the charged air cooler inlet duct to the turbocharger.
  12. Align the mark on the duct (2) with the mark on the turbocharger.
  13. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  14. Install the charged air cooler outlet duct to the intake.
  15. Align the mark on the duct (3) with the mark on the turbocharger.
  16. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  17. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  19. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose cam be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct.
  5. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
  6. Remove the charged air cooler inlet duct from the turbocharger.
  7. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  8. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  9. Remove the junction block to fuel injection pump fuel feed pipe.
  1. Install the junction block to fuel injection pump fuel feed pipe. Tighten: Tighten the fitting to 41 N.m (30 lb ft).
  2. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  3. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  4. Install the charged air cooler inlet duct to the turbocharger.
  5. Align the mark on the duct (2) with the mark on the turbocharger.
  6. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  7. Install the charged air cooler outlet duct to the intake.
  8. Align the mark on the duct (3) with the mark on the turbocharger.
  9. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  10. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  4. Remove the charged air cooler outlet duct.
  5. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  6. Remove the charged air cooler inlet duct from the turbocharger.
  7. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  8. Remove the heater pipe bolt and pipe.
  9. Remove the fuel feed front pipe bracket nut.
  10. Remove the fuel feed front pipe (1).
  11. Remove the generator. Refer to «Generator Replacement (4.3L Engine)»(ref-184144-S33974241872005082200000) or «Generator Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S04235530972005082200000) or «Generator Replacement (6.6L (LB7) Engine)»(ref-184144-S05774264832005082200000) or «Generator Replacement (6.6L (LLY) Engine)»(ref-184144-S21907438982005082200000) or «Generator Replacement (8.1L Engine)»(ref-184144-S35508253322005082200000) in Engine Electrical.
  12. Reposition the fuel hose clamps.
  13. Remove the fuel feed hoses from fuel feed block (1).
  14. Remove the fuel feed junction block bolt/nut and remove the feed block (1).
  15. Remove the fuel return pipe to cylinder head bolt.
  16. Remove the fuel return pipe (2).
  1. Install the fuel return pipe (2).
  2. Install the fuel return pipe to cylinder head bolt. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  3. Install the fuel feed junction block (1) and bolt/nut. Tighten: Tighten the bolt/nut to 25 N.m (18 lb ft).
  4. Install the fuel feed hoses to fuel feed block (1).
  5. Reposition the fuel hose clamps.
  6. Install the generator. Refer to «Generator Replacement (4.3L Engine)»(ref-184144-S33974241872005082200000) or «Generator Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S04235530972005082200000) or «Generator Replacement (6.6L (LB7) Engine)»(ref-184144-S05774264832005082200000) or «Generator Replacement (6.6L (LLY) Engine)»(ref-184144-S21907438982005082200000) or «Generator Replacement (8.1L Engine)»(ref-184144-S35508253322005082200000) in Engine Electrical.
  7. Install the fuel feed front pipe (1).
  8. Install the fuel feed front pipe bracket nut. Tighten: Tighten the nut to 8 N.m (70 lb in).
  9. Install the heater pipe and bolt. Tighten: Tighten the bolt to 20 N.m (14 lb ft).
  10. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  11. Install the charged air cooler inlet duct to turbocharger.
  12. Align the mark on the duct (2) with the mark on the turbocharger.
  13. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  14. Install the charged air cooler outlet duct to the intake.
  15. Align the mark on the duct (3) with the mark on the turbocharger.
  16. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  17. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  18. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  9. Remove the heater pipe bolt and pipe.
  10. Remove the fuel feed front pipe bracket nut.
  11. Remove the fuel feed front pipe (1).
  12. Reposition the fuel hose clamps.
  13. Remove the fuel feed hoses from fuel feed block (1).
  14. Remove the fuel feed junction block bolt/nut and remove the feed block (1).
  1. Install the fuel feed junction block (1) and bolt/nut. Tighten: Tighten the bolt/nut to 25 N.m (18 lb ft).
  2. Install the fuel feed hoses to fuel feed block (1).
  3. Reposition the fuel hose clamps.
  4. Install the fuel feed front pipe (1).
  5. Install the fuel feed front pipe bracket nut. Tighten: Tighten the nut to 8 N.m (70 lb in).
  6. Install the heater pipe and bolt. Tighten: Tighten the bolt to 20 N.m (14 lb ft).
  7. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  8. Install the charged air cooler inlet duct to turbocharger.
  9. Align the mark on the duct (2) with the mark on the turbocharger.
  10. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  11. Install the charged air cooler outlet duct to the intake.
  12. Align the mark on the duct (3) with the mark on the turbocharger.
  13. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  14. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  16. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  9. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  10. Disconnect the fuel lines from the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  11. Remove the fuel feed front pipe bracket nut.
  12. Remove the fuel feed front pipe (1).
  13. Remove the fuel injection pump to junction block fuel feed front pipe.
  14. Remove the fuel rail feed pipe bracket
  15. Remove the fuel rail feed pipe from junction block.
  16. Remove the fuel rail feed pipe from right fuel rail.
  1. Install the fuel rail feed pipe to the right fuel rail. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel rail feed pipe to the junction block Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  3. Install the fuel rail feed pipe bracket
  4. Install the fuel injection pump to junction block fuel feed front pipe. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  5. Remove the fuel feed front pipe (1).
  6. Remove the fuel feed front pipe bracket nut. Tighten: Tighten the nut to 8 N.m (70 lb in).
  7. Connect the fuel lines to the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  8. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  9. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  10. Install the charged air cooler inlet duct to turbocharger.
  11. Align the mark on the duct (2) with the mark on the turbocharger.
  12. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  13. Install the charged air cooler outlet duct to the intake.
  14. Align the mark on the duct (3) with the mark on the turbocharger.
  15. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  16. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  18. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  9. Remove the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  10. Remove the fuel rail feed pipe from junction block.
  11. Remove the fuel rail feed pipe from right fuel rail.
  1. Install the fuel rail feed pipe to right fuel rail.
  2. Install the fuel rail feed pipe to junction block. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  3. Install the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  4. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184139-S34592423322005082200000) .
  5. Install the charged air cooler inlet duct to turbocharger.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  8. Install the charged air cooler outlet duct to the intake.
  9. Align the mark on the duct (3) with the mark on the turbocharger.
  10. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  13. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  2. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  3. Remove the charged air cooler outlet duct.
  4. Remove the heater outlet hose bolt (2) from the generator bracket.
  5. Remove the fuel filter. Refer to «Fuel Filter Replacement»(ref-184139-S21716815052005082200000) .
  6. Remove the fuel injection control module. Refer to «Fuel Injection Control Module Replacement»(ref-184139-S11886149422005082200000) .
  7. Position the heater outlet hose out of the way.
  8. Remove exhaust gas recirculation (EGR) valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-184139-S37431876232005082200000) .
  9. Before removing the fuel injector lines, use compressed air to blow any debris from between the injector line and fittings (1, 2). Wipe the fittings clean of debris.
  10. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings (1, 2) to assist in containing any debris during removal.
  11. Remove the fuel injector feed pipe retainer bolts and retainers.
  12. Remove fuel injector feed pipes.
  1. Install the fuel injector feed pipes.
  2. Tighten the fuel injector feed pipe fittings (1, 2). Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  3. Install the fuel injector feed pipe retainers and bolts. Tighten: Tighten the screws to 4 N.m (35 lb in).
  4. After installing the fuel injector lines, clean the injector line and apply sealant, GM P/N 97720043, at the fittings (1, 2) to prevent moisture and debris from collecting between the line and fitting
  5. Install EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-184139-S37431876232005082200000) .
  6. Position the heater outlet hose.
  7. Install the fuel filter. Refer to «Fuel Filter Replacement»(ref-184139-S21716815052005082200000) .
  8. Install the fuel injection control module. Refer to «Fuel Injection Control Module Replacement»(ref-184139-S11886149422005082200000) .
  9. Install the heater outlet hose bolt (2) to the generator bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
  10. Install the charged air cooler outlet duct to the intake.
  11. Align the mark on the duct (3) with the mark on the turbocharger.
  12. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  13. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
  4. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  5. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the battery cable to generator nut.
  9. If equipped, remove the battery cable to auxiliary generator nut.
  10. Remove the battery cable harness clip from the bracket.
  11. Remove the battery cable junction block bolt from the power steering pump.
  12. Move and secure the battery cables out of the way.
  13. Disconnect the fuel lines from the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  14. Remove the fuel hose bracket nut from the upper valve rocker arm cover.
  15. Disconnect the engine wiring harness connectors. Lift up on the latch in order to disconnect the connectors.
  16. Remove the engine wiring harness bulk electrical connectors bolts (1).
  17. Remove the engine wiring harness bracket bolts (2).
  18. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  19. Remove the glow plug relay bracket. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  20. Remove the auxiliary generator, if equipped. Refer to «Generator Replacement - Auxiliary (6.6L (LB7) Engine)»(ref-184144-S18510786862005082200000) or «Generator Replacement - Auxiliary (6.6L (LLY) Engine)»(ref-184144-S28659530612005082200000) in Engine Electrical.
  21. Reposition the positive crankcase ventilation (PCV) hose clamp.
  22. Disconnect the PCV hose from the upper valve rocker arm cover.
  23. Before removing the fuel injector lines, use compressed air to blow any debris from between the injector line and fittings (1, 2). Wipe the fittings clean of debris.
  24. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings (1, 2) to assist in containing any debris during removal.
  25. Remove the fuel injector feed pipe retainer bolts and retainers.
  26. Remove fuel injector feed pipes.
  1. Install fuel injector feed pipes.
  2. Tighten the fuel injector feed pipe fittings (1, 2). Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  3. Install the fuel injector feed pipe retainers and bolts. Tighten: Tighten the screws to 4 N.m (35 lb in).
  4. After installing the fuel injector lines, clean the injector line and apply sealant, GM P/N 97720043, at the fittings (1, 2) to prevent moisture and debris from collecting between the line and fitting
  5. Install the PCV hose to the upper valve rocker arm cover.
  6. Position the PCV hose clamp.
  7. Install the engine wiring harness bracket bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Install the engine wiring harness bulk electrical connector bolts (1). Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  9. Connect the engine wiring harness bulk electrical connectors.
  10. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  11. Install the glow plug relay bracket. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  12. Install the auxiliary generator, if equipped. Refer to «Generator Replacement - Auxiliary (6.6L (LB7) Engine)»(ref-184144-S18510786862005082200000) or «Generator Replacement - Auxiliary (6.6L (LLY) Engine)»(ref-184144-S28659530612005082200000) in Engine Electrical.
  13. Connect the fuel lines to the chassis pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  14. Install the fuel hose bracket nut to the valve rocker arm cover. Tighten: Tighten the nut to 21 N.m (15 lb ft).
  15. Position the generator positive cable.
  16. Install the generator positive cable in the clip on the engine front cover.
  17. Install the generator positive cable and nut to the generator. Tighten: Tighten the nut to 9 N.m (80 lb in).
  18. Install the battery positive cable junction block bracket and bolt to the power steering pump. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  19. Install the charged air cooler inlet duct to the turbocharger.
  20. Align the mark on the duct (2) with the mark on the turbocharger.
  21. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  23. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  24. Install the upper intake manifold cover.
  25. Install the upper intake manifold cover to the outlet duct.
  26. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Relieve the fuel pressure.
  3. Disconnect the fuel pipes from the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  4. Remove the fuel cooler bolts (4, 6).
  5. Remove the fuel cooler (1).
  6. Remove the fuel cooler support bracket bolt (2, 5), and bracket (3) from the fuel cooler (1), if necessary.
  1. Install the fuel cooler support bracket (3), and bolts (2, 5) to the fuel cooler (1), if necessary. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  2. Install the fuel cooler (1) to the chassis and crossover.
  3. Install the fuel cooler bolts (4, 6). Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  4. Connect the fuel pipes to the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  5. Lower the vehicle.
  6. Purge the air from the fuel system.
  7. Start the engine and inspect for fuel leaks.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Relieve the fuel pressure.
  3. Disconnect the fuel pipes from the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  4. Remove the fuel cooler nuts (2).
  5. Remove the fuel cooler (1).
  1. Install the fuel cooler (1). NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel cooler nuts (2). Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  3. Connect the fuel pipes to the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  4. Lower the vehicle.
  5. Purge the air from the fuel system.
  6. Start the engine and inspect for fuel leaks.
  1. Remove the fuel tank filler housing to body screws (1) and retainer (2).
  2. Partially drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184139-S16015704432005082200000) .
  3. Remove the fuel tank filler pipe housing to fuel tank fill pipe screws.
  4. Remove the fuel tank filler housing.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel tank ground strap bolt.
  7. Remove the chassis harness ground strap and fuel tank ground strap.
  8. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
  9. Loosen the fuel tank fill pipe clamp.
  10. Remove the fuel fill pipe from the tank and the vehicle.
  11. Cap the opening on the fuel tank in order to prevent possible fuel system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel fill pipe to the vehicle and tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Tighten the fuel tank fill pipe clamp. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  4. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  5. Install the chassis harness ground strap and fuel tank ground strap.
  6. Install the fuel tank ground strap bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  7. Lower the vehicle.
  8. Install the fuel tank filler housing.
  9. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  10. Install the fuel tank filler housing to body screws (1) and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  11. Fill the fuel tank, if necessary.
  1. Relieve the fuel system pressure.
  2. Disconnect the fuel feed and pressure balance rear pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  3. Loosen the fuel fill and vent hose clamps at the tank.
  4. Remove the fuel fill pipe and vent hose from the tank.
  5. Cap the fuel and vent holes in the fuel tank in order to prevent possible fuel system contamination.
  1. Remove the caps from the fuel and vent holes in the fuel tank.
  2. Install the fuel fill pipe and vent hose to the tank. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Tighten the fuel fill vent hose clamps at the tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  4. Connect the fuel feed and pressure balance rear pipes. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  3. Reposition the inlet hose clamps.
  4. Remove the inlet hose from the radiator.
  5. Remove the inlet hose from the water outlet tube.
  6. Remove the bolt attaching the positive battery cable junction box and bracket and move it out of the way.
  7. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  8. Remove the charged air cooler inlet duct from the turbocharger.
  9. Disconnect the glow plug relay electrical connectors (1, 2, 3).
  10. Remove the glow plug bracket.
  11. Disconnect the engine wiring harness connectors. Lift up on the latch in order to disconnect the connectors.
  12. Remove the engine connector bracket and set aside.
  13. Disconnect the fuel in-line and return lines.
  14. Remove the L-bracket holding the fuel lines.
  15. Reposition the positive crankcase ventilation (PCV) hose clamp.
  16. Remove the PCV hose and move it out of the way.
  17. Remove the water pipe outlet from the thermostat housing.
  18. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  19. Remove the air conditioning (A/C) compressor bolts and position aside.
  20. Remove the line from the junction block to the injection pump.
  21. Loosen the fuel return rear pipe (1) at the back end of the fuel rail and remove.
  22. Remove the fuel junction block.
  23. Remove the fuel injector feed pipe retainer bolts and retainers.
  24. Remove the fuel injector pipes.
  25. Remove the fuel rail bolts and rail.
  1. Install the fuel rail and bolts. Tighten: Tighten the bolts to 26 N.m (19 lb ft).
  2. Install the fuel injector feed pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  3. Install the fuel injector feed pipe retainers and bolts. Tighten: Tighten the bolts to 4 N.m (35 lb in).
  4. Install the fuel junction block. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
  5. Connect the fuel return rear pipe (1) to the back end of the fuel rail. Tighten: Tighten the fitting to 44 N.m (32 lb ft).
  6. Install the line from the junction block to the injection pump. Tighten: Tighten the fitting to 40 N.m (30 lb ft).
  7. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  8. Install drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  9. Install the water outlet pipe to thermostat housing.
  10. Install the PCV hose.
  11. Reposition the PCV hose clamp.
  12. Install the L-bracket holding the fuel lines.
  13. Connect the fuel lines.
  14. Install the glow plug bracket.
  15. Install the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  16. Connect the glow plug relay electrical connectors (1, 2, 3).
  17. Install the charged air cooler inlet duct to the turbocharger.
  18. Align the mark on the duct (2) with the mark on the turbocharger.
  19. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  20. Install the bolt attaching the positive battery cable junction box and bracket.
  21. Install the inlet hose to the water outlet tube.
  22. Install the inlet hose to the radiator.
  23. Reposition the inlet hose clamps.
  24. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  25. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  26. Replace all hold down ties.
  27. Start the engine and check for leaks or noises.
  28. After the engine warms up, refill the coolant reservoir to the proper level.
  1. Disconnect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Reposition the positive crankcase ventilation (PCV) hose clamp.
  5. Remove the PCV hose.
  6. Remove the fuel injection control module. Refer to «Fuel Injection Control Module Replacement»(ref-184139-S11886149422005082200000) .
  7. Remove the fuel filter. Refer to «Fuel Filter Replacement»(ref-184139-S21716815052005082200000)
  8. Remove the exhaust gas recirculation (EGR) valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-184139-S37431876232005082200000) .
  9. Disconnect the fuel feed rear pipe from the junction block (1).
  10. Remove the fuel injector feed pipe retainer bolts and retainers.
  11. Remove the fuel injector pipes.
  12. Remove the fuel rail bolts and rail.
  1. Install the fuel rail and bolts. Tighten: Tighten the bolts to 26 N.m (19 lb ft).
  2. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
  3. Install the fuel injector feed pipe retainers and bolts. Tighten: Tighten the bolts to 4 N.m (35 lb in).
  4. Connect the fuel feed rear pipe at the end of the fuel rail (1). Tighten: Tighten the lines to 44 N.m (32 lb ft).
  5. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(ref-184139-S37431876232005082200000) .
  6. Install the fuel filter. Refer to «Fuel Filter Replacement»(ref-184139-S21716815052005082200000) .
  7. Connect the fuel injection control module. Refer to «Fuel Injection Control Module Replacement»(ref-184139-S11886149422005082200000) .
  8. Install the PCV hose.
  9. Reposition the PCV hose clamp.
  10. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  11. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  12. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  13. Replace all hold down ties.
  14. Start the engine and check for leaks or noises.
  15. After the engine warms up, refill the coolant reservoir.

Scheme 269

Scheme 269: Removal Procedure
Scheme 269: Removal Procedure
  1. Move the hood to the service position, by moving the hood hinge bolts (1) to the service position (2).
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. Loosen the outlet duct clamp at the upper intake manifold cover.
  4. Remove the upper intake manifold cover from the outlet duct.
  5. Remove the upper intake manifold cover.
  6. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  7. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  8. Reposition the air conditioning (A/C) compressor using the following procedure: Disconnect the A/C compressor clutch electrical connector. Disconnect the A/C cut out switch electrical connector. Remove the A/C compressor mounting bolts. Reposition the A/C compressor with the hoses attached to the right side of the engine compartment.
  9. Disconnect the left front injector harness electrical connector (1).
  10. Disconnect the oil pressure sending unit electrical connector.
  11. Disconnect the turbocharger coolant hose and clamp from the turbocharger bypass valve.
  12. Disconnect the water outlet tube using the following procedure: Remove the bolts attaching the water outlet tube to the left rocker arm cover. Remove the bolt attaching the water outlet tube to the thermostat housing. Remove the water outlet tube. Remove and discard the O-ring seal.
  13. Reposition the positive crankcase ventilation (PCV) hose clamp.
  14. Remove the PCV hose from the upper valve rocker arm cover.
  15. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  16. Remove the charged air cooler inlet duct from the turbocharger.
  17. Remove the banjo bolt (1) from the fuel junction block.
  18. Disconnect the fuel pipes (3) from the fuel junction block.
  19. Disconnect the fuel pipe junction block from the fuel rail (1).
  20. Remove the fuel junction block nuts.
  21. Remove the fuel junction block.
  1. Install the fuel junction block and nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  2. Install the fuel pipe junction block to the fuel rail (1). Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  3. Connect the fuel pipes (3) to the junction block. Tighten: Tighten the fittings to 44 N.m (32 lb ft).
  4. Connect the fuel pipe junction block to the fuel rail (1). Tighten: Tighten the fitting to 44 N.m (32 lb ft).
  5. Install the charged air cooler inlet duct to the turbocharger.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  8. Install the PCV hose to the upper valve rocker arm cover.
  9. Reposition the PCV hose clamp.
  10. Install the water outlet tube using the following procedure: Install a new O-ring seal on the water outlet tube. Lightly lubricate the O-ring seal with coolant. Install the water outlet tube. Install the bolt attaching the water outlet tube to the thermostat housing. Tighten: Tighten the bolt to 21 N.m (16 lb ft). Install the bolts attaching the water outlet tube to the rocker arm cover. Tighten: Tighten the bolts to 21 N.m (16 lb ft).
  11. Install the turbocharger coolant hose and clamp to the turbocharger bypass valve.
  12. Connect the oil pressure sending unit electrical connector.
  13. Connect the left front injector harness electrical connector (1).
  14. Install the A/C compressor using the following procedure: Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Connect the A/C cut out switch electrical connector. Connect the A/C compressor clutch electrical connector.
  15. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  16. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  17. Install the upper intake manifold cover.
  18. Install the upper intake manifold cover to the outlet duct.
  19. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  21. Position the hood in the normal operating position by moving the hood hinge bolts from the service position (2) to the normal operating position (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  22. Purge air from the fuel system.
  1. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(ref-184139-S39919690542005082200000) .
  2. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  3. Disconnect the A/C cut out switch electrical connector.
  4. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  5. Remove the A/C compressor bolts.
  6. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
  7. Remove the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  8. Disconnect both main harness electrical connectors.
  9. Remove both main harness electrical connector to bracket bolts (1).
  10. Remove the main harnesses from the bracket.
  11. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  12. Disconnect the barometric pressure (BARO) sensor electrical connector (1)
  13. Disconnect the glow plug relay electrical connectors (1, 2, 3).
  14. Disconnect the fuel rail temperature sensor electrical connector (1).
  15. Disconnect the left front fuel injector electrical connector (1).
  16. Disconnect the left rear fuel injector electrical connector (1).
  17. Disconnect the fuel pressure regulator electrical connector (1).
  18. Disconnect the oil level sensor harness electrical connector (1).
  19. Remove the positive crankcase ventilation (PCV) hose from both valve covers.
  20. Reposition the injection pump inlet clamp.
  21. Remove the injection pump inlet hose from the fuel feed distribution (leak-off) block. Reposition the hose.
  22. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
  23. Using compressed air, thoroughly blow dry the regulator and pump.
  24. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX®.
  25. Remove the fuel pressure regulator (1).
  26. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following: Place a clean rag over the bore on order to collect the excess fuel. Bump the engine over in order to flush any debris out of the regulator bore.
IMPORTANTIf the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.
  1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil. IMPORTANT: If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage.
  2. Install the fuel pressure regulator (1).
  3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX®. Tighten: Tighten the screws a first pass to 4 N.m (35 lb in). Tighten the screws a final pass to 7 N.m (62 lb in).
  4. Install the injection pump inlet hose to the fuel feed distribution (leak) block.
  5. Position the injection pump inlet clamp.
  6. Install the PCV hose to both valve covers.
  7. Connect the oil level sensor harness electrical connector (1).
  8. Connect the fuel pressure regulator electrical connector (1).
  9. Connect the left rear fuel injector electrical connector (1).
  10. Connect the left front fuel injector electrical connector (1).
  11. Connect the fuel rail temperature sensor electrical connector (1).
  12. Connect the glow plug relay electrical connectors (1, 2, 3).
  13. Connect the BARO sensor electrical connector (1)
  14. Connect the ECT sensor electrical connector (1).
  15. Install the main harnesses to the bracket.
  16. Install both main harness electrical connector to bracket bolts (1). Tighten: Tighten the bolts to 21 N.m (15 lb ft).
  17. Connect both main harness electrical connectors.
  18. Install the water outlet tube. Refer to «Water Outlet Tube Replacement (6.6L (LB7) Engine)»(ref-184167-S14199026622005082200000) or «Water Outlet Tube Replacement (6.6L (LLY) Engine)»(ref-184167-S28051507212005082200000) in Engine Cooling.
  19. Position the A/C compressor.
  20. Install the A/C compressor bolts. Tighten: Tighten the bolts to 53 N.m (37 lb ft).
  21. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  22. Connect the A/C cut out switch electrical connector.
  23. Connect the A/C compressor clutch electrical connector.
  24. Install the air intake pipe. Refer to «Air Intake Pipe Replacement»(ref-184139-S39919690542005082200000) .

Fuel Pressure Relief Valve Replacement

At this time the fuel pressure relief valve is serviced as part of the Junction Block. Refer to Fuel Junction Block Replacement .

  1. Disconnect negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the air intake duct between the air cleaner and the turbocharger inlet housing.
  3. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
  4. Remove the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) or «Fan Shroud Replacement - Upper (W/HP2)»(ref-184167-S13444932982005082200000) in Engine Cooling.
  5. Remove the fan. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) in Engine Cooling.
  6. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  7. Remove the bolt holding the positive battery cable junction box and bracket and move out of the way.
  8. Remove the A/C compressor. Refer to «Compressor Replacement (L18)»(ref-184172-S36134357292005082200000) or «Compressor Replacement (LB7)»(ref-184172-S08881900412005082200000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-184172-S04348428702005082200000) in HVAC.
  9. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(ref-184156-S27669940212005082200000) or «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-184156-S27622231802005082200000) or «Power Steering Pump Replacement (8.1L)»(ref-184156-S09574380352005082200000) or «Power Steering Pump Replacement (6.6L Diesel)»(ref-184156-S26835758592005082200000) or «Power Steering Pump Replacement (Parallel Hybrid Truck)»(ref-184156-S42024159772005082200000) in Power Steering Systems.
  10. Position the A/C compressor and power steering pump aside.
  11. Remove the oil filler tube. Refer to «Oil Fill Tube Replacement»(ref-184191-S11543010562005082200000) in Engine Mechanical - 6.6L.
  12. Remove the air conditioning/power steering bracket.
  13. Remove the generator. Refer to «Generator Replacement (4.3L Engine)»(ref-184144-S33974241872005082200000) or «Generator Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S04235530972005082200000) or «Generator Replacement (6.6L (LB7) Engine)»(ref-184144-S05774264832005082200000) or «Generator Replacement (6.6L (LLY) Engine)»(ref-184144-S21907438982005082200000) or «Generator Replacement (8.1L Engine)»(ref-184144-S35508253322005082200000) in Engine Mechanical - 6.6L.
  14. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts.
  15. Remove the positive crankcase ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and move to the side.
  16. Remove the generator bracket. Refer to «Generator Bracket Replacement (4.3L Engine)»(ref-184144-S26765978552005082200000) or «Generator Bracket Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S10814021282005082200000) or «Generator Bracket Replacement (6.6L (LB7) Engine)»(ref-184144-S13438957352005082200000) or «Generator Bracket Replacement (6.6L (LLY) Engine)»(ref-184144-S00721751172005082200000) or «Generator Bracket Replacement (8.1L Engine)»(ref-184144-S10246421212005082200000) in Engine Electrical.
  17. Remove the turbo cooling hose return line clamp and hose.
  18. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way.
  19. Remove bolt holding wiring support bracket at thermostat housing.
  20. Move the main wiring harness by disconnecting the following: The fuel pressure regulator connector on the fuel injection pump The fuel injection control module connectors
  21. Flip the wire harness and harness tray towards the back and set aside.
  22. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing.
  23. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(ref-184139-S39919690542005082200000) .
  24. Remove the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L (LB7) Engine)»(ref-184167-S16071792312005082200000) or «Thermostat Housing Crossover Replacement (6.6L (LLY) Engine)»(ref-184167-S02673552142005082200000) in Engine Cooling.
  25. Remove the hose to the turbo water feed line. Refer to «Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LB7) Engine)»(ref-184167-S40349494602005082200000) or «Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Inlet Pipe)»(ref-184167-S41132208552005082200000) or «Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Outlet Pipe)»(ref-184167-S21090995642005082200000) in Engine Cooling.
  26. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and function block. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184139-S13007011312005082200000) .
  27. Remove the supply hose from the fuel injection pump.
  28. Remove the fuel return hose from fuel injection pump.
  29. Remove the high pressure line from the injection pump to the junction block.
  30. Remove fuel injection pump from the block using two screwdrivers to work the pump from the block towards rear of engine keeping the pump straight.
  31. Remove fuel injection pump.
  1. Install the fuel injection pump.
  2. Install the fuel injection pump bolts to the front of the engine front cover. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  3. Connect the fuel return line banjo bolt at the junction block. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  4. Install the fuel supply hose and hose clamp to the fuel injection pump.
  5. Install fuel return hose and hose clamp to the fuel injection pump.
  6. Install high pressure lines to the injection pump to the junction block. Tighten: Tighten the fittings to 44 N.m (32 lb ft).
  7. Install the fuel pressure sensor connector at the junction block.
  8. Replace the hose to turbocharger water feed line. Refer to «Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LB7) Engine)»(ref-184167-S40349494602005082200000) or «Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Inlet Pipe)»(ref-184167-S41132208552005082200000) or «Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Outlet Pipe)»(ref-184167-S21090995642005082200000) in Engine Cooling.
  9. Install the thermostat housing crossover. Refer to «Thermostat Housing Crossover Replacement (6.6L (LB7) Engine)»(ref-184167-S16071792312005082200000) or «Thermostat Housing Crossover Replacement (6.6L (LLY) Engine)»(ref-184167-S02673552142005082200000) in Engine Cooling.
  10. Install air intake pipe. Refer to «Air Intake Pipe Replacement»(ref-184139-S39919690542005082200000) .
  11. Install the heater pipe using the following procedure: Install new O-ring lubricated with clean engine oil. Install the heater pipe bracket bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft). Install the heater pipe to water crossover bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  12. Connect the engine wiring harness.
  13. Install upper radiator hose at outlet pipe using the following procedure: Install upper radiator hose mounting bolts and brackets. Tighten: Tighten the bolts to 10 N.m (89 lb ft). Install the upper radiator hose clamp.
  14. Install turbo cooling hose return and clamp.
  15. Install the left idler pulley and bolt.
  16. Install PCV catch tank, hose clamp and bolt to the right front of the engine.
  17. Install the thermostat housing bracket, wiring, fuel test port and nuts.
  18. Install the generator. Refer to «Generator Replacement (4.3L Engine)»(ref-184144-S33974241872005082200000) or «Generator Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S04235530972005082200000) or «Generator Replacement (6.6L (LB7) Engine)»(ref-184144-S05774264832005082200000) or «Generator Replacement (6.6L (LLY) Engine)»(ref-184144-S21907438982005082200000) or «Generator Replacement (8.1L Engine)»(ref-184144-S35508253322005082200000) in Engine Electrical.
  19. Install a new O-ring to the oil fill tube and lubricate the O-ring with clean engine oil.
  20. Install the oil fill tube. Refer to «Oil Fill Tube Replacement»(ref-184191-S11543010562005082200000) in Engine Mechanical - 6.6L.
  21. Install the air conditioning/power steering bracket and bolts. Tighten: Tighten the bolts to 46 N.m (34 lb ft).
  22. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.3L)»(ref-184156-S27669940212005082200000) or «Power Steering Pump Replacement (4.8L, 5.3L and 6.0L)»(ref-184156-S27622231802005082200000) or «Power Steering Pump Replacement (8.1L)»(ref-184156-S09574380352005082200000) or «Power Steering Pump Replacement (6.6L Diesel)»(ref-184156-S26835758592005082200000) or «Power Steering Pump Replacement (Parallel Hybrid Truck)»(ref-184156-S42024159772005082200000) in Power Steering System.
  23. Install the air conditioning compressor. Refer to «Compressor Replacement (L18)»(ref-184172-S36134357292005082200000) or «Compressor Replacement (LB7)»(ref-184172-S08881900412005082200000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-184172-S04348428702005082200000) in HVAC.
  24. Install the positive battery cable junction box and bolt.
  25. Install the serpentine belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  26. Install the fan blade. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) in Engine Cooling.
  27. Install the upper fan shroud. Refer to «Fan Shroud Replacement - Upper (W/O M74)»(ref-184167-S29876023482005082200000) or «Fan Shroud Replacement - Upper (W/M74)»(ref-184167-S38104134012005082200000) or «Fan Shroud Replacement - Upper (W/HP2)»(ref-184167-S13444932982005082200000) in Engine Cooling.
  28. Refill the coolant. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  29. Install the air intake duct between the air cleaner and the turbocharger inlet housing.
  30. Connect the negative battery cables. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  31. Replace all of the hold down ties.
  32. Start the engine and check for leaks or noises.
  33. After the engine warms up, refill coolant reservoir to proper level.
IMPORTANTRefer to Engine Controls Component Views for fuel injector locations. Failure to identify the correct cylinder will result in misdiagnosis.
  1. Remove the lower valve cover. Refer to «Valve Rocker Arm Cover Replacement - Lower Left»(ref-184191-S40011019652005082200000) or «Valve Rocker Arm Cover Replacement - Lower Right»(ref-184191-S15957937092005082200000) in Engine Mechanical - 6.6L. IMPORTANT: When the fuel injector pressure lines are removed, debris may fall into the fuel injector inlet fitting. Remove any debris from the inlet fitting of the fuel injector.
  2. Remove the fuel injector return line from fuel injectors.
  3. Remove the bolt from the fuel injector bracket.
  4. Install J 44639 (2) onto the injector retainer bracket.
  5. Install a wrench onto J 44639 (2) and pry away from the fuel injector (1).
  6. Remove the fuel injector(s).
  7. Remove the copper compression washer from the injector hole if the washer was not removed with the injector.
  1. If the fuel injector sleeve was pulled from the cylinder head when removing the injector(s), refer to «Fuel Injector Sleeve Replacement»(ref-184191-S16796294672005082200000) in Engine Mechanical - 6.6L.
  2. Install a NEW O-ring onto the fuel injector(s).
  3. Lubricate the O-ring with clean engine oil.
  4. Install a NEW copper washer into the fuel injector bore in the cylinder head.
  5. Install the fuel injector with injector bracket.
  6. Install the injector bracket bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
  7. Install the return pipe assembly.
  8. Install the fuel injector return line to injector eye bolts and washers. Lubricate the washers with diesel fuel prior to installing. Tighten: Tighten the fuel injector line to injector eye bolts to 16 N.m (12 lb ft).
  9. Install the fuel injector return line to cylinder head eye bolts and washers. Lubricate the washers with diesel fuel prior to installing. Tighten: Tighten the fuel injector return line to cylinder head eye bolts to 17 N.m (12 lb ft).
  10. Install the lower valve cover. Refer to «Valve Rocker Arm Cover Replacement - Lower Left»(ref-184191-S40011019652005082200000) or «Valve Rocker Arm Cover Replacement - Lower Right»(ref-184191-S15957937092005082200000) in Engine Mechanical - 6.6L.
  1. Remove the air conditioning (A/C) compressor. Refer to «Compressor Replacement (L18)»(ref-184172-S36134357292005082200000) or «Compressor Replacement (LB7)»(ref-184172-S08881900412005082200000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-184172-S04348428702005082200000) in Heating, Ventilation, and Air Conditioning.
  2. Disconnect the fuel rail pressure sensor (1) electrical connector.
  3. Prior to removal, clean the function block and fuel pressure sensor thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
  4. Using compressed air, thoroughly blow dry the block and sensor.
  5. Remove the sensor and metal gasket from the function block. Discard the gasket.
  1. If a crows foot is used to torque the sensor then special attention to the position of the crows foot in relation to the torque wrench is required.
  2. Install the sensor and a NEW metal gasket to the function block.
  3. If the crows foot is kept perpendicular (90 degrees) to the torque wrench during the entire tightening procedure, then the torque wrench can be set to the listed torque specification. Tighten: Tighten the sensor to 70 N.m (52 lb ft).
  4. Connect the sensor (1) electrical connector.
  5. Install the A/C compressor. Refer to «Compressor Replacement (L18)»(ref-184172-S36134357292005082200000) or «Compressor Replacement (LB7)»(ref-184172-S08881900412005082200000) or «Compressor Replacement (LR4, LM7, and LQ4)»(ref-184172-S04348428702005082200000) in Heating, Ventilation, and Air Conditioning.
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
  4. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler inlet duct from the turbocharger.
  6. Disconnect the fuel temperature sensor electrical connector (1).
  7. Remove the fuel temperature sensor.
  1. Install the fuel temperature sensor. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
  2. Connect the fuel temperature sensor electrical connector (1).
  3. Install the charged air cooler inlet duct to the turbocharger.
  4. Align the mark on the duct (2) with the mark on the turbocharger.
  5. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  6. Install the upper intake manifold cover.
  7. Install the upper intake manifold cover to the outlet duct.
  8. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Remove the glow plug nuts from the desired glow plug(s).
  5. Remove the harness from the desired glow plug(s) (1).
  6. Remove the desired glow plug(s).
  1. Install the glow plug(s). NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the buss bar (2) and wiring, if equipped. Tighten: Tighten the plug to 18 N.m (13 lb ft).
  3. Install the harness to the desired glow plug(s) (1).
  4. Install the glow plug nuts to the desired glow plug(s). Tighten: Tighten the nut to 2 N.m (18 lb in).
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  6. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Remove the glow plug nuts from the desired glow plug(s).
  5. Remove the harness from the desired glow plug(s) (1).
  6. Remove the harness from the desired glow plug(s). IMPORTANT: On the Federal Emissions equipped vehicle, there is a buss bar connecting the glow plugs on each bank of the engine.
  7. Remove the desired glow plug(s).
  1. Install the glow plug(s). Tighten: Tighten the plug to 18 N.m (13 lb ft).
  2. Install the buss bar and wiring, if equipped.
  3. Install the glow plug electrical nut. Tighten: Tighten the nut to 2 N.m (18 lb in).
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  5. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) .
  6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Loosen the outlet duct clamp at the upper intake manifold cover.
  3. Remove the upper intake manifold cover from the outlet duct.
  4. Remove the upper intake manifold cover.
  5. Using a flat bladed screwdriver, disengage the glow plug controller cover clips.
  6. Remove the glow plug controller cover.
  7. Remove the glow plug relay terminal nuts and wires.
  8. Remove the glow plug controller nuts.
  9. Lift the glow plug controller off the studs.
  10. Separate the glow plug relay from the glow plug controller housing by inserting a small screwdriver between them while prying the relay assembly outward.
  11. Slide the glow plug relay outward to disengage it from the glow plug controller housing.
  12. Using a flat bladed screwdriver, disengage the glow plug relay clip.
  13. Remove the glow plug relay.
  1. Install the glow plug relay.
  2. Slide the glow plug relay inward to engage it to the glow plug controller housing.
  3. Set the glow plug controller onto the studs.
  4. Install the glow plug controller nuts. Tighten: Tighten the nuts to 42 N.m (31 lb ft).
  5. Install the glow plug relay terminal wires and nuts. Tighten: Tighten the nuts to 5 N.m (44 lb in).
  6. Install the glow plug controller cover.
  7. Install the upper intake manifold cover.
  8. Install the upper intake manifold cover to the outlet duct.
  9. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Loosen the outlet duct clamp at the upper intake manifold cover.
  3. Remove the upper intake manifold cover from the outlet duct.
  4. Remove the upper intake manifold cover.
  5. Remove the battery supply cable nut (1) and cable from the glow plug relay battery voltage supply post.
  6. Disconnect the glow plug electrical connectors (2) from the glow plug relay (3).
  7. Remove the glow plug relay bolt (6).
  8. Remove the glow plug relay (3) from the bracket (4).
  1. Install the glow plug relay (3) onto the bracket (4). NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the glow plug relay bolt (6). Tighten: Tighten the bolt to 20 N.m (15 lb ft).
  3. Connect the glow plug electrical connectors (2) to the glow plug relay (3).
  4. Install the battery supply cable and nut (1) onto the glow plug relay. Tighten: Tighten the nut to 5 N.m (44 lb in).
  5. Install the upper intake manifold cover.
  6. Install the upper intake manifold cover to the outlet duct.
  7. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Remove the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  3. Disconnect the crankshaft position (CKP) sensor electrical connector.
  4. Remove the CKP sensor bolt (2).
  5. Remove the CKP sensor (1).
  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. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "B" spacer.
  3. If necessary, install the CKP sensor spacer. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. If necessary, install the CKP sensor spacer bolts. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  5. Lubricate a NEW CKP sensor O-ring with clean engine oil.
  6. Install the NEW O-ring to the CKP sensor (1).
  7. Install the CKP sensor bolt (2). Tighten: Tighten the bolt to 10 N.m (89 lb in).
  8. Connect the CKP sensor electrical connector.
  9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  10. Install the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
  1. Remove the cooling fan pulley (2). Refer to «Cooling Fan Pulley Replacement (6.6L (LB7) Engine)»(ref-184167-S15118344922005082200000) or «Cooling Fan Pulley Replacement (6.6L (LLY) Engine)»(ref-184167-S17201509152005082200000) in Engine Cooling.
  2. Disconnect the camshaft position (CMP) sensor electrical connector (1).
  3. Remove the CMP sensor bolt.
  4. Remove the CMP sensor.
  1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the CMP sensor bolt. Tighten: Tighten the bolt to 8 N.m (71 lb in).
  3. Install the cooling fan pulley (2). Refer to «Cooling Fan Pulley Replacement (6.6L (LB7) Engine)»(ref-184167-S15118344922005082200000) or «Cooling Fan Pulley Replacement (6.6L (LLY) Engine)»(ref-184167-S17201509152005082200000) in Engine Cooling.
  4. Connect the CMP sensor electrical connector (1).
  1. Drain cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Remove the turbocharger boost sensor bracket bolt.
  4. Remove the turbocharger boost sensor with bracket.
  5. Remove the intake heater and gasket.
  6. Remove the upper intake manifold tube nuts and upper tube.
  7. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
  8. Remove EGR inlet cooling hose (2) from cooling tube (1).
  9. Remove the EGR outlet cooling hose (1) from cooling tube (2).
  10. Remove the EGR assembly to intake manifold nuts.
  11. Remove the EGR assembly to exhaust pipe nuts.
  12. Remove the EGR assembly to EGR bracket (2) bolts.
  13. Remove the EGR assembly from the engine.
  14. Remove the EGR to EGR cooling tube bolts (1).
  15. Separate the EGR valve from the EGR cooling tube.
  1. Install the EGR valve to the EGR cooling tube. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the EGR to EGR cooling tube bolts (1). Tighten: Tighten bolts to 20 N.m (15 lb ft).
  3. Install the EGR assembly to the engine.
  4. Install the EGR assembly to EGR bracket bolts. Tighten: Tighten bolts to 20 N.m (15 lb ft).
  5. Install the EGR assembly to exhaust pipe nuts. Tighten: Tighten nuts to 20 N.m (15 lb ft).
  6. Install the EGR assembly to intake manifold nuts. Tighten: Tighten nuts to 19 N.m (14 lb ft).
  7. Install EGR outlet cooling hose (1) to EGR cooling tube (2).
  8. Install the EGR inlet cooling hose (2) to the EGR cooling tube (1).
  9. Connect the EGR vacuum hose to the EGR valve.
  10. Install the upper intake manifold tube and nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  11. Install the intake heater and gasket. Tighten: Tighten the heater to 50 N.m (37 lb ft).
  12. Install the turbocharger boost sensor with bracket.
  13. Install the turbocharger boost sensor bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  14. Install air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  15. Fill cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Remove the intake manifold tube. Refer to «Intake Manifold Tube Replacement (Federal Emissions)»(ref-184191-S26805020002005082200000) or «Intake Manifold Tube Replacement (California Emissions)»(ref-184191-S08397547522005082200000) in Engine Mechanical - 6.6L.
  4. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
  5. Remove the EGR inlet cooling hose (2) from the cooling tube (1).
  6. Remove the EGR outlet cooling hose (1) from the cooling tube (2).
  7. Remove the EGR assembly to intake manifold nuts.
  8. Remove the EGR assembly to exhaust pipe nuts.
  9. Remove the EGR assembly to EGR bracket bolts (2).
  10. Remove the EGR assembly.
  11. Remove the EGR assembly to EGR cooling tube bolts (1).
  12. Separate the EGR assembly from the EGR cooling tube.
  1. Install the EGR assembly to the EGR cooling tube. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the EGR assembly to EGR cooling tube bolts (1). Tighten: Tighten bolts to 20 N.m (15 lb ft.)
  3. Install the EGR assembly.
  4. Install the EGR assembly to the EGR bracket bolts. Tighten: Tighten bolts to 20 N.m (15 lb ft.)
  5. Install the EGR assembly to exhaust pipe nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft.)
  6. Install the EGR assembly to intake manifold nuts. Tighten: Tighten nuts to 19 N.m (14 lb ft.)
  7. Install the EGR outlet cooling hose (1) to the EGR cooling tube (2).
  8. Install the EGR inlet cooling hose (2) to the EGR cooling tube (1).
  9. Connect the EGR vacuum hose.
  10. Install the intake manifold tube. Refer to «Intake Manifold Tube Replacement (Federal Emissions)»(ref-184191-S26805020002005082200000) or «Intake Manifold Tube Replacement (California Emissions)»(ref-184191-S08397547522005082200000) in Engine Mechanical - 6.6L.
  11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  12. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  1. Remove right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right (6.6L (LB7) Engine)»(ref-184230-S18283606812005082200000) or «Exhaust Pipe Replacement - Right (6.6L (LLY) Engine)»(ref-184230-S32948903702005082200000) in Engine Exhaust.
  2. Remove the exhaust gas recirculation (EGR) valve cooler tube to bracket (2) bolts.
  3. Remove the EGR bracket to cylinder head bolts (1).
  4. Remove the bracket.
  1. Remove the bracket. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the EGR bracket to cylinder head bolts (1). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  3. Install the EGR valve cooler tube to bracket (2) bolts. Tighten: Tighten bolts to 20 N.m (15 lb ft).
  4. Install right exhaust pipe. Refer to «Exhaust Pipe Replacement - Right (6.6L (LB7) Engine)»(ref-184230-S18283606812005082200000) or «Exhaust Pipe Replacement - Right (6.6L (LLY) Engine)»(ref-184230-S32948903702005082200000) in Engine Exhaust.
  1. Remove the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) .
  2. Loosen the charged air cooler outlet duct to clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  3. Remove the charged air cooler outer duct.
  4. Remove the vacuum line from the exhaust gas recirculation (EGR) valve vacuum pump.
  5. Remove drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L
  6. Remove EGR vacuum pump nuts (1).
  7. Remove the EGR vacuum pump.
  1. Install the EGR vacuum pump.
  2. Install the EGR vacuum pump bolts (1). Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  3. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
  4. Install the vacuum line to the EGR vacuum pump.
  5. Install the charged air cooler outer duct to the intake.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  8. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(ref-184139-S29914489712005082200000) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Disconnect the exhaust gas recirculation (EGR) valve vacuum sensor electrical connector (1).
  3. Disconnect the EGR valve vacuum sensor vacuum line.
  4. Remove the EGR valve vacuum sensor from the bracket.
  1. Install the EGR valve vacuum sensor to the bracket.
  2. Connect the EGR valve vacuum sensor vacuum line.
  3. Connect the EGR valve vacuum sensor electrical connector (1).
  4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Disconnect the exhaust gas recirculation (EGR) valve vent solenoid electrical connector (1).
  3. Disconnect the EGR vent solenoid vacuum lines (1).
  4. Remove the EGR valve vent solenoid bolt (1) and solenoid.
  1. Install the EGR valve vent solenoid and bolt (1). Tighten: Tighten bolt to 10 N.m (89 lb in).
  2. Connect the EGR valve vent solenoid vacuum lines (1).
  3. Connect the EGR valve vent solenoid electrical connector (1).
  4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Disconnect the exhaust gas recirculation (EGR) valve solenoid electrical connector (1).
  3. Disconnect the EGR valve solenoid vacuum lines (1).
  4. Remove the EGR valve solenoid bolt (1) and solenoid.
  1. Install the EGR valve solenoid and bolt (1). Tighten: Tighten bolt to 10 N.m (89 lb in).
  2. Connect the EGR valve solenoid vacuum lines (1).
  3. Connect the EGR valve solenoid electrical connector (1).
  4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (1).
  2. Loosen the screws holding the air cleaner housing halves together.
  3. Separate the housing halves and remove the air filter element.
  4. Inspect the filter housing for debris and damage.
  1. Install the air filter element into the lower air cleaner housing. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the upper housing cover and tighten the screws. Tighten: Tighten the screws to 4 N.m (35 lb in).
  3. Connect the MAF/IAT sensor electrical connector (1).
  1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (1).
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  3. Grasp the air filter assembly (1) and pull the assembly retaining pins (2) away from the grommets (3).
  1. Line up the retaining pins (2) with the grommets (3) in the bracket.
  2. Install the air cleaner assembly until the air cleaner is seated fully on the mounts and is up against the fender apron.
  3. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  4. Connect the MAF/IAT sensor electrical connector (1).
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
  4. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
  5. Remove the outlet duct from the turbocharger and MAT/IAT sensor.
  1. Install the outlet duct to the turbocharger.
  2. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
  3. Install the outlet duct to the MAF/IAT sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  5. Install the upper intake manifold cover.
  6. Install the upper intake manifold cover to the outlet duct.
  7. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  2. Remove the glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  3. Remove positive crankcase ventilation (PCV) valve hose.
  4. Remove the air intake pipe to turbocharger bolts.
  5. Remove the air intake pipe (1) from the turbocharger (3).
  1. Clean the mating surfaces on the air intake pipe (1) and the turbocharger (3).
  2. Align the air intake pipe to the turbocharger. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the air intake pipe bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Install PCV valve hose.
  5. Install glow plug relay. Refer to «Glow Plug Relay Replacement (Federal Emissions)»(ref-184139-S04214921762005082200000) or «Glow Plug Relay Replacement (California Emissions)»(ref-184139-S27581976272005082200000) .
  6. Install air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184139-S16111342522005082200000) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  2. Loosen the charged air cooler outlet duct clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  3. Remove the charged air cooler outlet duct.
  4. Disconnect the exhaust gas recirculation (EGR) throttle valve solenoid electrical connector.
  5. Disconnect the EGR throttle valve solenoid vacuum lines (1).
  6. Remove the solenoid bolt and solenoid (1).
  1. Install the solenoid (1) and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  2. Connect the EGR throttle valve vacuum lines (1).
  3. Connect the EGR throttle valve solenoid electrical connector.
  4. Install the charged air cooler outlet duct to the intake.
  5. Align the mark on the duct (2) with the mark on the turbocharger.
  6. Position the clamp (1) as shown for proper clearance. Tighten: Tighten the clamp to 6 N.m (53 lb in).
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.

More articles — Engine Controls - 6.6L (LB7) (Introduction)