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

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

Scheme 329

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. Disconnect the ECM electrical connectors (2).
4. Release the ECM cover retaining tabs.
5. Remove the ECM cover from the bracket.
6. Remove the ECM cover.

Scheme 330

1. Install the ECM. IMPORTANT: The cover must be fully installed prior to the electrical connections being made to ensure the ECM is fully seated in the bracket.
2. Install the ECM cover to the bracket.
3. Engage the ECM cover retaining tabs.
4. Connect the ECM electrical connectors (2).
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.
6. If a NEW ECM was installed, program the ECM. Refer to «Service Programming System (SPS)»(ref-184120-S18443623862005082200000) in Programming.
7. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn Procedure»(ref-184140-S03829020612005082200000) .

Scheme 331

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 in order to relieve the fuel pressure.
3. Cut the tie strap attaching the harness to the bracket.
4. Disconnect the fuel injection control module (FICM) electrical connectors. Pull the retainers out until the connectors disengage.
5. Remove and discard the fuel line eyebolts.
6. Remove and discard the fuel line eyebolt washers from the banjo fittings.
7. Remove the FICM bolts.
8. Remove the FICM with insulators.
9. If necessary, remove the oil level indicator tube bracket bolt from the FICM bracket.
10. If necessary, remove the fuel line and engine harness clips from the FICM bracket.
11. If necessary, remove the FICM bracket bolts.
12. If necessary, remove the FICM bracket.

Scheme 332

1. If necessary, install the FICM bracket.
2. If necessary, install the FICM bracket bolts.
3. If necessary, install the fuel line and engine harness clips to the FICM bracket.
4. If necessary, install the oil level indicator tube bracket bolt to the FICM bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
5. Install the FICM with insulators.
6. Install the FICM bolts. Tighten: Tighten the bolt to 20 N.m (14 lb ft).
7. Lubricate the NEW eyebolt washers with diesel fuel prior to installing.
8. Install the NEW eyebolt washers to the banjo fittings.
9. Install the NEW fuel line eyebolts. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
10. Connect the FICM electrical connectors. Slide the retainers in to engage the connectors.
11. Install a NEW tie strap attaching the harness to the bracket.
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. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
15. Start the engine. If the engine stalls, repeat the above step.
16. Once the engine starts, inspect for fuel leaks.

Scheme 333

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 intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
3. Remove both front wheelhouse panels. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
4. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
5. Loosen the charged air cooler outlet duct to intake hose clamp. 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 outlet duct from the intake.
7. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
8. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
9. Disconnect the fuel injection control module electrical connectors.
10. Cut the tie strap attaching the harness to the bracket.
11. Remove the left glow plug harness bracket bolts.
12. Remove the right glow plug harness bracket bolts.
13. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
14. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
15. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
16. Disconnect the camshaft position (CMP) sensor electrical connector.
17. Remove the 2 ground bolts.
18. Disconnect the crankshaft position (CKP) sensor electrical connector.
19. Remove the tie strap from the electrical harness.
20. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
21. Open the harness clip (2).
22. Remove the main engine electrical harness connectors.
23. Disconnect the barometric sensor electrical connector.
24. Remove the main engine electrical harness connector bolts.
25. Disconnect the fuel pressure control valve electrical connector.
26. Disconnect the turbocharger boost sensor electrical connector.
27. Disconnect the oil level sensor electrical harness connector.
28. Disconnect the fuel temperature sensor electrical connector.
29. Disconnect the glow plug controller electrical connector.
30. Disconnect the glow plug controller battery feed electrical connector (1).
31. Disconnect and remove the turbocharger vane position sensor.
32. Disconnect the fuel injector electrical connectors.
33. Disconnect the turbocharger vane control solenoid valve.
34. Disconnect the fuel rail pressure sensor electrical connector.
35. Disconnect the oil pressure sensor electrical connector.
36. Remove the oil level sensor harness bolt.
37. Remove the glow plug controller bolts.
38. Remove the glow plug controller.
39. Remove the glow plug electrical connector nuts.
40. Remove the engine wiring harness.

Installation Procedure

1. Install the engine wiring harness.
2. Install the glow plug electrical connector nuts. Tighten: Tighten the nuts to 2 N.m (18 lb in).
3. Install the glow plug controller.
4. Install the glow plug controller bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the oil level sensor harness bolt. Tighten: Tighten the bolt to 40 N.m (30 lb ft).
6. Connect the oil pressure sensor electrical connector.
7. Connect the fuel rail pressure sensor electrical connector.
8. Connect the turbocharger vane control solenoid valve.
9. Connect the fuel injector electrical connectors.
10. Install and connect the turbocharger vane position sensor.
11. Connect the glow plug controller battery feed electrical connector (1).
12. Connect the glow plug controller electrical connector.
13. Connect the fuel temperature sensor electrical connector.
14. Connect the oil level sensor electrical harness connector.
15. Connect the turbocharger boost sensor electrical connector.
16. Connect the fuel pressure control valve electrical connector.
17. Install the main engine electrical harness connector screws. Tighten: Tighten the screws to 10 N.m (89 lb in).
18. Connect the barometric sensor electrical connector.
19. Connect the main engine electrical harness connectors.
20. Push down on the latches (1) in order to connect the connectors.
21. Close the harness clip (2).
22. Install a NEW tie strap to the electrical harness.
23. Connect the CKP sensor electrical connector.
24. Install the 2 ground bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
25. Connect the CMP sensor electrical connector.
26. Connect the EGR valve electrical connector.
27. Connect the ECT sensor electrical connector.
28. Install the PCV hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
29. Install the right glow plug harness bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
30. Install the right glow plug connectors to the glow plugs. Tighten: Tighten the glow plug connector nuts to 2 N.m (18 lb in).
31. Install the left glow plug harness bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in.
32. Install the left glow plug connectors to the glow plugs. Tighten: Tighten the glow plug connector nuts to 2 N.m (18 lb in).
33. Connect the fuel injection control module electrical connectors.
34. Install a NEW tie strap attaching the harness to the bracket.
35. Remove the tape from the turbocharger openings.
36. Install the charged air cooler inlet duct connector (4) to the turbocharger.
37. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
38. Install the charged air cooler outlet duct to the intake.
39. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten: Tighten the clamp to 6 N.m (53 lb in).
40. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
41. Install both front wheelhouse panels. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
42. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
43. 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.

Scheme 334

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.
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.

Scheme 335

1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
2. Install the ECT sensor (1). Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector.
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.

Scheme 336

1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1).
2. Remove the MAF/IAT sensor TORX® screws.
3. Remove the MAF/IAT sensor (1).

1. Install the MAF/IAT sensor (1).
2. Install the MAF/IAT sensor TORX® screws. Tighten: Tighten the screws to 8 N.m (70 lb in).
3. Connect the MAF/IAT sensor electrical connector (1).

Scheme 337

1. Disconnect the barometric pressure (BARO) sensor electrical connector.
2. Push the BARO sensor (1) downward in order to remove it from the bracket.

1. Push the BARO sensor (1) upward in order to remove it from the bracket.
2. Connect the BARO sensor electrical connector.

Scheme 338

1. Remove the right fuel rail fuel feed pipe. Refer to «Fuel Rail Fuel Feed Pipe Replacement - Right»(ref-184140-S03947583982005082200000) .
2. Remove the boost sensor bracket bolt (1).
3. Remove the boost sensor and bracket.
4. Separate the boost sensor from the bracket.
5. Inspect the sensor seal for damage, replace as necessary.

1. Position the boost sensor onto the bracket.
2. Install the boost sensor and bracket.
3. Install the boost sensor bracket bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
4. Install the right fuel rail fuel feed pipe. Refer to «Fuel Rail Fuel Feed Pipe Replacement - Right»(ref-184140-S03947583982005082200000) .

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.

Scheme 339

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.

Scheme 340

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 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. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the fittings together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the connections in order to make sure the connection is secure.
4. Install the retainers to the fuel feed/return pipes.
5. Install the fuel fill cap.
6. Connect the negative battery cable. Refer to «Battery Negative Cable 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 from around the quick connect fitting.
4. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY).
5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
6. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
7. Pull the connection apart.

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick connect fitting together in order to cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure.
4. Install the fuel fill cap.
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.

1. Install the water-in-fuel sensor to the NEW fuel filter.
2. Screw on the NEW fuel filter to the fuel filter adapter.
3. Connect the fuel filter connectors.
4. Install the fuel hoses.
5. Position the fuel hose clamps.
6. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining Procedure»(ref-184140-S06124440952005082200000) .
2. Remove the right front wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
3. Disconnect the fuel filter electrical connectors.
4. Remove the water-in-fuel sensor (3) from the fuel filter (2).

1. Install the water-in-fuel sensor (3) to the fuel filter (2).
2. Connect the fuel filter electrical connector.
3. Install the right front wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
4. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
5. Start the engine. If the engine stalls, repeat the above step.
6. Once the engine starts, inspect for fuel leaks.

1. Drain the fuel from the fuel filter. Refer to «Water-in-Fuel Draining Procedure»(ref-184140-S06124440952005082200000) .
2. Reposition the fuel hose clamps.
3. Remove the fuel hoses.
4. Disconnect the fuel filter electrical connectors.
5. Remove the fuel filter bracket bolts.
6. Remove the fuel filter assembly.
7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing.
8. Remove the fuel filter from the fuel filter/heater element housing.
9. Inspect the fuel filter, replace if necessary.

1. Install the fuel filter to the fuel filter/heater element housing.
2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
3. Install the fuel filter assembly.
4. Install the fuel filter bracket bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
5. Connect the fuel filter electrical connectors.
6. Install the fuel hoses.
7. Position the fuel hose clamps.
8. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
9. Start the engine. If the engine stalls, repeat the above step.
10. Once the engine starts, inspect for fuel leaks.

1. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-184140-S42787870412005082200000) .
2. Remove the fuel tank filler housing to body screws (1), and retainer (2).
3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.
5. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
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 ground strap bolt (1).
8. Reposition the fuel tank ground strap (3).
9. Loosen the fill pipe vent hose clamp (1) at the fuel tank.
10. Remove the fill pipe vent hose from the fuel tank.
11. Remove the fill pipe.
12. Remove the fuel system cooler. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184140-S19461777292005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184140-S14597487282005082200000) .
13. If equipped, remove the fuel tank shield bolts.
14. If equipped, remove the fuel tank shield.
15. Disconnect the fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
16. Cap the fuel lines in order to prevent possible fuel system contamination.
17. Place a suitable adjustable jack under the fuel tank.
18. Remove the fuel tank strap bolts.
19. Remove the fuel tank straps.
20. Lower the fuel tank until the sending unit electrical connector is accessible.
21. Disconnect the sending unit electrical connector.
22. Completely lower the fuel tank.
23. With the aid of an assistant, place the fuel tank in a suitable work area.
24. If necessary, disconnect and remove the fuel feed (1) and return (2) lines from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
25. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184140-S30811292652005082200000) .

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184140-S30811292652005082200000) .
2. Install and connect the fuel feed (1) and return (2) lines to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank until the sending unit electrical connection can be made.
5. Connect the sending unit electrical connector.
6. Install the fuel tank.
7. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
8. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
9. Remove the jack from under the fuel tank.
10. Remove the caps from the fuel lines.
11. Connect the fuel feed and return lines to the fuel tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
12. If necessary, install the fuel tank shield.
13. If necessary, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
14. Install the fuel system cooler. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184140-S19461777292005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184140-S14597487282005082200000) .
15. Install the fuel tank fill pipe and vent hose to the fuel tank.
16. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
17. Tighten the fuel tank vent hose clamp (1) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
18. Position the fuel tank ground strap (3).
19. Install the fuel tank ground strap bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
20. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
21. Lower the vehicle.
22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
24. 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).
25. Fill the fuel tank.
26. Install the fuel fill cap.
27. 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.
28. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
29. Start the engine. If the engine stalls, repeat the above step.
30. Once the engine starts, inspect for fuel leaks.

1. Disconnect the fuel feed and pressure balance rear lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
2. Loosen the fuel fill and vent hose clamps (1, 2) 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-184140-S42787870412005082200000) .
5. Disconnect the sending unit electrical connectors (1).
6. Disconnect the fuel feed and return lines from the fuel tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
7. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
8. If necessary, remove the fuel tank shield bolts.
9. If necessary, remove the fuel tank shield.
10. Place a suitable adjustable jack under the fuel tank.
11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps.
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 lines 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-184140-S30811292652005082200000) .

Scheme 341

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184140-S30811292652005082200000) .
2. Remove the caps from the fuel lines.
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»(ref-184123-S11449185592005082200000) 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. If necessary, install the fuel tank shield.
9. If necessary, 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 and return lines at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
12. Connect the sending unit electrical connectors (1).
13. Install the fuel fill pipe and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) 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 lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
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. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.

1. Loosen the fuel fill and vent hose clamps (1, 2) 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-184140-S42787870412005082200000) .
4. Disconnect the sending unit electrical connector.
5. Disconnect the fuel feed and return lines from the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
7. If equipped, remove the fuel tank shield bolts.
8. If equipped, remove the fuel tank shield.
9. Remove the fuel tank strap bolts.
10. Remove the fuel tank straps.
11. Lower the fuel tank.
12. With the aid of an assistant, place the fuel tank in a suitable work area.
13. Cap the fuel lines in order to prevent possible fuel system contamination.
14. If replacing the fuel tank, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184140-S30811292652005082200000) .

1. If the fuel tank was replaced, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184140-S30811292652005082200000) .
2. Remove the caps from the fuel lines.
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»(ref-184123-S11449185592005082200000) 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. If equipped, install the fuel tank cover.
9. If equipped, install the fuel tank cover bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
10. Lower the vehicle.
11. Connect the fuel feed and return lines to the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
12. Connect the sending unit electrical connector.
13. Install the fuel fill and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) 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. Using a scan tool, command the fuel transfer pump on.
19. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.

Scheme 342

1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-184140-S30811292652005082200000) .
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-184140-S30811292652005082200000) .

1. Loosen the fuel fill cap to relieve the fuel system pressure.
2. Disconnect the balance pump electrical connector.
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
4. Clean the fuel line connections and surrounding areas at the pump before disconnecting to avoid possible fuel system contamination.
5. Disconnect the fuel lines from the pump.
6. Slide the pump out of the bracket.
7. Cap the fuel lines.

1. Remove the caps from the fuel lines.
2. Install the NEW fuel line O-rings.
3. Position the new balance pump into the bracket.
4. Connect the fuel lines to the balance 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 balance pump electrical connector.
7. Tighten the fuel fill cap.
8. Using a scan tool, command the fuel transfer pump on.
9. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
10. Start the engine. If the engine stalls, repeat the above step.
11. Once the engine starts, inspect for fuel leaks.

1. Install the sending unit and a NEW seal.
2. Using J 45722 , install the sending unit lock ring.
3. Connect the fuel lines to the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) or «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184140-S23553132162005082200000) .
4. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184140-S35717125452005082200000) «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184140-S02256317682005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184140-S26735587002005082200000) .

Scheme 343

1. Reposition the hose clamps at the fuel filter and the return line.
2. Remove the fuel hose (1) from the fuel filter housing and the return line.

1. Install the fuel hose (1) to the fuel filter housing and return line.
2. Position the hose clamps at the fuel filter and the return line.
3. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
4. Start the engine. If the engine stalls, repeat the above step.
5. Once the engine starts, inspect for fuel leaks.

Scheme 344

1. Remove the water outlet. 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.
2. Remove the air intake tube. Refer to «Air Intake Pipe Replacement»(ref-184140-S06990164082005082200000) .
3. Reposition the fuel hose clamps (1) at the return/feed line as required.
4. Disconnect the fuel hoses from the return/feed line as required.
5. Reposition the fuel hose clamps (1) at the injection pump as required.
6. Disconnect the fuel hoses (2, 3) from the injection pump as required.
7. Remove the fuel hoses from the vehicle as required.

Scheme 345

1. Install the fuel hoses to the vehicle as required.
2. Connect the fuel hoses (2, 3) to the injection pump as required.
3. Position the fuel hose clamps (1) at the injection pump as required.
4. Connect the fuel hoses to the return/feed line as required.
5. Position the fuel hose clamps (1) at the return/feed line as required.
6. Install the air intake tube. Refer to «Air Intake Pipe Replacement»(ref-184140-S06990164082005082200000) .
7. Install the water outlet. 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. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
9. Start the engine. If the engine stalls, repeat the above step.
10. Once the engine starts, inspect for fuel leaks.

1. Remove the water outlet. 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.
2. Remove the air intake tube. Refer to «Air Intake Pipe Replacement»(ref-184140-S06990164082005082200000) .
3. Reposition the fuel hose clamps (1) at the return/feed line as required.
4. Disconnect the fuel hoses from the return/feed line as required.
5. Reposition the fuel hose clamps (1) at the injection pump as required.
6. Disconnect the fuel hoses (2, 3) from the injection pump as required.
7. Remove the fuel hoses from the vehicle as required.

1. Install the fuel hoses to the vehicle as required.
2. Connect the fuel hoses (2, 3) to the injection pump as required.
3. Position the fuel hose clamps (1) at the injection pump as required.
4. Connect the fuel hoses to the return/feed line as required.
5. Position the fuel hose clamps (1) at the return/feed line as required.
6. Install the air intake tube. Refer to «Air Intake Pipe Replacement»(ref-184140-S06990164082005082200000) .
7. Install the water outlet. 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. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
9. Start the engine. If the engine stalls, repeat the above step.
10. Once the engine starts, inspect for fuel leaks.

Scheme 346

1. Disconnect the fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
2. Remove the fuel line bracket nut.
3. Remove the fuel line bracket from the stud.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
5. Remove the fuel bundle clips (2) from the transmission brackets (1).
6. Disconnect the chassis harness from the retaining clips.
7. Remove the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184140-S19461777292005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184140-S14597487282005082200000) .
8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184140-S23553132162005082200000) .
9. Remove the fuel bundle nuts from the chassis.
10. Loosen the electronic brake control module (EBCM) bracket bolts (4).
11. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
12. Remove the fuel bundle using the following procedure: Guide the fuel bundle pipes towards the rear of the vehicle to clear the engine. Lower the fuel bundle while moving it forward 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»(ref-184123-S11449185592005082200000) 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 fuel feed and return lines to the fuel tank lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184140-S23553132162005082200000) .
4. Install the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184140-S19461777292005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184140-S14597487282005082200000) .
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 line bracket to the stud.
9. Install the fuel line bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
10. Connect the fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
11. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

1. Disconnect the fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
2. Remove the fuel line bracket nut.
3. Remove the fuel line bracket from the stud.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
5. Remove the fuel bundle clips (2) from the transmission brackets (1).
6. Disconnect the chassis harness from the retaining clips.
7. Remove the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184140-S19461777292005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184140-S14597487282005082200000) .
8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184140-S23553132162005082200000) .
9. Remove the fuel bundle nuts from the chassis.
10. Loosen the electronic brake control module (EBCM) bracket bolts (4).
11. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
12. Remove the fuel bundle using the following procedure: Guide the fuel bundle 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»(ref-184123-S11449185592005082200000) 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 fuel feed and return lines to the fuel tank lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184140-S23553132162005082200000) .
4. Install the fuel system cooler, if necessary. Refer to «Fuel System Cooler Replacement (Pickup)»(ref-184140-S19461777292005082200000) or «Fuel System Cooler Replacement (Cab/Chassis)»(ref-184140-S14597487282005082200000) .
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 line bracket to the stud.
9. Install the fuel line bracket nut. Tighten: Tighten the nut to 16 N.m (12 lb ft).
10. Connect the fuel feed and return lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
11. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

Scheme 347

1. Remove the front and auxiliary fuel tanks. Refer to «Fuel Tank Replacement (Pickup)»(ref-184140-S35717125452005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184140-S02256317682005082200000) «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184140-S26735587002005082200000) .
2. Disconnect the pressure balance pump electrical connector.
3. Remove the fuel bundle nuts.
4. Remove the fuel bundle.

Scheme 348

1. Install the fuel bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
2. Install the fuel bundle nuts. Tighten: Tighten the nuts to 16 N.m (12 lb ft).
3. Connect the pressure balance pump electrical connector.
4. Install the front and auxiliary fuel tanks. Refer to «Fuel Tank Replacement (Pickup)»(ref-184140-S35717125452005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184140-S02256317682005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184140-S26735587002005082200000) .

Scheme 349

1. Remove the glow plug controller. Refer to «Glow Plug Controller Replacement»(ref-184140-S25868579842005082200000) .
2. Disconnect the return line from the return/junction block line.
3. Remove the fuel return line clips.
4. Remove the fuel injector return line from the injectors.

1. Install the fuel injector return line to the injectors.
2. Install the fuel return line clips.
3. Connect the return line to the return/junction block line.
4. Install the glow plug controller. Refer to «Glow Plug Controller Replacement»(ref-184140-S25868579842005082200000) .
5. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
6. Start the engine. If the engine stalls, repeat the above step.
7. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel injection control module (FICM). Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
2. Remove the fuel filter and bracket. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
3. Disconnect the return line from the return/junction block line.
4. Remove the fuel return line clips.
5. Remove the fuel injector return line from the injectors.

1. Install the fuel injector return line to the injectors.
2. Install the fuel return line clips.
3. Connect the return line to the return/junction block line.
4. Install the fuel filter and bracket. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
5. Install the FICM. Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
6. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. 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.
2. Disconnect the fuel feed line quick connect fitting. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
3. Remove the fuel injection control module upper banjo bolt and washer.
4. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp.
5. Remove the EGR coolant pipe hose.
6. Remove the EGR coolant pipe bolts.
7. Remove the EGR coolant pipe.
8. Remove the fuel feed pipe nut and clip bolts.
9. Remove the fuel feed pipe.

1. Install the fuel feed pipe.
2. Install the fuel feed pipe nut and clip bolts. Tighten: Tighten the bolts/nut to 41 N.m (30 lb ft).
3. Install the EGR coolant pipe.
4. Install the EGR coolant pipe bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Install the EGR coolant pipe hose.
6. Position the EGR coolant pipe hose clamp.
7. Lubricate a NEW washer with diesel fuel.
8. Install the fuel injection control module upper banjo bolt and the NEW washer. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
9. Connect the fuel feed line quick connect fitting. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
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. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

Scheme 350

1. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184140-S29416603062005082200000) .
2. Remove the water outlet. 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. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
4. Reposition the fuel return line hose clamps (1).
5. Remove the fuel return line hoses from the return line.
6. Remove the fuel return line clamp bolts (1).
7. Reposition the fuel return line hose clamp (3) from the fuel rail.
8. Remove the fuel return line hose from the fuel rail.
9. Remove the fuel return line (2).

1. Install the fuel return line (2).
2. Install the fuel return line hose to the fuel rail.
3. Position the fuel return line hose clamp (3) at the fuel rail. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
4. Install the fuel return line clamp bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Install the fuel return line hoses to the return line.
6. Position the fuel return line hose clamps (1).
7. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
8. Install the water outlet. 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-184140-S29416603062005082200000) .
10. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
11. Start the engine. If the engine stalls, repeat the above step.
12. Once the engine starts, inspect for fuel leaks.

Scheme 351

1. Remove the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184140-S29416603062005082200000) .
2. Remove the water outlet. 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. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
4. Disconnect the right fuel rail feed pipe fittings (1, 3).
5. Remove the fuel rail pipe clamp bolts (2).
6. Remove the right fuel rail feed pipe.

Scheme 352

1. Install the right fuel rail feed pipe.
2. Install the fuel rail pipe clamp bolts (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Connect the right fuel rail feed pipe fittings (1, 3). Tighten: Tighten the fittings to 41 N.m (30 lb ft).
4. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
5. Install the water outlet. 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.
6. Install the engine wiring harness. Refer to «Engine Wiring Harness Assembly Replacement»(ref-184140-S29416603062005082200000) .
7. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
8. Start the engine. If the engine stalls, repeat the above step.
9. Once the engine starts, inspect for fuel leaks.

1. Remove the water outlet. 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.
2. Reposition the return line hose clamps at the return line and injection pump.
3. Remove the hose (3) from the return line and injection pump.
4. Disconnect the left fuel rail feed pipe fittings (1).
5. Remove the left fuel rail feed pipe.

1. Install the left fuel rail feed pipe.
2. Connect the left fuel rail feed pipe fittings (1). Tighten: Tighten the fittings to 41 N.m (30 lb ft).
3. Install the hose (3) to the return line and injection pump.
4. Position the return line hose clamps at the return line and injection pump.
5. Install the water outlet. 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.
6. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, inspect for fuel leaks.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
2. Loosen the charged air cooler outlet duct to intake hose clamp. 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 from the intake.
4. Remove the fuel filter. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
5. Remove the fuel rail pressure sensor. Refer to «Fuel Rail Pressure (FRP) Sensor Replacement»(ref-184140-S32426455472005082200000) .
6. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
7. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
8. Remove the fuel injector pipes.

Note. Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

1. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
2. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
3. Install the fuel rail pressure sensor. Refer to «Fuel Rail Pressure (FRP) Sensor Replacement»(ref-184140-S32426455472005082200000) .
4. Install the fuel filter. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
5. Installer the charged air cooler outlet duct to the intake.
6. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten: Tighten the clamp to 6 N.m (53 lb in).
7. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
8. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
9. Start the engine. If the engine stalls, repeat the above step.
10. Once the engine starts, inspect for fuel leaks.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
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. 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.
4. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
5. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
6. Remove the battery cable to generator nut.
7. If equipped, remove the battery cable to auxiliary generator nut.
8. Remove the battery cable harness clip from the bracket.
9. Remove the battery cable junction block bolt (1) from the power steering pump.
10. Move and secure the battery cables out of the way.
11. Disconnect the fuel lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
12. Remove the fuel line bracket nut.
13. Remove the fuel line bracket from the stud.
14. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
15. Open the harness clip (2).
16. Remove the main engine electrical harness connectors.
17. Remove the engine harness main electrical connectors bolts.
18. Disconnect the barometric sensor electrical connector.
19. Remove the engine harness main connector bracket bolts.
20. 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.
21. 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.
22. Disconnect the glow plug controller electrical connector.
23. Disconnect the glow plug controller battery feed electrical connector (1).
24. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
25. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
26. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
27. Remove the left fuel injector pipes.

Note. Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

1. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
2. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
3. Install the PCV hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
4. Connect the glow plug controller battery feed electrical connector (1).
5. Connect the glow plug controller electrical connectors.
6. 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.
7. 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.
8. Install the engine harness main connector bracket bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
9. Connect the barometric sensor electrical connector.
10. Install the engine harness main electrical connectors bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
11. Connect the main engine electrical harness connectors.
12. Push down on the latches (1) in order to connect the connectors.
13. Close the harness clip (2).
14. Install the fuel line bracket from the stud.
15. Install the fuel line bracket nut. Tighten: Tighten the nut to 21 N.m (15 lb ft).
16. Connect the fuel lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
17. Position the generator positive cable.
18. Install the generator positive cable in the clip on the engine front cover.
19. Install the generator positive cable and nut to the generator. Tighten: Tighten the nut to 9 N.m (80 lb in).
20. Install the battery positive cable junction block bracket and bolt (1) to the power steering bracket. Tighten: Tighten the bolt to 9 N.m (80 lb in).
21. Remove the tape from the turbocharger openings.
22. Install the charged air cooler inlet duct connector (4) to the turbocharger.
23. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
24. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
25. 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.
26. 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.
27. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
28. Start the engine. If the engine stalls, repeat the above step.
29. Once the engine starts, inspect for fuel leaks.

Scheme 353

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
2. Disconnect the fuel lines at the cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
3. Remove the fuel cooler bolts (4, 6).
4. Remove the fuel cooler (1).
5. 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 lines at the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
5. Lower the vehicle.
6. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
7. Start the engine. If the engine stalls, repeat the above step.
8. Once the engine starts, 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. Disconnect the fuel lines at the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
3. Remove the fuel cooler nuts (2).
4. Remove the fuel cooler (1).

Scheme 354

1. Install the fuel cooler (1). NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) 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 lines at the fuel cooler (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
4. Lower the vehicle.
5. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
6. Start the engine. If the engine stalls, repeat the above step.
7. Once the engine starts, inspect for fuel leaks.

1. Remove the fuel tank filler housing to body screws (1) and retainer (2).
2. Remove the fuel tank filler pipe housing to fuel tank fill pipe screws.
3. Remove the fuel tank filler housing.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
5. Remove the fuel tank ground strap bolt (1).
6. Remove the chassis harness ground strap (2) and fuel tank ground strap (3).
7. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
8. Loosen the fuel tank vent hose and fill hose clamps (1, 2).
9. Remove the vent hose from the tank.
10. Remove the fill hose 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 fill hose to the vehicle and tank.
3. Install the vent hose to the tank. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
4. Tighten the fuel tank vent hose and fill hose clamps (1, 2). Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
6. Position the chassis harness ground strap (2) and fuel tank ground strap (3).
7. Install the ground strap anti-rotation tab into the frame hole.
8. Install the fuel tank ground strap bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
9. Lower the vehicle.
10. Install the fuel tank filler housing.
11. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
12. 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).

1. Relieve the fuel system pressure.
2. Disconnect the fuel feed and pressure balance rear lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
3. Loosen the fuel fill and vent hose clamps (1, 2) at the tank.
4. Remove the fuel fill and vent hoses 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 and vent hoses to the tank. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Tighten the fuel fill and vent hose clamps (1, 2) at the tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
4. Connect the fuel feed and pressure balance rear lines. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .

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 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. Remove the battery cable junction block bracket bolt (1) from the power steering pump bracket.
4. Reposition the junction block and bracket.
5. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
6. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
7. Disconnect the fuel feed and return line quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
8. Remove the fuel line bracket nut.
9. Remove the fuel line bracket from the stud.
10. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
11. Remove the air conditioning (A/C) compressor bolts.
12. Reposition the A/C compressor aside.
13. Remove the banjo bolt and washer from the fuel injection control module.
14. Remove the fuel feed pipe nuts/bolts.
15. Remove the fuel feed pipe.
16. Disconnect the fuel rail balance pipe from the fuel rails.
17. Remove the fuel rail balance pipe bolts.
18. Remove the fuel rail balance pipe.
19. Disconnect the fuel injector return hose from the return/junction block line.
20. Reposition the return/junction block hose clamps at the injection pump.
21. Remove the fuel hoses from the return/junction block.
22. Reposition the return/junction block hose clamp at the rear of the left fuel rail.
23. Remove the fuel hose from the fuel rail.
24. Remove the return/junction block fuel line clip bolts.
25. Remove the return/junction block and lines.
26. Remove the fuel pipe bracket bolts.
27. Remove the fuel pipe bracket.
28. Disconnect the fuel inlet pipe from the fuel rail.
29. Disconnect the fuel inlet pipe from the injection pump.
30. Remove the inlet fuel pipe.
31. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
32. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
33. Remove the left fuel injector pipes.
34. Remove the fuel rail bolts.
35. Remove the fuel rail and bracket.

1. Install the fuel rail and bracket.
2. Install the fuel rail bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
4. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
5. Remove the inlet fuel pipe.
6. Connect the fuel inlet pipe to the injection pump.
7. Connect the fuel inlet pipe to the fuel rail. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
8. Install the fuel pipe bracket.
9. Install the fuel pipe bracket bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Install the return/junction block and lines.
11. Install the return/junction block fuel line clip bolts. Tighten: Tighten the bolts 25 N.m (18 lb ft).
12. Install the fuel hose to the fuel rail.
13. Position the return/junction block hose clamp at the rear of the left fuel rail.
14. Install the fuel hoses to the return/junction block.
15. Position the return/junction block hose clamps at the injection pump.
16. Connect the fuel injector return hose to the return/junction block line.
17. Install the fuel rail balance pipe.
18. Connect the fuel rail balance pipe to the fuel rails. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
19. Install the fuel rail balance pipe bolts. Tighten: Tighten the bolts 25 N.m (18 lb ft).
20. Install the fuel feed pipe.
21. Install the fuel feed pipe nut/bolt. Tighten: Tighten the nut/bolt to 25 N.m (18 lb ft).
22. Install the banjo bolt and washer to the fuel injection control module. Tighten: Tighten the bolt to 40 N.m (29 lb ft).
23. Position the A/C compressor aside.
24. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
25. Install the PCV hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
26. Install the fuel line bracket to the stud.
27. Install the fuel line bracket nut. Tighten: Tighten the nut to 21 N.m (15 lb ft).
28. Connect the fuel feed and return line quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184140-S14232518412005082200000) .
29. Remove the tape from the turbocharger openings.
30. Install the charged air cooler inlet duct connector (4) to the turbocharger.
31. Tighten the charged air cooler inlet duct to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
32. Position the junction block and bracket.
33. Install the battery cable junction block bracket bolt (1) to the power steering pump bracket. Tighten: Tighten the bolt to 9 N.m (80 lb in).
34. 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.
35. 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.
36. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
37. Start the engine. If the engine stalls, repeat the above step.
38. Once the engine starts, inspect for fuel leaks.

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. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
3. Remove the fuel injection control module (FICM). Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
4. Remove the fuel filter. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
5. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
6. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
7. Disconnect the fuel rail balance pipe from the fuel rails.
8. Remove the fuel rail balance pipe bolts.
9. Remove the fuel rail balance pipe.
10. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
11. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
12. Remove the fuel injector pipes.
13. Remove the fuel rail bolts.
14. Remove the fuel rail.

1. Install the fuel rail.
2. Install the fuel rail bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
4. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
5. Install the fuel rail balance pipe.
6. Connect the fuel rail balance pipe to the fuel rails. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
7. Install the fuel rail balance pipe bolts. Tighten: Tighten the bolts 25 N.m (18 lb ft).
8. Install the PCV hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
9. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
10. Install the fuel filter. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
11. Install the FICM. Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
12. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
13. 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.
14. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
15. Start the engine. If the engine stalls, repeat the above step.
16. Once the engine starts, inspect for fuel leaks.

1. Reposition the fuel hose clamp at the return/junction block.
2. Remove the hose (1) from the return/junction block.
3. Disconnect the right fuel return line from the return/junction block line.
4. Reposition the return/junction block hose clamps (3).
5. Remove the return/junction block hoses.
6. Remove the return/junction block line clamp bolt (2).
7. Remove the return/junction block bolt (1).
8. Remove the return/junction block.

1. Install the return/junction block.
2. Install the return/junction block bolt (1).
3. Install the return/junction block line clamp bolt (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the return/junction block hoses.
5. Position the return/junction block hose clamps (3).
6. Connect the right fuel return line to the return/junction block line.
7. Install the hose (1) to the return/junction block.
8. Position the fuel hose clamp at the return/junction block.
9. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
10. Start the engine. If the engine stalls, repeat the above step.
11. Once the engine starts, inspect for fuel leaks.

Scheme 355

1. Remove the air intake pipe. Refer to «Air Intake Pipe Replacement»(ref-184140-S06990164082005082200000) .
2. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
3. Disconnect the A/C cut out switch electrical connector.
4. Remove the A/C compressor bolts.
5. 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.
6. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.
7. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
8. Open the harness clip (2).
9. Remove the main engine electrical harness connectors.
10. Disconnect the barometric pressure (BARO) sensor electrical connector.
11. Remove the main engine harness electrical connector bolts.
12. Remove the main connectors from the bracket.
13. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
14. 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.
15. Disconnect the fuel temperature sensor electrical connector.
16. Disconnect the fuel pressure regulator electrical connector (1).
17. Disconnect the oil level sensor harness electrical connector.
18. Reposition the distribution block hose clamps.
19. Remove the distribution block hoses from the distribution block.
20. 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.
21. Using compressed air, thoroughly blow dry the regulator and pump.
22. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX®.
23. Remove the fuel pressure regulator (1).
24. 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.

1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.
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 distribution block hoses to the distribution block.
5. Position the distribution block hose clamps.
6. Connect the oil level sensor harness electrical connector.
7. Connect the fuel pressure regulator electrical connector (1).
8. Connect the fuel temperature sensor electrical connector.
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. Connect the ECT sensor electrical connector.
11. Install the main connectors to the bracket.
12. Install the main engine harness electrical connector bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
13. Connect the BARO sensor electrical connector.
14. Connect the main engine electrical harness connectors.
15. Push down on the latches (1) in order to connect the connectors.
16. Close the harness clip (2).
17. Position the A/C compressor.
18. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
19. Connect the A/C cut out switch electrical connector.
20. Connect the A/C compressor clutch electrical connector.
21. 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.
22. Install the air intake pipe. Refer to «Air Intake Pipe Replacement»(ref-184140-S06990164082005082200000) .
23. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
24. Start the engine. If the engine stalls, repeat the above step.
25. Once the engine starts, inspect for fuel leaks.

Fuel Pressure Relief Valve Replacement

At this time the fuel pressure relief valve is serviced as part of the fuel rail. Refer to Fuel Rail Assembly Replacement - Bank 1 .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. 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.
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
4. Remove the fuel injection control module. Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
5. 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) .
6. Remove the fan. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) in Engine Cooling.
7. Remove the battery cable junction block bolt (1) from the power steering pump bracket.
8. Reposition the battery cables out of the way.
9. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
10. Disconnect the A/C cut out switch electrical connector.
11. Remove the A/C compressor bolts.
12. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.
13. Remove the power steering pump bracket rear bolts (1).
14. Reposition the power steering pump, with the hoses attached, to the right side of the engine compartment.
15. Remove the A/C compressor/power steering pump bracket bolts and bracket.
16. Remove the heater outlet hose bolt from the generator bracket.
17. Remove the drive belt tensioner and bolt.
18. 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.
19. Remove the generator bracket bolts and bracket.
20. 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.
21. Disconnect the fuel balance pipe fitting from the right fuel rail.
22. Remove the fuel balance pipe retainer bolts.
23. Disconnect the fuel rail inlet pipe from the injection pump and rail.
24. Remove the inlet pipe.
25. Remove the center intake manifold. Refer to «Intake Manifold Replacement - Center»(ref-184188-S09184405742005082200000) in Engine Mechanical - 6.6L (LLY).
26. Reposition the injection pump hose clamps at the fuel line.
27. Remove the hoses from fuel lines.
28. Remove the fuel injection pump bolts.
29. Remove the fuel injection pump from the block. Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight.
30. The fuel injection pump may need to be rotated in order to remove it from the vehicle.

1. Install the fuel injection pump to the block.
2. Install the fuel injection pump bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
3. Install the hoses to fuel lines.
4. Position the injection pump hose clamps at the fuel line.
5. Install the center intake manifold. Refer to «Intake Manifold Replacement - Center»(ref-184188-S09184405742005082200000) in Engine Mechanical - 6.6L (LLY).
6. Install the inlet pipe.
7. Connect the fuel rail inlet pipe to the injection pump and rail. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
8. Connect the fuel balance pipe fitting to the right fuel rail. Tighten: Tighten the fitting to 41 N.m (30 lb ft).
9. Install the fuel balance pipe retainer bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. 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.
11. Install the generator bracket and bolts. Tighten: Tighten the bolts to 46 N.m (34 lb ft).
12. 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.
13. Install the drive belt tensioner and bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
14. Install the heater outlet hose bolt to the generator bracket Tighten: Tighten the bolt to 21 N.m (15 lb ft).
15. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
16. Install the A/C compressor/power steering pump bracket and bolts. Tighten: Tighten the bolt to 46 N.m (34 lb ft).
17. Position the power steering pump, with the hoses attached, to the bracket.
18. Install the power steering pump bracket rear bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
19. Position the A/C compressor, with the hoses attached, to the bracket.
20. Install the A/C compressor bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
21. Connect the A/C cut out switch electrical connector.
22. Connect the A/C compressor clutch electrical connector.
23. Position the battery cables to the bracket.
24. Install the battery cable junction block bolt to the power steering pump bracket. Tighten: Tighten the bolts to 9 N.m (80 lb in).
25. Install the fan. Refer to «Fan Replacement»(ref-184167-S03128565972005082200000) in Engine Cooling.
26. Install the fuel injection control module. Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
27. 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.
28. Install the air cleaner outlet duct. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) .
29. Connect 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.
30. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
31. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
32. Start the engine. If the engine stalls, repeat the above step.
33. Once the engine starts, inspect for fuel leaks.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
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. 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.
4. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
5. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
6. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
7. Open the harness clip (2).
8. Remove the main engine electrical harness connectors.
9. Remove the engine harness main electrical connectors bolts.
10. Remove the main electrical connectors from the bracket.
11. Disconnect the barometric sensor electrical connector.
12. Remove the engine wire harness from the clip.
13. Remove the main electrical harness bracket bolts.
14. Remove the main electrical harness bracket.
15. Disconnect the glow plug controller electrical connector.
16. Disconnect the glow plug controller battery feed electrical connector (1).
17. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
18. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
19. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
20. Remove the left fuel injector pipes.
21. Remove the fuel return hose clips.
22. Remove the fuel return hose from the injectors.
23. Disconnect the fuel injector electrical connectors.
24. Remove the fuel injector bracket bolts.
25. Install J-46594 into the bolt hole in the fuel injector bracket.
26. Install a flare nut wrench onto J-46594 and pull back away from the fuel injector, until the injector releases from its seat.
27. Remove J-46594 .
28. Remove the fuel injectors with brackets.
29. If necessary, remove the fuel injector bracket pins.
30. If necessary, remove and discard the copper washer from the fuel injector bore.
31. If necessary, remove and discard the O-ring from the fuel injector.

1. If necessary, install a NEW O-ring onto the fuel injector.
2. If necessary, install a NEW copper washer to the fuel injector bore.
3. If necessary, install the fuel injector bracket pins.
4. Install the fuel injectors with brackets.
5. Install the fuel injector bracket bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
6. Connect the fuel injector electrical connectors.
7. Install the fuel return hose to the injectors.
8. Install the fuel return hose clips.
9. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
10. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
11. Install the PCV hose/pipe. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
12. Connect the glow plug controller battery feed electrical connector (1).
13. Connect the glow plug controller electrical connector.
14. Install the main electrical harness bracket.
15. Install the main electrical harness bracket bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
16. Connect the barometric sensor electrical connector.
17. Install the engine wire harness to the clip.
18. Install the main electrical connectors to the bracket.
19. Install the engine harness main electrical connectors bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
20. Connect the main engine electrical harness connectors.
21. Push down on the latches (1) in order to connect the connectors.
22. Close the harness clip (2).
23. Remove the tape from the turbocharger openings.
24. Install the charged air cooler inlet duct connector (4) to the turbocharger.
25. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
26. 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.
27. 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.
28. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
29. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
30. Start the engine. If the engine stalls, repeat the above step.
31. Once the engine starts, inspect for fuel leaks.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
2. Loosen the charged air cooler outlet duct to intake hose clamp. 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 from the intake.
4. Remove the fuel filter and bracket. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
5. Remove the fuel injection control module (FICM). Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
6. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
7. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
8. Remove the fuel injector pipes.
9. Remove the fuel return hose clips.
10. Remove the fuel return hose from the injectors.
11. Disconnect the fuel injector electrical connectors.
12. Remove the fuel injector bracket bolts.
13. Install J-46594 into the bolt hole in the fuel injector bracket.
14. Install a flare nut wrench onto J-46594 and pull back away from the fuel injector, until the injector releases from its seat.
15. Remove J-46594 .
16. Remove the fuel injectors with brackets.
17. If necessary, remove the fuel injector bracket pins.
18. If necessary, remove and discard the copper washer from the fuel injector bore.
19. If necessary, remove and discard the O-ring from the fuel injector.

1. If necessary, install a NEW O-ring onto the fuel injector.
2. If necessary, install a NEW copper washer to the fuel injector bore.
3. If necessary, install the fuel injector bracket pins.
4. Install the fuel injectors with brackets.
5. Install the fuel injector bracket bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
6. Connect the fuel injector electrical connectors.
7. Install the fuel return hose to the injectors.
8. Install the fuel return hose clips.
9. Install the fuel injector pipes. Tighten: Tighten the fittings to 41 N.m (30 lb ft).
10. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
11. Install the FICM. Refer to «Fuel Injection Control Module Replacement»(ref-184140-S12524086862005082200000) .
12. Install the fuel filter with bracket. Refer to «Fuel Filter Replacement»(ref-184140-S03894690872005082200000) .
13. Install the charged air cooler outlet duct from the intake.
14. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten: Tighten the clamp to 6 N.m (53 lb in).
15. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
16. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
17. Start the engine. If the engine stalls, repeat the above step.
18. Once the engine starts, inspect for fuel leaks.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
2. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
3. Disconnect the fuel rail pressure sensor electrical connector.
4. Prior to removal, clean the fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
5. Using compressed air, thoroughly blow dry the sensor and surrounding area.
6. Remove the fuel pressure sensor (1).

1. Install the fuel pressure sensor (1). Tighten: Tighten the sensor to 70 N.m (52 lb ft).
2. Connect the fuel rail pressure sensor electrical connector.
3. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
5. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
6. Start the engine. If the engine stalls, repeat the above step.
7. Once the engine starts, inspect for fuel leaks.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical.
2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
3. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
4. Disconnect the fuel temperature sensor electrical connector.
5. 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.
3. Remove the tape from the turbocharger openings.
4. Install the charged air cooler inlet duct connector (4) to the turbocharger.
5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten: Tighten the clamp to 6 N.m (53 lb in).
6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical.
7. Prime the fuel system. Refer to «Fuel System Priming»(ref-184140-S27978403762005082200000) .
8. Start the engine. If the engine stalls, repeat the above step.
9. Once the engine starts, 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 left wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
3. Remove the glow plug harness nut(s).
4. Remove the harness from the glow plug(s).
5. Remove the glow plug(s).

1. Install the glow plug(s). Tighten: Tighten the plug to 18 N.m (13 lb ft).
2. Install the harness to the glow plug(s).
3. Install the glow plug harness nut(s). Tighten: Tighten the nut to 1.7 N.m (15 lb in).
4. Install the left wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
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. 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. Remove the glow plug harness nut(s).
4. Remove the harness from the glow plug(s).
5. Remove the glow plug(s).

1. Install the glow plug(s). Tighten: Tighten the plug to 18 N.m (13 lb ft).
2. Install the harness to the glow plug(s).
3. Install the glow plug harness nut(s). Tighten: Tighten the nut to 1.7 N.m (15 lb in).
4. Install the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
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. 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 glow plug controller electrical connector.
3. Disconnect the glow plug controller battery feed electrical connector (1).
4. Remove the glow plug controller bolts.
5. Remove the glow plug controller.

1. Install the glow plug controller.
2. Install the glow plug controller bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Connect the glow plug controller battery feed electrical connector (1).
4. Connect the glow plug controller electrical connector.
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. 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.
5. Remove the CKP sensor.
6. If necessary, remove the CKP sensor spacer bolts.
7. If necessary, remove the CKP sensor spacer.

1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil.
2. If necessary, install the NEW O-ring to the CKP sensor spacer. 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 "C" 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 bolts 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.
7. Install the CKP sensor.
8. Install the CKP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Connect the CKP sensor electrical connector.
10. Install the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-184166-S07972120782005082200000) in Body Front End.
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. Remove the cooling fan pulley. 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. Remove the camshaft position (CMP) sensor bolt.
3. Remove the CMP sensor.

1. Lubricate the CMP sensor O-ring with clean engine oil.
2. Install the CMP sensor. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Install the CMP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the cooling fan pulley. 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.

Scheme 356

1. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .
2. Remove the EGR valve bolts (3).
3. Remove the EGR valve/solenoid assembly (1).
4. Remove and discard the EGR valve/solenoid assembly gasket (2).

1. Install a NEW EGR valve/solenoid assembly gasket (2).
2. Install the EGR valve/solenoid assembly (1). NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Install the EGR valve bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
4. Install the EGR cooler tube. Refer to «Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement»(ref-184140-S29460381972005082200000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
3. Loosen the charged air cooler outlet duct to intake hose clamp. 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 from the intake.
5. 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.
6. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
7. If necessary, remove the tie strap from the electrical harness.
8. Remove the air inlet tube to intake manifold tube bolt and nut.
9. Remove the air inlet tube nuts.
10. Remove the air inlet tube.
11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
12. Disconnect the EGR cooler tube heater hose.
13. Remove the EGR coolant pipe bolts.
14. Remove the EGR coolant pipe.
15. Remove the rear EGR cooler tube bolts.
16. Remove the EGR cooler tube bolts.
17. Remove the EGR cooler tube.

1. Install the EGR cooler tube.
2. Install the EGR cooler tube bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the rear EGR cooler tube bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
4. Install the EGR coolant pipe.
5. Install the EGR coolant pipe bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Connect the EGR cooler tube heater hose.
7. Connect the EGR valve electrical connector.
8. Install the air inlet tube.
9. Install the air inlet tube nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
10. Install the air inlet tube to intake manifold tube bolt and nut. Tighten: Tighten the bolt/nut to 10 N.m (89 lb in).
11. If necessary, install a tie strap to the electrical harness.
12. Install the PCV hose/pipe. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
13. Install the charged air cooler outlet duct to the intake.
14. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten: Tighten the clamp to 6 N.m (53 lb in).
15. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
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. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Remove the turbocharger oil feed pipe banjo bolt and washer.
3. Reposition the oil feed pipe out of the way.
4. Disconnect the turbocharger vane control solenoid valve electrical connector.
5. Remove the vane control solenoid valve bracket bolt and bracket.
6. Remove the turbocharger vane control solenoid valve from the turbocharger.

1. Install the turbocharger vane control solenoid valve to the turbocharger.
2. Install the vane control solenoid valve bracket and bolt. Tighten: Tighten the bolt to 23 N.m (17 lb ft).
3. Connect the turbocharger vane control solenoid valve electrical connector.
4. Position the oil feed pipe to the turbocharger.
5. Install a NEW turbocharger oil feed pipe washer and the banjo bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
7. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn Procedure»(ref-184140-S03829020612005082200000) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Disconnect the turbocharger vane position sensor electrical connector.
3. Remove the turbocharger vane position sensor connector from the bracket.
4. Remove the turbocharger vane position sensor from the turbocharger.

1. Install the turbocharger vane position sensor to the turbocharger. Tighten: Tighten the sensor to 28 N.m (21 lb ft).
2. Install the turbocharger vane position sensor connector to the bracket.
3. Connect the turbocharger vane position sensor electrical connector.
4. Install the thermal reflective shield/tape, refer to the following procedure.

Thermal Reflective Shield/Tape Installation

1. Peel off the protective backing from the back side of the thermal reflective shield/tape.
2. With the sticky side of the shield/tape applied against the sensor body, align the bottom edge of the shield/tape with the bottom edge of the hex, and begin wrapping the sensor.
3. Completely wrap the shield/tape around the sensor.
4. Tuck the top of the shield/tape under the head of the brass cable crimp sleeve all around, allowing the shield/tape to fold over and overlap itself at the top.
5. The top of the shield/tape is now shown tucked under the head of the brass cable crimp sleeve all around.
6. Wrap the tie strap around the necked porting of the sensor body just above the hex. Insert the end of the strap in the buckle and tighten by pulling the end with needlenose pliers.
7. Bend the end of the tie strap 180 degrees over the top of the buckle.
8. Cut off the tie strap using side cutters so that the cut end will lie approximately over the center of the buckle. Push down the end of the tie strap over the buckle in order to minimize protrusion of the cut end or any sharp edges.
9. Finished installation is shown.
10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
11. Perform the turbocharger learn procedure. Refer to «Turbocharger Learn Procedure»(ref-184140-S03829020612005082200000) .

1. Disconnect the mass air flow (MAF)/intake air temperature (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.

1. Install the air filter element into the lower air cleaner housing.
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 (MAF)/intake air temperature (IAT) sensor electrical connector (1).
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
3. Grasp the air filter assembly (1) and pull up on the assembly in order to disengage the retaining pins (2) from the grommets (3).

1. Line up the retaining pins (2) with the grommets (3).
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-184140-S38052402752005082200000) .
4. Connect the MAF/IAT sensor electrical connector (1).

Scheme 357

1. Loosen the outlet duct clamps at the turbocharger and the mass air flow (MAF)/intake air temperature (IAT) sensor.
2. Remove the air cleaner outlet duct.

1. Install the air cleaner outlet duct.
2. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten: Tighten the clamps to 4 N.m (35 lb in).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
3. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
4. Disconnect the turbocharger electrical connector. Lift the metal retainer, in order to disconnect.
5. Remove the engine wire harness clamp bolt and reposition.
6. Loosen the air intake pipe to turbocharger clamp (1).
7. Remove the air intake pipe (2) from the turbocharger.

1. Clean the mating surfaces on the air intake pipe (2) and the turbocharger.
2. Align the air intake pipe (2) to the turbocharger. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
3. Tighten the air intake pipe to turbocharger clamp (1). Tighten: Tighten the clamp to 4.6 N.m (41 lb in).
4. Install the engine wire harness clamp bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Connect the turbocharger electrical connector.
6. Install the PCV hose/pipe. Refer to «Crankcase Ventilation Hoses/Pipes Replacement»(ref-184188-S26498984042005082200000) in Engine Mechanical - 6.6L (LLY).
7. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(ref-184140-S38052402752005082200000) .
8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-184188-S29213933562005082200000) in Engine Mechanical - 6.6L (LLY).