6 6l+engine

2008 Chevrolet Silverado 1500
2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado
2008 ENGINE
Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Specification
Application
Metric English
A/C Compressor Bolt 50 N.m 37 lb ft
Air Cleaner Outlet Duct Clamp 8 N.m 71 lb in
Air Conditioning Compressor/Power Steering Pump
46 N.m 34 lb ft
Bracket Bolt
Air Inlet Tube Nut 25 N.m 18 lb ft
Battery Cable Bracket Bolt 12 N.m 106 lb in
Battery Cable Bracket Nut 8 N.m 71 lb in
Bypass Pipe Bolt 25 N.m 18 lb ft
Camshaft Gear Bolt 234 N.m 173 lb ft
Camshaft Position Sensor Bolt 10 N.m 89 lb in
Camshaft Position Sensor Exciter Ring Bolt 9 N.m 80 lb in
Camshaft Thrust Plate Bolt 22 N.m 16 lb ft
Charged Air Cooler Bolt 21 N.m 15 lb ft
Charged Air Cooler Clamp 8 N.m 71 lb in
1st Step 64 N.m 1st Step 47 lb ft
2nd Step 30 2nd Step 30
Connecting Rod Cap Bolt - Angular Tightening
degrees degrees
Method
3rd Step 30 3rd Step 30
degrees degrees
Coolant Pipe Bolt and Nut 25 N.m 18 lb ft
Coolant Tube to Water Pump Nut 25 N.m 18 lb ft
Cooling Fan Pulley 41 N.m 30 lb ft
Crankshaft Balancer Bolt 2nd Step 105 2nd Step 105
degrees degrees
2nd Step 132 N.m 2nd Step 97 lb ft
MY
Wednesday, April 08, 2009 1:47:48
1:47:39 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Crankshaft Bearing Cap Bolt
degrees degrees
Crankshaft Bearing Cap Bolt - Angular Tightening
Method 2nd Step 90 2nd Step 90
degrees degrees
Crankshaft Bearing Cap Side Bolt 70 N.m 52 lb ft
Crankshaft Position Sensor Bolt 10 N.m 89 lb in
Crankshaft Position Sensor Spacer Bolt 10 N.m 89 lb in
Crossmember Bolt 100 N.m 74 lb ft
Cylinder Head M12 Bolt - Angular Tightening 2nd Step 80 N.m 2nd Step 59 lb ft
Method 3rd Step 60 degrees
4th Step 60 degrees
Cylinder Head M8 Bolt 25 N.m 18 lb ft
Drive Belt Tensioner Pulley Bolt 50 N.m 37 lb ft
EGR to EGR Cooler Bolt 25 N.m 18 lb ft
EGR Bracket 25 N.m 18 lb ft
EGR Bracket Bolt 25 N.m 18 lb ft
EGR Bracket to Cooler Bolt 25 N.m 18 lb ft
Electrical Harness Bracket Bolt 10 N.m 89 lb in
Engine Block Coolant Plug 18 N.m 13 lb ft
Engine Block Ground Bolt 34 N.m 25 lb ft
Engine Mount Through Bolt to Frame 75 N.m 55 lb ft
Engine Mount to Block Bolts 58 N.m 43 lb ft
Engine Mount to Frame Bolt 65 N.m 48 lb ft
Engine Shield Bolt 20 N.m 15 lb ft
Exhaust Heat Shield Nut 10 N.m 89 lb in
Exhaust Manifold Bolt/Nut 57 N.m 42 lb ft
Exhaust Manifold Heat Shield Bolts 10 N.m 89 lb in
Exhaust Outlet Clamp 15 N.m 11 lb ft
Exhaust Outlet Heat Shield Bolts 10 N.m 89 lb in
Exhaust Pipe Bracket Nut 53 N.m 39 lb ft
Exhaust Pipe Clamp 53 N.m 39 lb ft
Exhaust Pipe Heat Shield Bolts 10 N.m 89 lb in
Exhaust Pipe to EGR Cooler Nuts 26 N.m 19 lb ft
MY
Wednesday, April 08, 2009 1:47:39 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fan Pulley Bracket Bolt 50 N.m 37 lb ft

2nd Step 60 2nd Step 60
Flywheel Bolt - Angular Tightening Method degrees degrees
degrees degrees
Flywheel Housing Bolt 80 N.m 60 lb ft
Flywheel Housing to Upper Oil Pan Bolt 50 N.m 37 lb ft
Front Engine Cover Bolt 25 N.m 18 lb ft
Fuel Filter Bracket Bolt 30 N.m 22 lb ft
Fuel Injection Pipe Nut 41 N.m 30 lb ft
Fuel Injector Bracket Bolt 30 N.m 22 lb ft
Fuel Inlet Pipe Bracket Bolt 21 N.m 15 lb ft
Fuel Injection Pump Assembly to Cylinder Block
25 N.m 18 lb ft
Bolt
Fuel Injection Pump to Bracket Bolt 28 N.m 20 lb ft
Fuel Injection Pump Drive Gear Nut 70 N.m 52 lb ft
Fuel Line Bracket Nut 21 N.m 15 lb ft
Fuel Temperature Sensor 22 N.m 16 lb ft
Fuel Pipes Bracket Bolt 25 N.m 18 lb ft
Fuel Pressure Relief Valve 100 N.m 74 lb ft
Fuel Rail Assembly Bolt 25 N.m 18 lb ft
Fuel Rail Balance Pipe Bolt 21 N.m 15 lb ft
Generator Bracket Bolt and Nut 50 N.m 37 lb ft
Generator Positive Cable Nut 9 N.m 80 lb in
Glow Plug 18 N.m 13 lb ft
Glow Plug Controller Bolt 10 N.m 89 lb in
Glow Plug Harness Bracket Bolt 10 N.m 89 lb in
Glow Plug Nut 2 N.m 18 lb in
Glow Plug Power Feed Nut 15 N.m 11 lb ft
Glow Plug Relay Assembly Bolt 10 N.m 89 lb in
Heater Outlet Pipe Bolt 25 N.m 18 lb ft
Heater Pipe Bolt 25 N.m 18 lb ft
Hood Hinge Bolt 25 N.m 18 lb ft
Idle Pulley Bolt 50 N.m 37 lb ft
MY
Injector Bracket Bolt 23 N.m 16 lb ft

Intake Manifold Bolts/Nuts 25 N.m 18 lb ft
Oil Cooler Adapter Bolts 25 N.m 18 lb ft
Oil Cooler Adapter Nuts 25 N.m 18 lb ft
Oil Cooler Assembly Bolts 25 N.m 18 lb ft
Oil Cooler Adapter Stud 10 N.m 89 lb in
Oil Drain Plug 84 N.m 62 lb ft
Oil Fill Tube Bolt 25 N.m 18 lb ft
Oil Filter 24 N.m 18 lb ft
Oil Gallery Plugs 53 N.m 39 lb ft
Oil Level Indicator Tube Bolt 21 N.m 15 lb ft
Oil Level Sensor Bolt 10 N.m 89 lb in
Oil Level Sensor Harness Bolt 40 N.m 29 lb ft
Oil Pan Bolts/Nuts - Lower 10 N.m 89 lb in
Oil Pan Bolt - Upper 20 N.m 15 lb ft
Oil Pan Skid Plate Bolt 20 N.m 15 lb ft
Oil Pressure Sensor Unit 49 N.m 36 lb ft
Oil Pressure Relief Valve 39 N.m 29 lb ft
Oil Pump Bolt 21 N.m 15 lb ft
Oil Pump Driven Gear Nut 100 N.m 74 lb ft
Oil Pump Gear Cover Bolt 21 N.m 15 lb ft
Oil Pump Pipe and Screen Assembly Bolts and Nuts 25 N.m 18 lb ft
Piston Cooling Nozzle Eye Bolt 21 N.m 15 lb ft
Positive Cable Junction Block Bracket to Power
9 N.m 80 lb in
Steering Pump Bolt
Positive Crankcase Ventilation Cover Screws 4 N.m 35 lb in
Positive Crankcase Ventilation Oil Separator
25 N.m 18 lb ft
Bracket Nut
Power Steering Pump Bracket Bolt 50 N.m 37 lb ft
Power Steering Pump Bolt 50 N.m 37 lb ft
Rocker Arm Shaft Bracket Bolt 41 N.m 30 lb ft
Starter Motor Bolt 78 N.m 58 lb ft
Transmission Fill Tube Nut 18 N.m 13 lb ft
Thermostat Housing Bolts/Nuts 25 N.m 18 lb ft
Thermostat Cover Bolt 25 N.m 18 lb ft
MY
Torque Converter Bolt 60 N.m 44 lb ft

Transmission Oil Cooler Clip Nut 9 N.m 80 lb in
Turbocharger Bolt 108 N.m 80 lb ft
Turbocharger Coolant Outlet Pipe Bracket Nut 10 N.m 89 lb in
Turbocharger Heat Shield Bolts 10 N.m 89 lb in
Turbocharger Oil Return Pipe Stud 10 N.m 89 lb in
Turbocharger Oil Supply Hose Eye Bolt 26 N.m 19 lb ft
Turbocharger Oil Return Pipe Bolts/Nuts 25 N.m 18 lb ft
Upper Oil Pan to Flywheel Housing Bolts 20 N.m 15 lb ft
Valve Adjusting Nut 22 N.m 16 lb ft
Valve Lifter Holdown Bracket Bolt 11 N.m 97 lb in
Valve Rocker Arm Cover Bolt - Lower 10 N.m 89 lb in
8 N.m (Two 71 lb in (Two
Valve Rocker Arm Cover Bolt - Upper
Times) Times)
Water Outlet Bolts 25 N.m 18 lb ft
Water Pump Bolt 25 N.m 18 lb ft
Water Pump Inlet Pipe Bolts 25 N.m 18 lb ft
ENGINE MECHANICAL SPECIFICATIONS
Specification
Application Metric English
General
Engine Type 90 degree V-8
Displacement 6.6 Liter 402 cu in
RPO LMM
Bore 103 mm 4.0551 in
Stroke 99 mm 3.8976 in
Compression Ratio 16.8:1
Engine Compression Test - Minimum 2069 KPa 300 psi
Idle Speed 680 RPM
Firing Order
1-2-7-8-4-5-6-3
Block
103.11 mm 4.0594 in
MY
Cylinder Bore Diameter - Service Limits

Cylinder Bore Diameter - Production Value 103.0-103.014 mm 4.0551-4.0557 in
Cylinder Bore Out-of-Round - Production 0.015 mm 0.0006 in
Value
Cylinder Bore Taper - Production Value
0.015 mm 0.0006 in
Camshaft
Camshaft Bearing Inside Diameter - Service 61.07 mm 2.4043 in
Limit
Camshaft Bearing Inside Diameter - 61.00-61.03 mm 2.4016-2.4028 in
Production Value
Camshaft End Play - Service Limit 0.2 mm 0.0079 in
Camshaft Journal Diameter - Service Limit 60.92 mm 2.3984 in
Camshaft Journal Diameter - Production Value 60.932-60.962 mm 2.3990-2.4001 in
Camshaft Lobe Lift - Exhuast - Production 5.907 mm 0.2326 in
Value
Camshaft Lobe Lift - Intake - Production 7.273 mm 0.2863 in
Value
Camshaft Runout - Service Limit
0.05 mm 0.0020 in
Cooling System
Capacity @ Engine RPM 270 L/min @ 3172 RPM
Thermostat Full Open Temperature 110 degrees C 230 degrees F
Turbocharger Coolant Bypass Valve
60 degrees C 140 degrees F
Connecting Rod
Connecting Rod Bearing Clearance - Service 0.10 mm 0.0039 in
Limit
Connecting Rod Bearing Clearance - 0.036-0.077 mm 0.0014-0.0030 in
Production Value
Connecting Rod Bore Diameter - Bearing End 62.958-62.979 mm 2.4789-2.4795 in
- Production Value
Connecting Rod Bore Diameter - Pin End - 34.53 mm 1.3594 in
Service Limit
Connecting Rod Bore Diameter - Pin End -
MY
Production Value 34.512-34.522 mm 1.3587-1.3591 in

Connecting Rod Length 163.0 mm 6.42 in
Connecting Rod Side Clearance - Service 0.54 mm 0.0213 in
Limit
Connecting Rod Side Clearance - Production

0.31-0.49 mm 0.0122-0.0193 in
Value
Crankshaft
Connecting Rod Journal Diameter - Service 62.88 mm 2.4756 in
Limit
Connecting Rod Journal Diameter - Production 62.902-62.922 mm 2.4764-2.4772 in
Value
Crankshaft End Play - Service Limit 0.54 mm 0.0213 in
Crankshaft End Play - Production Value 0.04-0.205 mm 0.0016-0.0081 in
Crankshaft Main Bearing Clearance - Service 0.14 mm 0.0055 in
Limit
Crankshaft Main Bearing Clearance - 0.039-0.070 mm 0.0015-0.0028 in
Production Value
Crankshaft Main Journal Diameter - Service 79.89 mm 3.1453 in
Limit
Crankshaft Main Journal Diameter - 79.905-79.925 mm 3.1459-3.1466 in
Production Value
Crankshaft Runout - Service Limit 0.44 mm 0.0173 in
Crankshaft Runout - Production Value
0.05 mm 0.0020 in
Cylinder Head
Surface Flatness - Block Deck - Service Limit 0.2 mm 0.0079 in
Surface Flatness - Block Deck - Production 0.075 mm 0.0030 in
Value
Surface Flatness - Exhaust Manifold Deck - 0.1 mm 0.0039 in
Production Value
Surface Flatness - Intake Manifold Deck -

0.1 mm 0.0039 in
Production Value
Exhaust Manifold
0.3 mm 0.0118 in
MY
Surface Flatness- Production Value

Intake Manifold
Surface Flatness - Production Value
0.3 mm 0.0118 in
Lubrication System
Oil Capacity - with Filter 10 qt 9.5 L
Oil Capacity - without Filter 9.2 qt 8.7 L
Oil Pressure - Minimum- Hot - at idle 98 KPa 14 psi
Oil Pressure - Minimum - 1800 RPM 294 KPa 42 psi
Oil Relief Valve Opening Pressure 441 KPa 64 psi
Piston Cooling Jet Valve Opening Pressure
196 KPa 29 psi
Oil Pump
Gear Shaft Outside Diameter - Drive - Service 19.86 mm 0.7819 in
Limit
Gear Shaft Outside Diameter - Drive - 19.947-19.960 mm 0.7853-0.7858 in
Production Value
Gear Shaft Outside Diameter - Driven - 19.86 mm 0.7819 in
Service Limit
Gear Shaft Outside Diameter - Driven - 19.947-19.960 mm 0.7853-0.7858 in
Production Value
Gear Shaft-to-Bushing - Service Limit 0.14 mm 0.0055 in
Clearance
Gear-to-Cover Clearance - Drive/Driven - 0.109 mm 0.0043 in
Service Limit
Gear-to-Cover Clearance - Drive/Driven - 0.064-0.109 mm 0.0025-0.0043 in
Production Value
Gear-to-Housing Clearance - Drive/Driven - 0.22 mm 0.0087 in
Service Limit
Gear-to-Housing Clearance - Drive/Driven -

0.125-0.221 mm 0.0049-0.0087 in
Production Value
Piston Rings
Piston Ring End Gap-First Compression Ring - 1.37 mm 0.0539 in
Service Limit
MY
Piston Ring End Gap-First Compression Ring - 0.3-0.45 mm 0.0118-0.0177 in

Production Value
Piston Ring End Gap-Second Compression 1.35 mm 0.0531 in
Ring - Service Limit
Piston Ring End Gap-Second Compression 0.50-0.65 mm 0.0197-0.0256 in
Ring - Production Value
Piston Ring End Gap-Oil Control Ring - 1.20 mm 0.0472 in
Service Limit
Piston Ring End Gap-Oil Control Ring - 0.15-0.35 mm 0.0059-0.0138 in
Production Value
Piston Ring to Groove Clearance-First 0.26 mm 0.0102 in
Compression Ring - Service Limit
Piston Ring to Groove Clearance-First 0.08-0.17 mm 0.0030-0.0067 in
Compression Ring - Production Value
Piston Ring to Groove Clearance-Second 0.10 mm 0.0039 in
Compression Ring - Service Limit
Piston Ring to Groove Clearance-Second 0.01-0.03 mm 0.0004-0.0012 in
Compression Ring - Production Value
Piston Ring to Groove Clearance-Oil Control 0.12 mm 0.0047 in
Ring - Service Limit
Piston Ring to Groove Clearance-Oil Control

0.01-0.03 mm 0.0004-0.0012 in
Ring - Production Value
Pistons and Pins
Piston-Piston Diameter 102.948-102.960
4.0531-4.0535 in
mm
Piston-Piston Pin Bore Diameter 34.504-34.512 mm 1.3584-1.3587 in
Pin-Piston Pin Clearance to Piston Pin Bore - 0.017 mm 0.0007 in
Service Limit
Pin-Piston Pin Clearance to Piston Pin Bore - 0.004-0.017 mm 0.0002-0.0007 in
Production Value
Pin-Piston Pin Diameter - Service Limit 34.45 mm 1.3563 in
Pin-Piston Pin Diameter - Production Value 34.495-34.5 mm 1.3581-1.3583 in
Starter
MY
Rated Output
3.5 KW
Valve System
Valves-Valve Face Angle - Production Value 45 degrees
Valves-Valve Face Width - Service Limit 2.5 mm 0.0984 in
Valves-Valve Face Width - Production Value 2.1 mm 0.0827 in
Valves-Valve Head Diameter - Exhaust 31.0 mm 1.22 in
Valves-Valve Head Diameter - Intake 33.0 mm 1.30 in
Valves-Valve Seat Angle 45 degrees
Valves-Valve Stem Diameter 7.0 mm 0.28 in
Valves-Valve Stem Oil Seal Installed Height 6.05 mm 0.2382 in
Valves-Valve Stem-to-Guide Clearance - 0.20 mm 0.0079 in
Service Limit
Valves-Valve Stem-to-Guide Clearance - 0.038-0.071 mm 0.0015-0.0028 in
Exhaust - Production Value
Valves-Valve Stem-to-Guide Clearance - 0.030-0.063 mm 0.0012-0.0025 in
Intake - Production Value
Valves-Valve Stem-to-Guide Clearance 0.20 mm 0.0079 in
Valve Lifters/Push Rods-Push Rod Straightness 0.8 mm 0.0315 in
Rocker Arms-Valve Rocker Arm Bore 22.010-22.035 mm 0.8665-0.8675 in
Diameter
Rocker Arms-Valve Rocker Arm Bore-to- 0.20 mm 0.0079 in
Shaft Clearance - Service Limit
Rocker Arms-Valve Rocker Arm Bore-to- 0.010-0.056 mm 0.0004-0.0022 in
Shaft Clearance - Production Value
Rocker Arms-Valve Rocker Arm Ratio - 1.69:1
Exhaust
Rocker Arms-Valve Rocker Arm Ratio - 1.36:1
Intake
Rocker Arms-Valve Rocker Arm Shaft 21.85 mm 0.8602 in
Diameter - Service Limit
Rocker Arms-Valve Rocker Arm Shaft 21.979-22.000 mm 0.8653-0.8661 in
Diameter - Production Value
MY
Valve Springs-Valve Spring Free Length - 56.6 mm 2.2283 in

Production Value
Valve Springs-Valve Spring Installed Height - 41 mm 1.6142 in
Production Value
Valve Springs-Valve Spring Load - Exhaust - 275 N at 41 mm 61.8 lb at 1.61 in
Service Limit
Valve Springs-Valve Spring load - Exhaust - 315-363 N at 41 71-81.6 lb at 1.61
Production Value mm in
Valve Springs-Valve Spring Load - Intake - 306 N at 41 mm 68.8 lb at 1.61 in
Service Limit
Valve Springs-Valve Spring Load - Intake - 315-363 N at 41 71-81.6 lb at 1.61
Production Value mm in
SEALERS, ADHESIVES, AND LUBRICANTS
GM Part Number
United
Application Type of Material States Canada
Locktite 272T or
Sealing Cup Plug 12345493 10953488
Equivalent
Upper Oil Pan to Cylinder Block Sealant 12378521 88901148
Flywheel Housing to Cylinder Block Sealant 12378521 88901148
Engine Front Cover to Cylinder Block Sealant 12378521 88901148
Lower Oil Pan to Upper Oil Pan Sealant 12378521 88901148
Crankshaft Bearing Side Cap Bolts Sealant 12346004 10953480
Intake Manifold to Cylinder Head Sealant 12378521 88901148
Camshaft Bearing Engine Oil 12345634 993297
Rocker Arm Shaft Engine Oil 12345634 993297
Valve Bridge Cap Engine Oil 12345634 993297
Valve Stem Seal Engine Oil 12345634 993297
Valve Lifter Engine Oil 12345634 993297
Piston Ring Engine Oil 12345634 993297
Crankshaft Bearing Engine Oil 12345634 993297
Connecting Rod Bearing Engine Oil 12345634 993297
Thrust Bearing Engine Oil 12345634 993297
MY
Camshaft Bearing Engine Oil 12345634 993297

Camshaft Engine Oil 12345634 993297
Connecting Rod Small End Bushing Engine Oil 12345634 993297
Push Rod Engine Oil 12345634 993297
Molybdenum
Crankshaft Bearing Cap Bolt 1052948 992926
Disulfide
Lithium Grease Lubricant 12346293 -
Parts Cleaner Cleaner 12377981 10953463
CONNECTING ROD BEARINGS SELECTION SPECIFICATIONS
Connecting Rod Bearing Grade

Connecting
Rod Grade Use This Bearing Thickness Oil Clearance
(Stamped on Bearing
Connecting Color Metric (mm) English (in) Metric (mm) English (in)
Rod)
0.0790 - 0.0015 -
A Green 2.007 - 2.013 0.037 - 0.076
0.0793 0.0030
0.0792 - 0.0015 -
B Yellow 2.011 - 2.017 0.037 - 0.076
0.0794 0.0030
CYLINDER HEAD GASKET SELECTION SPECIFICATIONS
MY
Fig. 1: View Of Cylinder Head Gasket Selection Marks

Courtesy of GENERAL MOTORS CORP.
Callout Component Name

1 Grade A
2 Grade B
3 Grade C
4 Block Over-Bored
5 Block Over-Bored and Deck Milled
Cylinder Head Ti Max (Piston Projection) Compressed Gasket Thickness

Gasket Grade Metric (mm) English (in) Metric (mm) English (in)
Grade A 0.223 -0.274 0.0088 -0.0108 0.90-1.00 0.0354-0.0394
Grade B 0.274-0.325 0.0108-0.0128 0.95-1.05 0.0374-0.0413
Grade C 0.325-0.376 0.0128-0.0148 1.00-1.10 0.0394-0.0433
Block Over-
Bored 0.010-
0.223-0.376 0.0088-0.0148 1.00-1.10 0.0394-0.0433
0.030 in (0.254-
0.762 mm)
MY
Block Over-
Bored 0.010-
0.030 in (0.254-
0.762 mm) and 0.4257-0.5777 0.0168-0.0228 1.25-1.35 0.0492-0.0532
Deck Milled
0.008 in (0.203
mm)
CRANKSHAFT BEARING SELECTION SPECIFICATIONS
Cylinder Block Crankshaft Identification Oil Clearance

Grade Journal Grade Bearing Color Metric (mm) English (in)
1 1 Black 0.041-0.068 0.0016-0.0027
1 2 Brown 0.039-0.065 0.0015-0.0026
2 1 Blue 0.043-0.070 0.0017-0.0028
2 2 Black 0.041-0.067 0.0016-0.0027
VALVE CLEARANCE ADJUSTMENT SPECIFICATIONS
Adjust at No 1 Adjust at No 1 Exhaust

Cylinder Compression Stroke TDC Stroke TDC
Left Bank Right Bank Intake Exhaust Intake Exhaust
- 1 X X - -
2 - - X X -
- 3 X - - X
4 - - - X X
- 5 X - - X
6 - X - - X
- 7 - X X -
8 - - X X -
THREAD REPAIR SPECIFICATIONS
Cylinder Head - Exhaust View
MY
Fig. 2: Cylinder Head (Exhaust View)

Cylinder Head - Exhaust View

Drill Tap
Service Depth Depth
Hole Thread Counterbore Stop (Max) (Min)
Location Size Drill Tool Collar Tap Driver Insert mm (in) mm (in)
M 10 x
1 -211 -212 N/A -213 -214 -215 25 0.985 21 0.827
1.5
Cylinder Head - Intake View
Fig. 3: Cylinder Head (Intake View)

MY
Cylinder Head - Intake View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 21 0.827 17 0.669
1.25
Cylinder Head - Top View
Fig. 4: Cylinder Head (Top View)

Cylinder Head - Top View

Drill Tap
Service Depth Depth
M6x
1 -201 -202 N/A -203 -204 -205 17 0.669 13 0.512
1.0
M8x
2 -206 -207 N/A -208 -209 -210 26 1.024 20 0.788
1.25
MY
M 10 x
3 -211 -212 N/A -213 -214 -215 26 1.024 20 0.788
1.5
Cylinder Head - Rear View
Fig. 5: Cylinder Head (Rear View)

Cylinder Head - Rear View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
M 10 x
2 -211 -212 N/A -213 -214 -216 20 0.788 16 0.630
1.5
Cylinder Head - Front View
MY
Fig. 6: Cylinder Head (Front View)

Cylinder Head - Front View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
M 10 x
2 -211 -212 N/A -213 -214 -216 20 0.788 16 0.630
1.5
Intake Manifold - Right Side View
MY
Fig. 7: Intake Manifold (Right Side View)

Intake Manifold - Right Side View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -415 16 0.630 13 0.512
1.25
M8x
2 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
M6x
3 -201 -202 N/A -203 -204 -205 16 0.0630 12 0.472
1.0
Intake Manifold - Left Side View
MY
Fig. 8: Intake Manifold (Left Side View)

Intake Manifold - Left Side View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
M6x
2 -201 -202 N/A -203 -204 -205 14 0.551 11 0.433
1.0
M6x
3 -201 -202 N/A -203 -204 -205 16 0.630 12 0.472
1.0
Oil Cooler
MY
Fig. 9: View Of Oil Cooler

Oil Cooler
Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 21 0.827 17 0.669
1.25
M8x
2 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
MY
EGR Cooler - Rear View
Fig. 10: EGR Cooler (Rear View)

EGR Cooler - Rear View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
EGR Cooler - Front View
MY
Fig. 11: EGR Cooler (Front View)

EGR Cooler - Front View

Drill Tap
Service Depth Depth
MY
M8x
1 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
EGR - Top View
Fig. 12: EGR (Top View)

MY
EGR - Top View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
Thermostat Housing - Top View
Fig. 13: Thermostat Housing (Top View)

Thermostat Housing - Top View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 21 0.827 17 0.669
1.25
M8x
2 -206 -207 N/A -208 -209 -210 THRU THRU
1.25
3 NPT 3/8 -2013 N/A N/A -294 -2015 -2016 THRU THRU
M8x
4 -206 -207 N/A -208 -209 -210 19 0.748 15 0.591
1.25
MY
AC Bracket
Fig. 14: View Of AC Bracket

AC Bracket
Drill Tap
Service Depth Depth
M 10 x
1 -211 -212 N/A -213 -214 -420 30 1.182 25 0.985
1.5
Generator Bracket - Front View
MY
Fig. 15: Generator Bracket (Front View)

Generator Bracket - Front View

Drill Tap
Service Depth Depth
M 10 x
1 -211 -212 N/A -213 -214 -215 THRU THRU
1.5
M8x
2 -206 -207 N/A -208 -209 -415 17 0.669 12 0.472
1.25
M 10 x
3 -211 -212 N/A -213 -214 -420 THRU 25 0.985
1.5
M8x
4 -206 -207 N/A -208 -209 -210 22 0.866 17 0.669
1.25
MY
Generator Bracket - Rear View
Fig. 16: Generator Bracket (Rear View)

Generator Bracket - Rear View

Drill Tap
Service Depth Depth
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M 10 x
1 -211 -212 N/A -213 -214 -215 THRU THRU
1.5
Generator Bracket - Side View
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Fig. 17: Generator Bracket (Side View)

Generator Bracket - Side View

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Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 22 0.866 17 0.669
1.25
M8x
2 -206 -207 N/A -208 -209 -210 17 0.669 12 0.472
1.25
Engine Front Cover - Front View
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Fig. 18: Engine Front Cover (Front View)

Engine Front Cover - Front View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 19 0.748 15 0.591
1.25
M 10 x
2 -211 -212 N/A -213 -214 -216 20 0.788 16 0.630
1.5
M6x
3 -201 -202 N/A -203 -204 -205 14 0.551 10 0.394
1.0
Engine Front Cover - Side View
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Fig. 19: Engine Front Cover (Side View)

Engine Front Cover - Side View

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Drill Tap
Service Depth Depth
M6x
1 -201 -202 N/A -203 -204 -205 14 0.551 10 0.394
1.0
M6x
2 -201 -202 N/A -203 -204 -205 THRU 10 0.394
1.0
Engine Front Cover - Bottom View
Fig. 20: Engine Front Cover (Bottom View)

Engine Front Cover - Bottom View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
Lower Rocker Arm Cover - Top View
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Fig. 21: Lower Rocker Arm Cover (Top View)

Lower Rocker Arm Cover - Top View

Drill Tap
Service Depth Depth
M6x
1 -201 -202 N/A -203 -204 -205 18 0.709 15 0.591
1.0
Lower Rocker Arm Cover - Side View
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Fig. 22: Lower Rocker Arm Cover (Side View)

Lower Rocker Arm Cover - Side View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 21 0.827 17 0.669
1.25
Upper Rocker Arm Cover - Top View
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Fig. 23: Upper Rocker Arm Cover (Top View)

Upper Rocker Arm Cover - Top View

Drill Tap
Service Depth Depth
M5x
1 N/A N/A N/A N/A N/A N.A 13 0.512 10 0.394
0.8
M8x
2 -206 -207 N/A -208 -209 -210 21 0.827 17 0.669
1.25
M6x
3 -201 -202 N/A -203 -204 -205 16 0.630 12 0.472
1.0
Upper Rocker Arm Cover - Bottom View
Fig. 24: Upper Rocker Arm Cover (Bottom View)

Upper Rocker Arm Cover - Bottom View

Drill Tap
Service Depth Depth
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M5x
1 N/A N/A N/A N/A N/A N/A 13 0.512 10 0.394
0.8
Flywheel Housing - Rear View
Fig. 25: Flywheel Housing (Rear View)

Flywheel Housing - Rear View

Drill Tap
Depth Depth
Service
(Max) (Min)
Hole Thread Counterbore Stop
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M 12 x
1 -856 -857 N/A -858 -859 -855 28 1.103 23 0.906
1.75
Flywheel Housing - Top View
Fig. 26: Flywheel Housing (Top View)

Flywheel Housing - Top View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
Flywheel Housing - Bottom View
Fig. 27: Flywheel Housing (Bottom View)

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Flywheel Housing - Bottom View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 21 0.827 18 0.709
1.25
M8x
2 -206 -207 N/A -208 -209 -210 17 0.669 14 0.551
1.25
Flywheel Housing - Right View
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Fig. 28: Flywheel Housing (Right View)

Flywheel Housing - Right View

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Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
Flywheel Housing - Left View
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Fig. 29: Flywheel Housing (Left View)

Flywheel Housing - Left View

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Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
Upper Oil Pan - Bottom View
Fig. 30: Upper Oil Pan (Bottom View)

Upper Oil Pan - Bottom View

Drill Tap
Service Depth Depth
M6x
1 -201 -202 N/A -203 -204 -205 THRU THRU
1.0
M 6 x -201 -202 N/A -203 -204 -205 17 0.669 13 0.512
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2 1.0
Upper Oil Pan - Top View
Fig. 31: Upper Oil Pan (Top View)

Upper Oil Pan - Top View

Drill Tap
Service Depth Depth
M8x
1 -206 -207 N/A -208 -209 -210 17 0.669 13 0.512
1.25
Upper Oil Pan - Front View
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Fig. 32: Upper Oil Pan (Front View)

Upper Oil Pan - Front View

Drill Tap
Service Depth Depth
M6x
1 -201 -202 N/A -203 -204 -205 17 0.669 13 0.512
1.0
M8x
2 -206 -207 N/A -208 -209 -210 21 0.827 17 0.669
1.25
Upper Oil Pan - Rear View
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Fig. 33: Upper Oil Pan (Rear View)

Upper Oil Pan - Rear View

Drill Tap
Service Depth Depth
M 12 x
1 -856 -857 N/A -858 -859 -855 22 0.866 16 0.630
1.75
Upper Oil Pan - Side View
Fig. 34: Upper Oil Pan (Side View)

Upper Oil Pan - Side View

Drill Tap
Service Depth Depth
M6x
1 -201 -202 N/A -203 -204 -205 17 0.669 13 0.512
1.0
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SCHEMATIC AND ROUTING DIAGRAMS

ENGINE MECHANICAL SCHEMATICS
Fig. 35: ngine Mechanical Schematic

COMPONENT LOCATOR
DISASSEMBLED VIEWS
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Fig. 36: Engine Block, Crankshaft, Piston Components View


100 Engine Block
101 Dowel Pin
102 Engine Block Plug
103 Engine Block Heater
105 Crankshaft Bearing Cap Bolt
108 Upper Crankshaft Bearings
109 Upper Thrust Bearing
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110 Crankshaft
111 Crankshaft Pin
112 Lower Crankshaft Bearings
113 Lower Thrust Bearings
113 Lower Thrust Bearings
114 Crankshaft Bearing Cap
115 Crankshaft Bearing Cap Bolt
116 Dowel Pin
117 Crankshaft Gear
118 Crankshaft Position Sensor Exciter Ring
119 Crankshaft Position Sensor Exciter Ring Bolt
120 Crankshaft Position Sensor Exciter Ring Pin
121 Oil Pump Drive Gear
122 Crankshaft Balancer
123 Crankshaft Balancer Washer
124 Crankshaft Balancer Bolt
125 Flywheel - Manual Transmission
126 Flywheel Washer
127 Flywheel Bolt
128 Flywheel Plate
129 Dowel Pin
130 Flywheel - Automatic Transmission
131 Ring Gear
132 Dowel Pin
133 Connecting Rod Cap
134 Connecting Rod Bearings
135 Connecting Rod
136 Connecting Rod Bushing
137 Piston Pin
138 Piston Pin Retainer
139 Piston
140 Piston Rings
141 Connecting Rod Bolt
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Fig. 37: Cylinder Head, Valves, Lifters, Timing Components, Camshaft Components
View

200 Cylinder Head
200 Cylinder Head
201 Cylinder Head Gasket
201 Cylinder Head Gasket
202 Cylinder Head Bolt
202 Cylinder Head Bolt
203 Exhaust Valve
204 Pushrod
205 Valve Spring Seat
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206 Valve Spring

207 Valve Spring Retainer
208 Valve Key
209 Valve Bridge
210 Valve Bridge Pin
211 Rocker Arm Shaft Plug
212 Rocker Arm Shaft Mount
213 Rocker Arm Shaft Mount Bolt
214 Rocker Arm Shaft Assembly Lock Nut
215 Rocker Arm
216 Rocker Arm Shaft Assembly
217 Fuel Injector
218 Fuel Injector O-ring Seal
219 Fuel Injector Gasket
220 Fuel Injector Bracket
221 Fuel Injector Bracket Bolt
222 Fuel Return Pipe
223 Fuel Return Pipe Bolt
224 Glow Plug
225 Valve Lifter Guide Bracket
226 Valve Lifter Guide
227 Valve Lifter
228 Camshaft
229 Camshaft Bearings
230 Camshaft Pin
231 Camshaft Thrust Plate
232 Camshaft Thrust Plate Bolt
233 Camshaft Gear
234 Camshaft Gear Washer
235 Camshaft Gear Bolt
236 Camshaft Position Sensor Exciter Ring
237 Camshaft Position Sensor Exciter Ring Pin
238 Camshaft Position Sensor Exciter Ring Bolt
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Fig. 38: Cooling, Water Pump Components View


300 Water Pump
301 Water Pump Bolt
302 Water Pump O-ring Seal
303 Water Pump Gasket
304 Cooling Fan Pulley Insulator
305 Cooling Fan Pulley Stud
306 Cooling Fan Pulley Nut
307 Cooling Fan Pulley Bolt
308 Cooling Fan Pulley
309 Cooling Fan Pulley Bracket
310 Thermostat Housing Bolt
310 Thermostat Housing Bolt
311 Thermostat Housing Stud
312 Thermostat Housing Nut
313 Thermostat Bypass Pipe
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314 Thermostat Bypass Pipe O-ring

315 Thermostat Bypass Pipe Gasket
316 Thermostat Bypass Pipe Bolt
317 Thermostat
318 Heater Pipe
319 Heater Pipe Bolt
320 Thermostat Cover
321 Thermostat Cover Bolt
322 Water Outlet
323 Water Outlet Bolt
323 Water Outlet Bolt
324 Water Outlet O-ring Seal
325 Thermostat Housing
326 Thermostat Housing Gasket
327 Thermostat Bypass Pipe Crossover Tube
328 Thermostat Bypass Pipe Crossover Tube Clamps
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Fig. 39: Oil Pan, Pump, Filter, Tube Components View


400 Oil Pump Housing
401 Oil Pump Cover
402 Oil Pump Cover Bolt
403 Oil Pump Drive Gear
404 Oil Pump Driven Gear
405 Oil Pump Gear
406 Oil Pump Gear Nut
407 Oil Level Indicator Tube
408 Oil Level Indicator Tube Bolt
409 Oil Level Indicator
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410 Oil Level Indicator Tube O-ring

411 Oil Pump Pipe and Screen Assembly
412 Oil Pump Pipe and Screen Assembly Bolt
413 Oil Pump Pipe and Screen assembly Gasket
414 Upper Oil Pan
415 Upper Oil Pan Bolt
416 Lower Oil Pan
417 Lower Oil Pan Bolt
418 Oil Level Sensor
419 Oil Level Sensor Bolt
420 Oil Level Sensor Retainer
421 Oil Drain Plug
422 Engine Oil Cooler
423 Engine Oil Cooler O-ring
424 Engine Oil Cooler Bolt
424 Engine Oil Cooler Bolt
425 Oil Filter Adapter
426 Oil Filter
427 Oil Pressure Relief Valve Spring Cup
428 Oil Pressure Relief Valve Spring
429 Oil Pressure Relief Valve Spring Plug
430 Oil Cooler Tube
431 Oil Fill Tube
432 Oil Fill Tube Cap
433 Oil Fill Tube Bolt
434 Oil Fill Tube O-ring
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Fig. 40: Intake Manifold, Rails, Covers


500 Intake Manifold
500 Intake Manifold
501 Intake Manifold Bolt
501 Intake Manifold Bolt
502 Intake Manifold Stud
503 Intake Manifold Nut
504 Intake Manifold Crossover
505 Intake Manifold Crossover Gasket
505 Intake Manifold Crossover Gasket
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506 Intake Manifold Tube

507 Air Inlet Tube
508 EGR
509 EGR Bracket
510 EGR Gasket
511 EGR Cooler
512 EGR Cooler Bracket
513 Fuel Pipe
514 Fuel Pipe Bolt
515 PCV Hose
516 Lower Turbocharger Heat Shield
517 Turbocharger
518 Turbocharger Bolt
519 Turbocharger Air Inlet
520 Turbocharger Air Inlet Clamp
521 Upper Turbocharger Heat Shield
522 Upper Turbocharger Heat Shield Bolt
523 Fuel Inlet Pipe Assembly
524 Fuel Inlet Pipe Assembly Bolt
524 Fuel Inlet Pipe Assembly Bolt
525 Fuel Feed Pipe
526 Fuel Feed Pipe Bolt
527 Fuel Feed Pipe Nut
528 Fuel Rail Balance Pipe
529 Fuel Rail Balance Pipe Bolt
530 Turbocharger Oil Supply Line
531 Turbocharger Oil Supply Line Bolt
532 Fuel Injection Pump
533 Fuel Injection Pump Bolt
534 Fuel Filter Assembly
535 Fuel Rail
535 Fuel Rail
536 Fuel Rail Bolts
536 Fuel Rail Bolts
537 Fuel Rail Bracket
MY 537
Fuel Rail Bracket

538 Fuel Injection Pump Pipe
539 Injection Pipes
539 Injection Pipes
540 Lower Valve Rocker Arm Cover
540 Lower Valve Rocker Arm Cover
541 Lower Valve Rocker Arm Cover Gasket
541 Lower Valve Rocker Arm Cover Gasket
542 Lower Valve Rocker Arm Cover Bolt
543 Upper Valve Rocker Arm Cover Gasket
543 Upper Valve Rocker Arm Cover Gasket
544 Upper Valve Rocker Arm Cover
544 Upper Valve Rocker Arm Cover
545 Upper Valve Rocker Arm Cover Bolt
546 Engine Front Cover
547 Engine Front Cover Bolt
548 Flywheel Housing
549 Flywheel Housing Bolt
550 Dowel Pin
551 Crankshaft Rear Oil Seal
552 Flywheel Housing Oil Cooler Adapter
553 Flywheel Housing Oil Cooler Adapter Bolt
554 Flywheel Housing Oil Cooler Adapter Gasket
555 Flywheel Housing O-ring
556 Flywheel Housing Cover
557 Flywheel Housing Cover Bolt
558 Flywheel Housing Cover Gasket
559 Fuel Schrader Valve
560 Fuel Schrader Valve Nuts
561 Fuel Schrader Valve Bracket
561 Fuel Schrader Valve Bracket
562 Intake Pipe
563 Intake Heater
MY 707
Turbocharger Boost Sensor
Fig. 41: Exhaust Manifolds, EGR, Air Components View


600 Exhaust Manifold
600 Exhaust Manifold
601 Exhaust Manifold Gasket
601 Exhaust Manifold Gasket
602 Exhaust Manifold Bolt
602 Exhaust Manifold Bolt
603 Exhaust Manifold Heat Shield
603 Exhaust Manifold Heat Shield
604 Exhaust Manifold Heat Shield Bolt
604 Exhaust Manifold Heat Shield Bolt
605 Exhaust Manifold Nut
605 Exhaust Manifold Nut
606 Exhaust Pipe
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607 Exhaust Pipe Gasket

608 Exhaust Pipe Bolt
609 Exhaust Pipe Stud
610 Exhaust Pipe Nut
611 Exhaust Crossover Pipe
612 Exhaust Crossover Pipe Gasket
613 Exhaust Crossover Pipe Bolt
613 Exhaust Crossover Pipe Bolt
614 Exhaust Crossover Pipe Heat Shield
615 Exhaust Crossover Pipe Heat Shield Bolt
616 Exhaust Outlet Adapter
617 Exhaust Outlet Heat Shield
618 Exhaust Outlet Adapter Clamp
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Fig. 42: Miscellaneous, Sensors, Ignition, Vacuum Hoses, Electrical


700 Engine Wiring Harness
701 Glow Plug Controller
702 Glow Plug Controller Bracket
703 PCV Cover
704 PCV Cover Bolt
705 PCV Diaphragm
706 PCV Spring
710 Oil Pressure Sensor
711 Coolant Temperature Sensor
712 Crankshaft Position Sensor
713 Crankshaft Position Sensor Bolt
714 Crankshaft Position Sensor O-ring
715 Camshaft Position Sensor
716 Camshaft Position Sensor Bolt
717 Camshaft Position Sensor O-ring
718 Generator Mounting Bracket
719 Idler Pulley
719 Idler Pulley
719 Idler Pulley
720 Idler Pulley Bolt
720 Idler Pulley Bolt
721 Generator Mounting Bracket Bolt
722 Drive Belt Tensioner
723 Drive Belt Tensioner Bolt
724 Power Steering Pump Bracket
725 Power Steering Pump Bracket Bolt
ENGINE IDENTIFICATION
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Fig. 43: View Of Engine Identification Tag

The engine identification tag is located on the left side of the block. It is on the front edge of the
block.
DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembled Views, Engine Component
Description and Lubrication Description and the Drive Belt System Description. Reviewing
MY
the description and operation information will help you determine the correct symptom
diagnostic procedure when a malfunction exists. Reviewing the description and operation
information will also help you determine if the condition described to you by the customer is
normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct
procedure for diagnosing the system and where the procedure is located.
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
1. Perform the Diagnostic Starting Point - Engine Controls before using the symptom
tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions.
Refer to Disassembled Views, Engine Component Description, and Lubrication
Description, and to the Drive Belt System Description.
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform
approach for repairing all systems. The diagnostic flow may always be used in order to resolve a
system problem. The diagnostic flow is the place to start when repairs are necessary. For a
detailed explanation, refer to Strategy Based Diagnosis .
Visual/Physical Inspection
Inspect for aftermarket devices which could affect the operation of the engine.
Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Check for the correct oil level, proper oil viscosity, and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as
engine RPM, ambient temperature, engine temperature, amount of engine warm-up time,
and other specifics.
Compare the engine sounds, if applicable, to a known good engine and make sure you are
not trying to correct a normal condition.
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system
is operating properly.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the
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symptom:
Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Compression Test
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES
Condition Action
Abnormalities (severe cracking, bumps or Abnormalities in the accessory drive belt
missing areas) in the accessory drive belt. and/or components may cause engine RPM
Also worn, damaged, or misaligned accessory variations, noises similar to a faulty lower
drive components or excessive pulley runout. engine and also lead to a misfire condition. A
misfire code may be present without an actual
misfire condition.
1. Inspect the accessory drive components.

2. Repair or replace all damaged
components.
Loose and/or damaged crankshaft balancer A misfire code may be present without an
actual misfire condition.
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1. Inspect crankshaft balancer and

balancer bolt.
components.
Loose torque converter bolts A misfire code may be present without an
1. Inspect torque converter bolts and

flywheel.
components.
Loose and/or damaged flywheel A misfire code may be present without an
1. Inspect flywheel and flywheel attaching

bolts.
components.
Restricted exhaust system A severe restriction in the exhaust flow can
cause significant loss of engine performance
and may set a misfire code. Possible causes of
restrictions include collapsed or dented pipes,
plugged mufflers and/or catalytic converters.
Repair or replace all damaged components.
Air in fuel system 1. Inspect fuel filter, fuel system for leaks
and/or restrictions.
components.
Bent and/or worn valve pushrod 1. Inspect valve pushrod and valve rocker
arm.
components.
Sticking valve Carbon on the valve stem or valve seat may
cause the valve to stick.
1. Inspect valves and valve guides.

MY
components.
Damaged or misaligned timing gears 1. Inspect timing gears.
2. Replace all damaged components.
Worn or faulty camshaft lobes 1. Inspect camshaft lobes.
2. If damaged replace camshaft and all
lifters.
Excessive piston-to-cylinder bore clearance 1. Perform cylinder leak down and
compression tests.
2. Inspect the piston, piston rings and
cylinder bore.
components.
Faulty cylinder head gaskets and/or cracking 1. Perform cylinder leak down and
or other damage to the cylinder heads and compression tests.
engine block cooling system passages.
(Coolant consumption may or may not cause
cylinder bore.
the engine to overheat.)
components.
Overfilled Crankcase 1. Check engine oil level with vehicle on a
level surface.
2. Correct any overfilled condition.
3. Inspect for fuel leaks into the crankcase.
Refer to Fuel in Engine Oil.
4. Repair any fuel leaks.
BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES
Condition Action
Abnormalities (severe cracking, bumps or Abnormalities in the accessory drive belt
missing areas) in the accessory drive belt. and/or components may cause engine RPM
variations, noises similar to a faulty lower
engine and also lead to a misfire condition. A
misfire code may be present without an actual
misfire condition.

MY

components.
Worn, damaged, or misaligned accessory A misfire code may be present without an
drive components or excessive pulley runout actual misfire condition.

components.
Loose and/or damaged crankshaft balancer A misfire code may be present without an
1. Inspect crankshaft balancer and

balancer bolt.
components.
Loose torque converter bolts A misfire code may be present without an
1. Inspect torque converter bolts and

flywheel.
components.
Loose and/or damaged flywheel A misfire code may be present without an
1. Inspect flywheel and flywheel attaching

bolts.
components.
compression tests
cylinder bore.
components.
Excessive crankshaft thrust bearing clearance Severely worn thrust surfaces on the
crankshaft and/or thrust bearing may permit
MY
for and aft movement of the crankshaft and

create a misfire code without an actual
misfire condition.
1. Inspect the crankshaft end play and

crankshaft thrust bearings.
components.
Overfilled crankcase 1. Check engine oil level with vehicle on a
level surface.
2. Correct any overfilled condition.
3. Inspect for fuel leaks into the crankcase.
4. Repair any fuel leaks.
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
Condition Action
Loose, worn or damaged rocker arm 1. Inspect valve rocker arm and rocker arm
shaft.
components.
Loose valve rocker arm attachments 1. Inspect valve rocker arm and rocker arm
shaft.
components.
Worn or damaged pushrods 1. Inspect the pushrods for excessive wear.
2. Inspect the pushrods for bent condition.
3. Inspect the pushrods for broken tip.
4. Replace pushrod if any damage is found.
Broken valve springs 1. Inspect valve springs.
components.
Worn and/or damaged valve rotator 1. Inspect valve rotators.
components.
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components.
lifters.
Excessive valve lash 1. Check the valve lash adjustment, and
correct if above specifications.
components.
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Inspection Action
DEFINITION: Base engine misfire with coolant consumption
Preliminary Inspection Verify that there are no external coolant
leaks. Refer to Loss of Coolant .
Cylinder balance test with scan tool
Cooling system pressurization
Isolate Affected Cylinders Inspection of glow plugs
Compression test
Cylinder leakdown test
1. Inspect EGR valve and intake system for
evidence of coolant leakage.
EGR System Inspection
2. Replace the EGR cooler if any problem
is found.
Remove cylinder heads of the affected
Cylinder Head Gasket Leakage cylinder bank and inspect for damage.
Replace components as necessary.
1. Inspect the cylinder heads for cracks and
warpage.
2. Inspect the cylinder block for damage.
MY
3. Inspect the cylinder block to head

Cylinder Head or Engine Block Damage mating surface for straightness.
4. Replace components as necessary.
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION
Condition Action
Worn valve guides 1. Inspect the valves and valve guides.
components.
Worn valve stem oil seals 1. Inspect the valve stem oil seals.
components.
compression tests to determine the
cause.
2. Inspect the piston rings for low ring
tension, broken or worn rings.
3. Inspect cylinder bore.
components.
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
Condition Action
Incorrect oil viscosity 1. Drain the oil.
2. Install the correct viscosity oil.
Excessive piston-to-cylinder bore clearance 1. Inspect the piston and piston skirt,
connecting rod, and cylinder bore.
components.
Damaged or faulty oil filter by-pass valve 1. Inspect the oil filter by-pass valve for
proper operation.
2. Repair or replace as necessary.
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UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Condition Action
Low oil pressure Insufficient or poor oil supply to valve train.
1. Perform oil pressure test.

components.
Improper lubrication to the valve rocker 1. Inspect valve rocker arm and shaft,
arms valve pushrod, oil filter bypass valve, oil
pump and pump screen, and engine
block oil galleries.
components.
Excessive valve lash 1. Check the valve lash adjustment, and
correct if above specifications.
components.
Worn pushrod upper end ball 1. Inspect pushrod end ball.
components.
Bent valve pushrod 1. Inspect valve pushrod and valve rocker
arm.
components.
Loose, worn or damaged valve rocker arm 1. Inspect valve rocker arm and rocker arm
shaft.
components.
Loose valve rocker arm attachments 1. Inspect valve rocker arm and rocker arm
shaft.
components.
Broken valve springs 1. Inspect valve springs.
MY
components.
Worn and/or damaged valve spring shims, 1. Inspect valve spring shims, seats, and
seats, or keys keys.
components.

components.
Missing or improperly positioned lifter 1. Inspect lifter guides.
guides
components.
lifters.
Worn valve guide 1. Inspect the valves and valve guides.
components.
Damaged or misaligned timing gears 1. Inspect timing gears.
2. Replace all damaged components.
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Condition Action
Worn accessory drive components 1. Inspect the accessory drive components.
(abnormalities such as severe cracking,
bumps or missing areas in the accessory drive
components.
belt and/or misalignment of the system
components.)
Low oil pressure Insufficient or poor oil supply to crankshaft
and connecting rod bearings.

MY
components.
Leaking and/or sticking fuel injection nozzle 1. Use the cylinder balance diagnostic
(A stuck fuel injection nozzle can cause a procedure to help locate the cylinder
noise similar to a damaged piston, rod or rod that is the source of the noise.
bearing.)
2. If you cannot locate the cylinder that is
the source of the noise, diagnose the
engine for mechanical damage.
3. If it has been determined that the fuel
injection nozzle is causing the noise,
replace the fuel injection nozzle.
Loose and/or damaged crankshaft balancer 1. Inspect crankshaft balancer and
balancer bolt.
components.
Loose torque converter bolts 1. Inspect torque converter bolts and
flywheel.
components.
Loose and/or damaged flywheel 1. Inspect flywheel and flyweel attaching
bolts.
components.
Excessive piston-to-cylinder bore clearance 1. Inspect the piston, piston rings and
cylinder bore.
components.
Excessive piston pin-to-bore clearance 1. Inspect the piston, piston pin, and the
connecting rod.
components.
Misaligned or bent connecting rod 1. Inspect connecting rod and connecting
rod bearings.
components.
Excessive connecting rod bearing clearance 1. Inspect the connecting rod bearings,
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connecting rods, crankshaft and

crankshaft journals.
components.
Excessive crankshaft bearing clearance 1. Inspect the crankshaft bearings and
components.
Oil pump pickup tube or screen bent or loose 1. Inspect the oil pump pickup tube and/or
screen.
2. Repair or repalce all damaged
components.
ENGINE NOISE UNDER LOAD
Cause Correction
Low oil pressure Insufficient or poor oil supply to components.

components.
Loose torque converter bolts 1. Inspect the torque converter bolts and
flywheel.
components.
Loose and/or damaged flywheel 1. Inspect the flywheel and flywheel
attaching bolts.
components.
Excessive piston-to-cylinder bore clearance 1. Inspect the piston rings for low ring
tension, broken or worn rings, inspect
cylinder bore.
components.
Excessive crankshaft thrust bearing clearance 1. Inspect the crankshaft end play and
crankshaft thrust bearings.
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components.
Excessive crankshaft bearing clearance 1. Inspect the crankshaft bearings and
components.
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE
Cause Correction
Seized accessory drive system component 1. Remove accessory drive belt(s).
2. Remove the glow plugs.
3. Rotate crankshaft by hand at the
balancer.
Hydraulically locked cylinder 1. Inspect for fluid at glow plug hole.
Coolant/antifreeze in cylinder 2. Inspect for broken head gasket(s).
Oil in cylinder 3. Inspect for cracked engine block or
cylinder head.
Fuel in cylinder
4. Inspect for a sticking fuel injector.
Seized automatic transmission torque 1. Remove the engine assembly. The
converter torque converter bolts are not
accessible with the engine installed to
the transmission.
balancer or flywheel location.
Seized manual transmission 1. Disengage the clutch.
balancer.
Material in cylinder: 1. Inspect cylinder for damaged
components and/or foreign materials.
Broken valve

2. Repair or replace as required.
Piston material
Foreign material
Seized crankshaft or connecting rod bearings 1. Inspect crankshaft and connecting rod
bearings.
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2. Repair as required.
Bent or broken connecting rod 1. Inspect connecting rods.
Broken crankshaft 1. Inspect crankshaft.
COOLANT IN COMBUSTION CHAMBER
Inspection Action
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust
pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative
cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may
cause engine component damage.
Preliminary Inspection Verify that there are no external coolant
leaks. Refer to Loss of Coolant .
Isolate Affected Cylinders Cylinder balance test with scan tool
Cooling system pressurization

Inspection of glow plugs
Compression test
Cylinder leakdown test
EGR System Inspection 1. Inspect EGR valve and intake system for
evidence of coolant leakage.
2. Replace the EGR cooler if any problem
is found.
Remove cylinder heads of the affected
Cylinder Head Gasket Leakage cylinder bank and inspect for damage.
Replace components as necessary.
1. Inspect the cylinder heads for cracks and
warpage.
2. Inspect the cylinder block for damage.
Cylinder Head or Engine Block Damage
3. Inspect the cylinder block to head
mating surface for straightness.
4. Replace components as necessary.
COOLANT IN ENGINE OIL

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Cause Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate
coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a
faulty thermostat may lead to an "overtemperature" condition which may cause engine
component damage. Contaminated engine oil and oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant
may not properly lubricate the crankshaft bearings and may lead to component
damage. Refer to Lower Engine Noise, Regardless of Engine Speed.
2. Inspect by performing a Cylinder Leak-Down Test. During this test, excessive air
bubbles within the cooling system may indicate a faulty gasket or damaged
component.
3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on
the engine block with low compression may indicate a failed cylinder head gasket.
Refer to Engine Compression Test.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning
and Inspection and Cylinder Head
Replacement - Left Side or Cylinder Head
Replacement - Right Side .
Warped cylinder head Replace the cylinder head gasket. Refer to
Cylinder Head Replacement - Left Side or
Cylinder Head Replacement - Right Side .
Cracked cylinder head Replace the cylinder head and gasket.
Cracked engine block Replace the components as required.
Cylinder head, block, or manifold porosity Replace the components as required.
Leaking engine oil cooler Replace components as required.
Faulty water pump Replace components as required.
Leaking cylinder head cup plug (under
Replace components as required.
rocker cover)
FUEL IN ENGINE OIL
Definition: If fuel is suspected of leaking into the crankcase, the following procedure should be
performed to verify the condition.
1. Remove the oil level indicator and allow oil to drop onto a clean white paper towel.
2. If the oil is diluted with fuel, it will become apparent as the towel wicks the fuel away from
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the drop of oil on the towel. The fuel will expand out in a ring around the oil droplet.
3. If fuel dilution is apparent, refer to Fuel Leak Diagnosis for diagnosis and repair. Inspect
the vehicle for aftermarket performance accessories that may cause damage to the injection
pump. After repairs are completed, perform the test again to verify the condition is
corrected.
4. If no fuel dilution is present, verify the oil level and correct as needed.
TURBOCHARGER WHINE NOISE
Condition Action
Some whine noise is normal. Compare to a known good vehicle.
Leaking charge air cooler/pipes/hoses Inspect for leaks in charge air
cooler/pipes/hoses using J 46091 .
Worn turbocharger bearings Visually inspect for evidence of compressor
wheel to housing contact.
If the turbocharger bearings are worn or
damaged, inspect for a Turbocharger Lack
of Oil Supply.
Intake system leaks or obstructions 1. With the engine off, pressurize the
intake system using J 46091 and inspect
for intake manifold leaks.
2. Inspect for obstructions in the intake
manifolds.
TURBOCHARGER HISSING NOISE
Condition Action
Air inlet leaks or obstructions Inspect for leaks or obstructions in the
turbocharger inlet pipes/hoses.
Leaking charge air cooler/pipes/hoses Inspect for leaks or obstructions in the charge
air cooler/pipes/hoses using J 46091 .
Leaking or restricted exhaust system 1. Inspect for a leak in the exhaust system.
2. Inspect for a restricted exhaust system.
1. With the engine off, pressurize the
Intake system leaks or obstructions intake system using J 46091 and inspect
for intake manifold leaks.
2. Inspect for obstructions in the intake
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manifolds.
TURBOCHARGER OIL LEAK FROM COMPRESSOR SEAL
Condition Action
IMPORTANT:
Oil in the turbocharger air inlet duct,oil on the compressor wheel, and oil throughout the charge air
cooler system is normal with a closed PCV system. Do not attempt repairs for this condition.
Restricted air system Inspect for clogged air filter element or
restricted air inlet system.
Restricted exhaust system Inspect for a restricted exhaust.
Leaking exhaust system. Inspect for exhaust manifold leaks.
Poor oil drainage from turbocharger Inspect for restricted turbocharger oil drain
pipe.
Restricted crankcase ventilation system Inspect for restricted crankcase ventilation
system.
Worn internal engine components Inspect for excessive blowby or engine oil
consumption.
TURBOCHARGER OIL LEAK FROM TURBINE SEAL
Condition Action
Poor oil drainage from turbocharger Inspect for a restricted turbocharger oil drain
pipe.
Restricted crankcase ventilation system Inspect for a restricted crankcase ventilation
system.
Worn internal engine components Inspect for excessive blowby or engine oil
consumption.
TURBOCHARGER LACK OF OIL SUPPLY
Condition Action
Restricted oil supply hose Inspect for restricted turbocharger oil supply
hose.
Spun camshaft bearing 1. Remove the oil supply hose. Refer to
Turbocharger Oil Feed Pipe
Replacement .
2. Visually inspect for correct alignment of
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the camshaft bearing oil hole.

3. Rotate the engine 1/2 turn and inspect
the camshaft bearing oil hole for
movement, indicating a spun camshaft
bearing.
ENGINE COMPRESSION TEST
Tools Required
J 26999 Compression Gage. See Special Tools.

EN-47603 Compression Gage Adapter. See Special Tools.
Test
1. Ensure that the vehicle's batteries are in good condition, and fully charged.
2. Operate the vehicle until the engine is at normal operating temperature.
3. Shut off engine.
4. Disconnect the crankshaft position sensor.
5. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from
the engine during each cylinder test to obtain valid test results.
6. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If
the cranking speed is below 140 RPM, repair the slow cranking speed condition before
continuing with the compression test. Refer to Engine Cranks Slowly .
7. Install the EN-47603 in the glow plug hole for the cylinder that is being checked. See
Special Tools.
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Fig. 44: View Of J 26999 For A Compression Test

NOTE: Do not add oil to any cylinder during a compression test as

extensive engine damage may result.
8. Connect the J 26999 to the EN-47603 . See Special Tools.

9. Using the vehicle's starter motor, rotate or crank the engine for 6 compression strokes, puffs,
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for the cylinder being tested.

10. Observe the J 26999 and note the reading as the compression test is being performed. See
Special Tools. A normal cylinder reading will be indicated if compression builds up
quickly and evenly to the specified level. An abnormal reading will be indicated if
compression is low on the first compression stroke, starts increasing on the following
compression strokes but does not reach the specified level.
11. Record the compression reading for the cylinder just tested.
12. Disconnect the J 26999 from the EN-47603 and remove adapter from the glow plug hole.
See Special Tools.
13. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to
obtain valid test results. Record the readings.
14. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be
more than 345 kPa (50 psi) difference between a suspect cylinder and the average
compression of all 8 cylinders.
Normal-Compression builds up quickly and evenly to the specified compression for
each cylinder.
Piston Rings Leaking-Compression is low on the first stroke. Compression builds up
with the following strokes but does not reach normal.
Valves Leaking-Compression is low on the first stroke. Compression usually does not
build up on the following strokes.
CYLINDER LEAKAGE TEST
Tools Required
J 35667-A Cylinder Head Leakdown Tester

J-35667-8 Cylinder Head Leakdown Adapter. See Special Tools.
Test
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Fig. 45: Testing Cylinder Leakage

CAUTION: Refer to BATTERY DISCONNECT CAUTION
IMPORTANT: A leakage test may be performed to measure

cylinder/combustion chamber leakage. High cylinder leakage
may indicate one or more of the following:
Worn, burnt, or stuck valves

Broken valve springs
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Incorrect valve lash

Damaged valve train components
Damaged piston
Worn piston rings
Worn or scored cylinder bore
Damaged cylinder head gasket
Cracked or damaged cylinder head
Cracked or damaged engine block
1. Disconnect the battery ground negative cable.

2. Remove the glow plugs.
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center
(TDC) of the compression stroke.
4. Install J-35667-8 and J 35667-A . See Special Tools.
IMPORTANT: It may be necessary to hold the crankshaft balancer bolt to

prevent the engine from rotating.
5. Apply shop air pressure to J 35667-A and adjust according to the manufacturers
instructions.
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered
excessive and may require component service. In excessive leakage situations, inspect for
the following conditions:
Air leakage sounds at the intake manifold tube, may indicate a worn, stuck or burnt
intake valve, broken valve spring, incorrect valve lash or damaged valve train
components.
Air leakage sounds at the exhaust system tailpipe may indicate a worn, burnt, or stuck
exhaust valve, broken valve spring, incorrect valve lash or damaged valve train
components.
Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube may
indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a
damaged engine block or a damaged cylinder head.
Air bubbles in the cooling system may indicate a damaged cylinder head or gasket.
7. Perform the leakage test on the remaining cylinders and record the values.
OIL CONSUMPTION DIAGNOSIS

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The accepted rate of oil consumption, not due to leaks, is the use of 0.946 liter (1 qt) or less
within 379 liters (100 gallons) of fuel used. This rate only applies to vehicles under warranty,
maintained in accordance with the appropriate maintenance schedule, driven at legal speeds and
within design intent of the vehicle.
Oil economy should not be tested until the vehicle has accumulated at least 8000 km (5000 mi)
and the oil has been changed for the first time. During initial engine break-in periods before the
first oil change, oil consumption may exceed 1.9 liters (2 qts) or more per 379 liters (100 gallons)
of fuel used.
Checks Causes
Preliminary The causes of excessive oil consumption may include the
following conditions:
External oil leaks
Refer to Oil Leak Diagnosis.
Incorrect oil level or improper reading of the oil level

indicator
With the vehicle on a level surface, run the engine for a

few minutes, allow adequate drain down time (2-3
minutes) and check for the correct engine oil level.
Improper oil viscosity
Refer to the vehicle owners manual and use the

recommended SAE grade and viscosity for the prevailing
temperatures.
Continuous high speed driving and/or severe usage

Crankcase ventilation system restrictions or
malfunctioning components
Oil residue in the charge air cooler system is normal with
a closed PCV system
Worn valve guides and/or valve stems
Worn or improperly installed valve stem oil seals
Piston rings broken, worn, not seated properly
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Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
Piston and rings improperly installed or improperly fit to

the cylinder bore
OIL PRESSURE DIAGNOSIS AND TESTING
Step Action Yes No

DEFINITION: Low or no engine oil pressure indicates a potentially serious condition with
all of the engine mechanical components. Once the cause of the low or no oil pressure
condition has been identified, repair all collateral damage to the engine mechanical
components as well as the initial cause of the condition.
Check engine oil level. Use only the GM service
parts brand and recommended grade of engine
1 oil specified for the vehicle.
Is the engine oil level between ADD and FULL
on the oil level indicator? Go to Step 2 -
1. Operate vehicle until engine reaches normal
operating temperature. Refer to Engine
Mechanical Specifications.
2. Park vehicle on a level surface.
3. Wait 15 minutes.
2 4. Check engine oil level. Use only the GM
service parts brand and recommended
grade of engine oil specified for the
vehicle.
Is the engine oil level between ADD and FULL

on the oil level indicator? Go to Step 3 -
Operate the engine and measure the engine oil
pressure with the vehicle gage or light. Refer to
3
Engine Mechanical Specifications.
Is engine oil pressure within specification? System OK Go to Step 4
1. Remove the oil pressure sender or engine
block oil gallery plug.
2. Install a mechanical oil pressure gage.
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3. Operate the engine and measure the engine

oil pressure with the mechanical oil
4 pressure gage. Refer to Engine
Mechanical Specifications.

Change the engine oil and filter.
Use only the GM service parts brand and

recommended grade of engine oil specified
for the vehicle. Refer to Owners' Manual.
Use only the GM service parts brand and
recommended type of engine oil filter
5 specified for the vehicle. Refer to Owners'
Manual.
Operate the engine and measure the engine oil

pressure with the mechanical oil pressure gage.
Refer to Engine Mechanical Specifications.
1. Inspect the engine for mechanical damage.
Special interest should be shown to the
following areas:
Malfunctioning oil bypass valve
Oil pump worn or dirty
Oil pump-to-engine block bolts loose
Oil pump O-ring damaged or missing
Oil pump to oil pump pipe and screen

6
assembly gasket missing or damaged
Oil pump pipe and screen assembly
restrictions or damaged
Oil pump driven gear damaged or
loose
Oil pump drive gear damaged
Oil cooler restrictions
Oil cooler O-rings damaged or

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missing
Excessive bearing clearances
Cracked, porous or restricted oil

galleries
Oil gallery plugs missing or
incorrectly installed
Damaged or missing oil spray cooling
nozzles
2. Inspect the engine for customer
modifications.
Is there mechanical damage, or customer

modifications to the engine? Go to Step 7 Go to Step 1
Repair or replace all damaged or modified
7 components. -
Is the repair complete? Go to Step 1
OIL LEAK DIAGNOSIS
Step Action Yes No

IMPORTANT:
You can repair most fluid leaks by first visually locating the leak, repairing or replacing the
component, or by resealing the gasket surface. Once the leak is identified, determine the cause of
the leak. Repair the cause of the leak as well as the leak itself.
1. Operate the vehicle until it reaches normal

operating temperature.
2. Park the vehicle on a level surface, over a
1 large sheet of paper or other clean surface.
3. Wait 15 minutes.
4. Check for drippings.
Are drippings present? Go to Step 2 System OK

Can you identify the type of fluid and the
2
approximate location of the leak? Go to Step 7 Go to Step 3
1. Visually inspect the suspected area. Use a

small mirror to assist in looking at hard to
see areas.
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2. Check for leaks at the following locations:

Sealing surfaces
Fittings
3
Cracked or damaged components

1. Completely clean the entire engine and
surrounding components.
2. Apply an aerosol-type powder (baby
powder, foot powder, etc.) to the suspected
area.
3. Operate the vehicle for several
4 kilometers/miles at normal operating
temperature and at varying speeds.
4. Identify the type of fluid, and the
approximate location of the leak, from the
discolorations in the powder surface.

Use J 28428-E in order to identify the type of
fluid, and the approximate location of the leak.
Refer to the manufacturer's instructions when
5
using the tool.
1. Visually inspect the suspected area. Use a
small mirror to assist in looking at hard to
see areas.
2. Check for leaks at the following locations:
Sealing surfaces
6
Fittings
Cracked or damaged components

approximate location of the leak? Go to Step 7 System OK
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1. Inspect the engine for mechanical damage

and repair or replace as necessary. Special
attention should be shown to the following
areas:
Plugged or malfunctioning crankcase
ventilation system. Refer to
Crankcase Ventilation System
Inspection/Diagnosis.
Higher than recommended fluid levels
Higher than recommended fluid

pressures
Plugged or malfunctioning fluid filters
or pressure bypass valves
7
Improperly tightened or damaged
fasteners
Cracked or porous components
Improper sealants or gaskets where

required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer

modifications.
Is there mechanical damage, or customer

modifications to the engine? Go to Step 8 System OK
Repair or replace all damaged or modified
8 components.
Does the engine still leak oil? Go to Step 1 System OK
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS
Concern Action
IMPORTANT:
Oil in the charged air cooler, hoses, turbocharger, or intake manifolds is normal with a closed
crankcase ventilation system.
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The maximum crankcase pressure is 4 kPa or 16 in of water at 3,100 RPM measured at the
oil level indicator tube.
PVC check valve stuck Excessive crankcase pressure

closed Possible oil leaks. Replace the valve.
Odors Normal situation

Noise Cracked hoses
Smoke Damaged PCV diaphragm
Excessive Oil Consumption Damaged PCV diaphragm, missing or broken spring
DRIVE BELT CHIRPING, SQUEAL, AND WHINE DIAGNOSIS
Diagnostic Aids
A chirping or squeal noise may be intermittent due to moisture on the drive belts or the
pulleys. It may be necessary to spray a small amount of water on the drive belts in order to
duplicate the customers concern. If spraying water on the drive belt duplicates the symptom,
cleaning the belt pulleys may be the probable solution.
If the noise is intermittent, verify the accessory drive components by varying their loads
making sure they are operated to their maximum capacity. An overcharged A/C system,
power steering system with a pinched hose or wrong fluid, or a generator failing are
suggested items to inspect.
A chirping, squeal or whine noise may be caused by a loose or improper installation of a
body or suspension component. Other items of the vehicle may also cause the noise.
The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2: The noise may not be engine related. This step is to verify that the engine is making the
noise. If the engine is not making the noise do not proceed further with this table.
3: The noise may be an internal engine noise. Removing the drive belts one at a time and
operating the engine for a brief period will verify the noise is related to the drive belt. When
removing the drive belt the water pump may not be operating and the engine may overheat.
Also DTCs may set when the engine is operating with the drive belts removed.
4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be
strings in the drive belt grooves from the accumulation of rubber dust.
6: Misalignment of the pulleys may be caused from improper mounting of the accessory
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drive component, incorrect installation of the accessory drive component pulley, or the
pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a
straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is
found refer to that accessory drive component for the proper installation procedure for that
pulley.
10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or
washer was installed.
12: Inspecting the pulleys for being bent should include inspecting for a dent or other
damage to the pulleys that would prevent the drive belt from not seating properly in all of
the pulley grooves or on the smooth surface of a pulley when the back side of the belt is
used to drive the pulley.
14: This test is to verify that the drive belt tensioner operates properly. If the drive belt
tensioner is not operating properly, proper belt tension may not be achieved to keep the
drive belt from slipping which could cause a squeal noise.
15: This test is to verify that the drive belt is not too long, which would prevent the drive
belt tensioner from working properly. Also if an incorrect length drive belt was installed, it
may not be routed properly and may be turning an accessory drive component in the wrong
direction.
found refer to that accessory drive component for the proper installation procedure for that
pulley.
17: This test is to verify that the pulleys are the correct diameter or width. Using a known
good vehicle compare the pulley sizes.
19: Replacing the drive belt when it is not damaged or there is not excessive pilling will
only be a temporary repair.
Step Action Yes No

NOTE:
Refer to Belt Dressing Notice .
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
Chirping may occur on cold damp start-ups and will subside once the vehicle reaches
normal operating temp.
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DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt. This is unusual for a
drive belt with multiple ribs.
The noise occurs when a heavy load is applied to the drive belt, such as an air
conditioning compressor engagement snapping the throttle, or slipping on a seized
pulley or a faulty accessory drive component.
DEFINITION: The following items are indications of drive belt whine:
A high pitched continuous noise.

The noise may be caused by an accessory drive component failed bearing.
Did you review the drive belt symptom Go to Symptoms
1 operation and perform the necessary - Engine
inspections? Go to Step 2 Mechanical
Verify that there is a chirping, squeal or whine
noise.
2
Does the engine make the chirping squeal or Go to Diagnostic
whine noise? Go to Step 3 Aids
1. Remove the drive belt.
If the engine has multiple drive belts,

remove the belts one at a time and
perform the test below each time a belt is
removed.
3 2. Operate the engine for no longer than 30-
40 seconds.
3. Repeat this test if necessary by removing
the remaining belt(s).
Go to Symptoms
Does the chirping, squeal or whine noise still - Engine
exist? Mechanical Go to Step 4
If diagnosing a chirping noise, inspect for
severe pilling exceeding 1/3 of the belt groove
depth.
4
If diagnosing a squeal or whine noise, proceed
to step 13.
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Do the belt grooves have pilling? Go to Step 5 Go to Step 6

Clean the drive belt pulleys with a suitable wire
5 brush.
Did you complete the repair? Go to Step 20 Go to Step 6
Inspect for misalignment of the pulleys.
6
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
Replace or repair any misaligned pulleys.
7
Inspect for bent or cracked brackets.
8
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
Replace any bent or cracked brackets.
9
Inspect for improper, loose or missing fasteners.
10
Did you find the condition? Go to Step 11 Go to Step 12
NOTE:
Refer to Fastener Notice .
1. Tighten any loose fasteners. Refer to

11 Fastener Tightening Specifications.
2. Replace any improper or missing
fasteners.

Inspect for a bent pulley.
12
Inspect for an accessory drive component
seized bearing or a faulty accessory drive
component.
13
If diagnosing a whine noise and the condition
still exist, proceed to Diagnostic Aids.
Did you find and correct the condition? Go to Step 20 Go to Step 14
Test the drive belt tensioner for proper
operation. Refer to Drive Belt Tensioner
14
Diagnosis.
Inspect for the correct drive belt length.
15
Inspect for misalignment of a pulley.
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16 Did you find and correct the condition? Go to Step 20 Go to Step 17

Inspect for the correct pulley size. Go to Diagnostic
17
Did you find and correct the condition? Go to Step 20 Aids
Replace the bent pulley.
18
Replace the drive belt. Refer to Drive Belt
19 Replacement . Go to Diagnostic
Did you complete the repair? Go to Step 20 Aids
Operate the system in order to verify the repair.
20
Did you correct the condition? System OK Go to Step 3
DRIVE BELT RUMBLING AND VIBRATION DIAGNOSIS
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the
engine operating may cause a body component or another part of the vehicle to make rumbling
noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over
charged, the power steering system restricted or the incorrect fluid, or an extra load on the
generator. To help identify an intermittent or an improper condition, vary the loads on the
accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing
the drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
2: This test is to verify that the symptom is present during diagnosing. Other vehicle
components may cause a similar symptom.
3: This test is to verify that one of the drive belts is causing the rumbling noise or vibration.
Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts.
When removing the drive belts the water pump may not be operating and the engine may
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overheat. Also DTCs may set when the engine is operating with the drive belts removed.
4: Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks
across the ribs of the drive belt will not cause the noise. Belt separation is identified by the
plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the
belt.
5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe
the drive belt does not have a smooth surface for proper operation.
9: Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer,
or washer was installed.
11: This step should only be performed if the water pump is driven by the drive belt. Inspect
the water pump shaft for being bent. Also inspect the water pump bearings for smooth
operation and excessive play. Compare the water pump with a known good water pump.
12: Accessory drive component brackets that are bent, cracked, or loose may put extra
strain on that accessory component causing it to vibrate.
Step Action Yes No

NOTE:
DEFINITION: The following items are indications of drive belt rumbling:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in
the drive belt pulley groove
The separation of the drive belt
A damaged drive belt
DEFINITION: The following items are indications of drive belt vibration:
The vibration is engine-speed related.

The vibration may be sensitive to accessory load.

Verify that there is a rumbling noise or that the
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vibration is engine related.

2 Does the engine make the rumbling noise or Go to Diagnostic
vibration? Go to Step 3 Aids
IMPORTANT:
If the engine has multiple drive belts, remove
the belts one at a time and perform the test
below each time a belt is removed.
1. Remove the drive belt. Go to Symptoms

3 2. Operate the engine for no longer than 30- - Engine
40 seconds. Mechanical
3. Repeat this test if necessary by removing or
the remaining belt(s). Go to Vibration
Analysis -
Does the rumbling or vibration still exist? Engine Go to Step 4
Inspect the drive belts for wear, damage,
separation, sections of missing ribs, and debris
4
build-up.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of
5 the drive belt pulley grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a
suitable wire brush.
6 2. Reinstall the drive belts. Refer to Drive
Belt Replacement .
Did you correct the condition? Go to Step 8 Go to Step 7

Install a new drive belt. Refer to Drive Belt
7 Replacement .
Did you complete the replacement? Go to Step 8 Go to Step 9
8
9
Did you find any of these conditions? Go to Step 10 Go to Step 11
NOTE:
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Fastener Tightening Specifications.
10 2. Replace improper or missing fasteners.

Inspect for a bent water pump shaft. Refer to
Water Pump Replacement (LU3) or Water
Pump Replacement (LY6, L76 and L92) or
11 Water Pump Replacement (LH6, LY2,
LY5, and LMG) or Water Pump
Replacement (LMM) .
Inspect for bent or cracked brackets. Go to Diagnostic
12
Did you find and correct the condition? Go to Step 13 Aids
13
DRIVE BELT FALLS OFF AND EXCESSIVE WEAR DIAGNOSIS
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension
on the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive
belt for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably
cause the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
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2: This inspection is to verify the condition of the drive belt. Damage may of occurred to
the drive belt when the drive belt fell off. The drive belt may of been damaged, which
caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or
damaged belt plys.
found refer to that accessory drive component for the proper installation procedure of that
pulley.
5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage
to the pulleys that would prevent the drive belt from not seating properly in all of the pulley
grooves or on the smooth surface of a pulley when the back side of the belt is used to drive
the pulley.
6: Accessory drive component brackets that are bent or cracked will let the drive belt fall
off.
7: Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or
washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment
from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket.
13: The inspection is to verify the drive belt is correctly installed on all of the drive belt
pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one
groove on a pulley.
14: The installation of a drive belt that is too wide or too narrow will cause wear on the
drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
15: This inspection is to verify the drive belt is not contacting any parts of the engine or
body while the engine is operating. There should be sufficient clearance when the drive belt
accessory drive components load varies. The drive belt should not come in contact with an
engine or a body component when snapping the throttle.
Step Action Yes No

NOTE:
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the
pulleys.DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly
installed drive belt.
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If diagnosing excessive wear, proceed to
step 13.
2 If diagnosing a drive belt that falls off,
inspect for a damaged drive belt.

Install a new drive belt. Refer to Drive Belt
3 Replacement .
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step 5
Inspect for a bent or dented pulley.
5
Inspect for a bent or a cracked bracket.
6
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
NOTE:

8 Fastener Tightening Specifications.
2. Replace improper or missing fasteners.

Test the drive belt tensioner for operating
correctly. Refer to Drive Belt Tensioner
9
Diagnosis.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive
10 Belt Tensioner Replacement .
Inspect for failed drive belt idler and drive belt
11 tensioner pulley bearings. Go to Diagnostic
Did you find and repair the condition? Go to Step 12 Aids
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12
Inspect the drive belt for the proper installation.
13 Refer to Drive Belt Replacement .
Did you find this condition? Go to Step 16 Go to Step 14
Inspect for the proper drive belt.
14
Did you find this condition? Go to Step 16 Go to Step 15
Inspect for the drive belt rubbing against a
15 bracket, hose, or wiring harness. Go to Diagnostic
Did you find and repair the condition? Go to Step 17 Aids
Replace the drive belt. Refer to Drive Belt
16 Replacement .
Did you complete the replacement? Go to Step 17 -
17
Did you correct the condition? System OK -
DRIVE BELT TENSIONER DIAGNOSIS
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Fig. 46: View Of Drive Belt Tensioner

NOTE: Allowing the drive belt tensioner to snap into the free position
may result in damage to the tensioner.
IMPORTANT: When the engine is operating the drive belt tensioner arm
will move. Do not replace the drive belt tensioner because of
movement in the drive belt tensioner arm.
1. Remove the drive belt. Refer to Drive Belt Replacement .

2. Position a 3/8-inch drive breaker bar into the drive belt tensioner opening and rotate the
tensioner counterclockwise.
3. Move the drive belt tensioner through its full travel.
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The movement should feel smooth

There should be no binding
The tensioner should return freely
4. If any binding is observed, replace the drive belt tensioner. Refer to Drive Belt Tensioner
Replacement .
5. Install the drive belt. Refer to Drive Belt Replacement .
DESCRIPTION AND OPERATION

DRIVE BELT SYSTEM DESCRIPTION
The drive belt system consists of the following components:
The drive belt

The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
The accessory drive component mounting brackets
The accessory drive components
The power steering pump, if belt driven
The generator
The A/C compressor, if equipped
The engine cooling fan, if belt driven
The water pump, if belt driven
The vacuum pump, if equipped
The air compressor, if equipped
The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend
backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of
different types of rubbers, chloroprene or EPDM, and have different layers or plys containing
either fiber cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
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the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
ENGINE COMPONENT DESCRIPTION
Engine Block
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Fig. 47: Identifying 6.6L Cylinder Locations

The engine block utilizes a deep skirt design for increased rigidity. The cylinders are positioned
in a 90 degree "V" orientation with the number one cylinder being the right front. The block is
induction hardened for increased durability. The crankshaft bearing caps are cross-bolted to
enhance structural rigidity.
Upper Oil Pan
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A single piece cast aluminum upper oil pan contributes to crankshaft and block rigidity while
reducing overall weight.
Crankshaft
The crankshaft is a nitride hardened steel design with five main bearings. Crankshaft thrust is
controlled by the number 5 bearing.
Connecting Rods
The connecting rods are one-piece hot forged steel. The connecting rods and caps are of a
fractured split design to improve durability and reduce internal friction. The connecting rod small
end is tapered cut for reduced weight and improved durability.
Pistons
The pistons are a full-floating design. The piston pins are a slip fit in the bronze bushed
connecting rod and are retained in the piston by round wire retainers. The pistons have a piston
cooling oil channel cast inside of the piston. These cooling oil channels utilize an oil jet located at
the bottom of the cylinder bore to direct oil into the piston channel. There are two compression
rings and one oil control ring. There is a groove machined into the pistons between the first and
second compression rings. This groove reduces compression ring leakage by providing an empty
space for expanding gases, reducing the combustion gas pressure on the second compression ring.
Cylinder Heads
The cylinder heads are made of aluminum for lighter weight and rapid heat dissipation. There are
4 valves per cylinder and the ports are of a high swirl design for improved combustion. The
cylinder head gaskets consist of an all steel laminated construction.
Valve Train
The engine utilizes a mechanical roller lifter for valve operation. The shaft mounted rocker arms
have roller tips for reduced friction and wear. One rocker arm operates two valves simultaneously
through a valve bridge.
Fuel System
The fuel system is of a direct injection fuel rail design. A high pressure pump mounted within the
valley is gear driven directly from the camshaft. This pump provides a continuous and constant
high pressure fuel supply to the fuel rails. The electronically controlled fuel injectors receive their
fuel supply from these fuel rails. The fuel injection control utilizes a pilot injection method to
reduce the combustion noise that is common in traditional diesel engines. The pilot injection
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method reduces noise by supplying a small amount of fuel to the cylinder just before the normal
combustion timing.
Turbocharger
The turbocharger is water cooled for improved durability.

Oil Cooler
The oil cooler lowers engine temperature by cooling the oil with engine coolant. Engine coolant
is directed from the water pump to the oil cooler by a coolant tube. The oil filter attaches directly
to the oil cooler.
Oil Pump
The oil pump is gear driven directly from the crankshaft. The oil pump drive gear is a slip fit to
the crankshaft.
Water Pump
The water pump is gear driven for improved reliability.

Engine Covers
There is a front engine cover and a flywheel housing, both are made of aluminum. The full bell
flywheel housing is cross bolted to the upper oil pan. The flywheel housing also supplies a
crossover passage for engine coolant. The front engine cover houses the gear train and provides a
mounting surface for the cooling fan pulley assembly.
LUBRICATION DESCRIPTION
Lubrication Flow Schematic
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Fig. 48: Lubrication Flow Schematic

Engine lubrication is supplied by a gear type oil pump assembly. The pump is mounted on the
front of the engine block and driven by the oil pump drive gear on the crankshaft. The pump gears
rotate and draw oil from the oil pan sump through a pick-up screen and pipe. The oil is
pressurized as it passes through the pump and is sent through the engine block oil galleries.
Contained within the oil pump assembly is a safety relief valve that eliminates overpressurization.
Pressurized oil is directed through the sub oil gallery (5) to the full flow oil filter where harmful
contaminants are removed. Two bypass valves are incorporated into the oil cooler assembly
which will permit oil flow in the event the filter or the oil cooler become restricted.
The oil is directed to the main oil gallery (4), and from the main oil gallery it flows to the piston
cooling channel left bank (3), and the sub oil gallery (6) on the right bank. The sub oil gallery on
the right bank supplies oil to the right bank piston cooling channel (1). Located in the front cover
at the sub oil gallery (6) is an oil pressure relief valve which regulates oil pressure within
operating range.
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Oil flows from the main gallery (4) to the vertical crankshaft/camshaft bearing galleries (2). From
the crankshaft/camshaft bearing galleries (2), the oil flows to both the camshaft bearings and the
crankshaft main bearings. Oil flows from the crankshaft main bearings to the connecting rod big
end.
Oil flows from the crankshaft/camshaft bearing galleries (2) to the number 1 camshaft bearing
(7), where it splash lubricates the fuel injection pump gear.
Oil flows from the crankshaft/camshaft bearing galleries (2) to the number 2 and 5 camshaft
bearings (8).
Oil flows from the crankshaft/camshaft bearing galleries (2) to the number 3 camshaft bearing
(9), where it exits to both cylinder heads and enters the hollow rocker arm shafts. Oil flows
through the rocker arm shafts and rocker arms where it lubricates the upper valve train
components.
On production LB7 engines through 2004, oil flowed through the rocker arms, through the
passage in the valve adjusting screw, and into the hollow pushrods where it was directed to the
valve lifters. Beginning with the 2004.5 engine (LLY), lifters with hardened rollers were used
and did not require hollow pushrods for additional oil flow. However, hollow pushrods were
used in production until approximately the start of the 2006 model year, after which the hole in
the push rod ends was removed. The hollow pushrods can be used for any model year, whereas
the pushrods without the holes in the ends can only be used for 2004.5 model year and newer
production engines.
Oil flows from the crankshaft/camshaft bearing galleries (2) to the number 4 camshaft (10), where
it exits into the turbocharger oil supply line to lubricate the turbocharger. Oil exiting the
turbocharger is routed through the turbocharger oil return pipe and into the flywheel housing.
CLEANLINESS AND CARE
An automobile engine is a combination of many of the following surfaces:
Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service
any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil
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to the friction areas during assembly in order to protect and lubricate the surfaces on initial
operation. Throughout this section, practice proper cleaning and protection procedures to the
machined surfaces and to the friction areas.
NOTE: Engine damage may result if an abrasive paper, pad, or motorized

wire brush is used to clean any engine gasket surfaces.
Whenever you remove the valve train components, keep the components in order. Follow this
procedure in order to install the components in the same locations and with the same mating
surfaces as when removed.
CAUTION: Refer to BATTERY DISCONNECT CAUTION .
Disconnect the negative battery cables before you perform any major work on the engine. For
more information on the disconnection of the battery, refer to Battery Negative Cable
Disconnection and Connection (w/Single Battery) or Battery Negative Cable
Disconnection and Connection (w/Auxiliary Battery) or Battery Negative Cable
Disconnection and Connection (w/Dual Batteries) .
SEPARATING PARTS
IMPORTANT: Many internal engine components will develop specific wear

patterns on their friction surfaces.
When disassembling the engine, internal components MUST be
separated, marked, or organized in a way to ensure reinstallation
to their original location and position.
Separate, mark, or organize the following components:
Piston and the piston pin

Piston to the specific cylinder bore
Piston rings to the piston
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap
A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod
or cap near the bearing bore may affect component geometry.
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Crankshaft main and connecting rod bearings

Camshaft and valve lifters
Valve lifters, guides, pushrods, pivot supports and rocker arms
Valve to the valve guide
Valve spring and shim to the cylinder head location
Engine block main bearing cap location and direction
Oil pump drive and driven gears
REPLACING ENGINE GASKETS
Gasket Reuse and Applying Sealant
Do not reuse any gasket unless specified.

Gaskets that can be reused will be identified in the service procedure.
Do not apply sealant to any gasket or sealing surface unless specified in the service
procedure.
Separating Components
Use a rubber mallet in order to separate the components.

Bump the part sideways in order to loosen the components.
Bumping of the component should be done at bends or reinforced areas of the component to
prevent distortion of the components.
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALANT
Sealant Types
IMPORTANT: The correct sealant and amount of sealant must be used in the
proper location to prevent oil leaks, coolant leaks, or the
loosening of the fasteners. DO NOT interchange the sealants. Use
only the sealant (or equivalent) as specified in the service
procedure.
The following 2 major types of sealant are commonly used in engines:
Aerobic sealant (Room Temperature Vulcanizing (RTV))

Anaerobic sealant, which include the following:
Gasket eliminator
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Pipe
Threadlock
Aerobic Type Room Temperature Vulcanizing (RTV) Sealant
Aerobic type Room Temperature Vulcanizing (RTV) sealant cures when exposed to air. This type
of sealant is used where 2 components (such as the intake manifold and the engine block) are
assembled together.
Use the following information when using RTV sealant:
Do not use RTV sealant in areas where extreme temperatures are expected. These areas
include:
The exhaust manifold
The head gasket
Any other surfaces where a different type of sealant is specified in the service
procedure
Always follow all the safety recommendations and the directions that are on the RTV
sealant container.
Use a plastic or wood scraper in order to remove all the RTV sealant from the components.
IMPORTANT: Do not allow the RTV sealant to enter any blind threaded
holes, as it may prevent the fasteners from clamping
properly or cause damage when the fastener is tightened.
The surfaces to be sealed must be clean and dry.

Use a RTV sealant bead size as specified in the service procedure.
Apply the RTV sealant bead to the inside of any bolt holes areas.
Assemble the components while the RTV sealant is still wet to the touch (within 3 minutes).
Do not wait for the RTV sealant to skin over.
Tighten the fasteners in sequence (if specified) and to the proper torque specifications. DO
NOT overtighten the fasteners.
Anaerobic Type Gasket Eliminator Sealant
Anaerobic type gasket eliminator sealant cures in the absence of air. This type of sealant is used
where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled
and no sealant or gasket is readily noticeable, then the 2 parts were probably assembled using an
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anaerobic type gasket eliminator sealant.
Use the following information when using gasket eliminator sealant:
Always follow all the safety recommendations and directions that are on the gasket
eliminator sealant container.
Apply a continuous bead of gasket eliminator sealant to one flange.
IMPORTANT: Do not allow the gasket eliminator sealant to enter any blind
threaded holes, as the gasket eliminator sealant may prevent
the fasteners from clamping properly, seating properly, or
cause damage when the fastener tightened.
Apply the gasket eliminator sealant evenly to get a uniform thickness of the gasket
eliminator sealant on the sealing surface.
IMPORTANT: Gasket eliminator sealed joint fasteners that are partially

torqued and the gasket eliminator sealant allowed to cure
more than five minutes, may result in incorrect shimming
and sealing of the joint.
After properly tightening the fasteners, remove the excess gasket eliminator sealant from the
outside of the joint.
Anaerobic Type Threadlock Sealant
Anaerobic type threadlock sealant cures in the absence of air. This type of sealant is used for
threadlocking and sealing of bolts, fittings, nuts, and studs. This type of sealant cures only when
confined between 2 close fitting metal surfaces.
Use the following information when using threadlock sealant:
Always follow all safety recommendations and directions that are on the threadlock sealant
container.
The threaded surfaces to be sealed must be clean and dry.
Apply the threadlock sealant as specified on the threadlock sealant container.
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IMPORTANT: Fasteners that are partially torqued and then the threadlock
sealant allowed to cure more than five minutes, may result in
incorrect clamp load of assembled components.
Anaerobic Type Pipe Sealant
Anaerobic type pipe sealant cures in the absence of air and remains pliable when cured. This type
of sealant is used where 2 parts are assembled together and require a leak proof joint.
Use the following information when using pipe sealant:
Do not use pipe sealant in areas where extreme temperatures are expected. These areas
include:
The exhaust manifold
The head gasket
Surfaces where a different sealant is specified
Always follow all the safety recommendations and the directions that are on the pipe sealant
container.
Use a pipe sealant bead of the size or quantity as specified in the service procedure.
IMPORTANT: Do not allow the pipe sealant to enter any of the blind
threaded holes, as the pipe sealant may prevent the fastener
from clamping properly, or cause component damage when
the fastener is tightened.
Apply the pipe sealant bead to the inside of any bolt hole areas.
Apply a continuous bead of pipe sealant to 1 sealing surface.
TOOLS AND EQUIPMENT
Special tools are listed and illustrated throughout this section with a complete listing at the
end of the section. These tools or their equivalents, are specially designed to quickly and
safely accomplish the operations for which they are intended. The use of these special tools
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will also minimize possible damage to engine components. Some precision measuring tools
are required for inspection of certain critical components. Torque wrenches and a torque
angle meter are necessary for the proper tightening of various fasteners.
To properly service the engine assembly, the following items should be readily available:
Approved eye protection and safety gloves
A clean, well-lit, work area
A suitable parts cleaning tank
A compressed air supply
Trays or storage containers to keep parts and fasteners organized
An adequate set of hand tools
Approved engine repair stand
An approved engine lifting device that will adequately support the weight of the
components
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Special Tools
Illustration Tool Number/Description
EN 47603
Compression Gage Adapter
EN 47909
Injector Bore and Sleeve Cleaning Kit
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J 7872
Dial Indicator Set
J 8037
Piston Ring Compressor
J 8062
Valve Spring Compressor
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J 9666
Valve Spring Tester
J 24270
Cylinder Bore Ridge Reamer
J 26900-12
Dial Indicator
J 26900-13
Magnetic Indicator Base
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J 26999
Compression Gage
J 28428-E
High Intensity Black Light
J 35667-A
Cylinder Leakdown Tester
J 35667-8
Cylinder Head Leakdown Adapter
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J 36857
Engine Lift Bracket
J 37228
Seal Cutter
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J 38820
Valve Stem Oil Seal Remover
J 41712
Oil Pressure Switch Socket
J 43181
Quick Connect Connector Remover
J 43244
Relay Puller Pliers
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J 43654
Piston Pin Retainer Clip Remover/ Installer
J 44640
Valve Stem Seal Installer
J 44641
Crankshaft Rear Oil Seal Remover
J 44642
Crankshaft Rear Oil Seal Installer
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J 44643
Flywheel Holding Tool
J 44644
Crankshaft Front Oil Seal Remover
J 44645
Crankshaft Front Oil Seal Installer
J 44646
Valve Spring Compressor
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J 45059
Angle Meter
J 45299
Engine Preluber
J 46091
Charge Air Cooler Tester
J 46594
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Fuel Injector Puller
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2008 ENGINE
ON-VEHICLE REPAIR INSTRUCTIONS

DRIVE BELT REPLACEMENT
Removal Procedure
1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud
Replacement (Mechanical) or Engine Coolant Fan Upper Shroud Replacement
(Automatic Transmission - Diesel) .
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Fig. 1: Identifying Fan Shroud Mounting Brackets & Bolts

2. Remove the 3 engine cooling fan shroud bolts (1).
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Fig. 2: View Of Cooling Fan Shroud

3. Position the engine cooling fan shroud (1) forward to the radiator.
4. Install a 3/8-inch breaker bar into the tensioner opening and rotate the tensioner
counterclockwise.
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5. Remove the belt from the tensioner.

6. Slowly release the tension on the tensioner arm.
Fig. 3: View Of Drive Belt (Single Generator)

7. Remove the drive belt from the drive pulleys, if equipped with a single generator.
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Fig. 4: View Of Drive Belt (Dual Generator)

8. Remove the drive belt from the drive pulleys, if equipped with dual generators.
9. Inspect the drive belt for excessive cracking or any visible damage and replace if necessary.
Installation Procedure
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Fig. 5: View Of Drive Belt (Dual Generator)

1. Install the drive belt, if equipped with dual generators.

2. Route the drive belt over and/or around all the drive pulleys except for the tensioner.
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Fig. 6: View Of Drive Belt (Single Generator)

3. Install the drive belt, if equipped with a single generator.

4. Route the drive belt over and/or around all the drive pulleys except for the tensioner.
5. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner
counterclockwise.
6. Install the belt over and/or around the tensioner.
7. Slowly release the tension on the tensioner arm.
8. Inspect the drive belt for proper installation on and/or around all pulleys.
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Fig. 7: Identifying Fan Shroud Mounting Brackets & Bolts

9. Position the engine cooling fan shroud on the 3 mounting brackets (1).
NOTE: Refer to Fastener Notice .
10. Install the bolts. Loosely tighten the top mounting bolt at the oil filler neck.
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Fig. 8: View Of Cooling Fan Shroud

11. Center the engine cooling fan shroud to the fan blade in 3 places (1).
IMPORTANT: Maintain a 6 mm (0.25 in) minimum clearance at all 3 places.
12. Fully tighten the 3 engine cooling fan shroud bolts (1).
Tighten: Tighten the bolts to 8 N.m (71 lb in).
13. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement
(Mechanical) or Engine Coolant Fan Upper Shroud Replacement (Automatic
Transmission - Diesel) .
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DRIVE BELT TENSIONER REPLACEMENT
Removal Procedure

1. Remove the drive belt. Refer to Drive Belt Replacement.

2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.
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1. Install the drive belt tensioner. Align the pin with the hole in the generator bracket.
2. Install the drive belt tensioner bolt.
Tighten: Tighten bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to Drive Belt Replacement.
DRIVE BELT IDLER PULLEY REPLACEMENT

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Removal Procedure
Fig. 11: View Of Right Side Idler & Center Idler Pulley Bolts

2. Remove the bolt (1) from the right side idler pulley.
3. Remove the idler pulley.
4. Remove the bolt (2) for the center idler pulley.
6. If equipped with dual generators, remove the bolt from the left side idler pulley.
7. If equipped with dual generators, remove the idler pulley.
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1. Install the right side idler pulley and bolt (1).
Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2. Install the center idler pulley and bolt (2).
3. If equipped with dual generators, install the left side idler pulley and bolt.
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INTAKE MANIFOLD COVER REPLACEMENT
Removal Procedure
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Fig. 13: View Of Intake Manifold Cover

1. Loosen the intake manifold cover clamp (1) at the resonator.

2. Loosen the intake manifold cover bolt (2).
3. Remove the intake manifold cover.
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Fig. 14: View Of Intake Manifold Cover

1. Install the intake manifold cover.

2. Tighten the intake manifold cover bolt (2) until snug.

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3. Tighten the intake manifold cover clamp (1) at the resonator.
Tighten: Tighten the clamp to 6 N.m (53 lb in).
ENGINE MOUNT INSPECTION
Fig. 15: Identifying Oil Pan Skid Plate

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1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

2. Remove the oil pan skid plate.
Fig. 16: Identifying Engine Shield And Retaining Bolts

3. Remove the engine protection shield.
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Fig. 17: View Of Engine Mount To Engine Mount Frame Bracket

NOTE: Refer to Engine Mounting Notice .
4. Inspect for loose or missing bolts at the following locations:

Engine mount bracket to engine
Engine mount frame bracket to frame
Engine mount to engine mount bracket
Engine mount to engine mount frame bracket
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5. Replace missing or loose bolts. Refer to Engine Mechanical Specifications .
Fig. 18: View Of Ground Wire Bolt Bosses (Left Side)

NOTE: Refer to Engine Lifting Notice .
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6. If the vehicle is 4-wheel drive (4WD), you will not be able to access the lifting points on the
engine. In order to raise the engine, attach a chain to the front of the engine. Then follow the
inspection steps.
7. If the vehicle is rear-wheel drive (RWD), in order to raise the engine to inspect the left
engine mount, use a suitable jack on the ground wire bolt bosses on the left side of the
engine
Fig. 19: View Of Ground Wire Bolt Bosses (Right Side)

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8. If equipped with an automatic transmission, remove the bolt retaining the transmission oil
cooler line bracket.
9. Move the transmission oil cooler lines aside.
10. In order to raise the engine to inspect the right engine mount, use a suitable jack on the
ground wire bolt bosses on the right side of the engine
11. Perform the following in order to inspect the engine mounts:
1. Raise the engine to remove weight from the engine mount.
2. Place a slight tension on the rubber cushion.
3. Observe the engine mount for the following while raising the engine:
Heat check cracks covering the hard rubber surface
The rubber cushion is separated from the metal plate of the engine mount.
There is a split through the rubber cushion.
12. Replace the engine mount if any of the above conditions exist.
MY

13. Install the engine protection shield and bolts.
Tighten: Tighten the engine protection shield bolts to 20 N.m (15 lb ft).
MY

14. Install the oil pan skid plate and bolts.
Tighten: Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).
15. Lower the vehicle.
MY
ENGINE MOUNT REPLACEMENT - LEFT SIDE
Removal Procedure
1. If RWD vehicle, raise the vehicle to a height to work through the front wheelhouse opening.
Refer to Lifting and Jacking the Vehicle .
2. If 4-wheel drive (4WD) vehicle, raise the vehicle in order to remove the front tires and
wheels and support with jackstands.
3. Remove the wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement -
Left Side (Chevrolet) or Front Wheelhouse Liner Replacement - Left Side (GMC) .
MY

NOTE: Refer to ENGINE MOUNTING NOTICE .
4. Working through the wheelhouse opening remove the 3 bolts retaining the engine mount to
the engine mount frame bracket.

MY
5. Remove the oil pan skid plate, if equipped.

6. Remove the engine protection shield from the vehicle, if equipped.
NOTE: Refer to ENGINE LIFTING NOTICE .
MY
Fig. 25: View Of Ground Wire Bolt Bosses (Left Side)

IMPORTANT: When raising the engine only raise enough to separate the
engine mount from the engine mount bracket. Raising any
further will require removal of the fan shroud or the exhaust
pipe.
MY
7. If RWD vehicle, using a suitable jack on the ground wire bolt bosses, raise the engine.
Only raise the engine enough to separate the engine mount to engine mount bracket.
8. If 4WD vehicle, attach a chain to the front of the engine. Use accessible mounting bolts for
the generator mounting bracket and the power steering pump mounting bracket.
9. Raise the engine with a suitable lifting device to remove the engine mount.
Fig. 26: Identifying Engine Mount Bolts

10. Remove the bolts holding the engine mount to the engine.
MY
Fig. 27: Identifying Engine Mount Frame Bracket Through Bolt

11. Remove the 2 through-bolts for the engine mount frame bracket.
12. Remove the engine mount frame bracket.
13. Remove the engine mount.
MY

1. Position the engine mount frame bracket on the frame. Do not install the bolts.
MY

2. Install the engine mount.

3. Perform the following procedure prior to installing the engine mount bracket bolts.
1. Remove all traces of the original adhesive patch.
2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the
bolts.
4. Install the 2 through-bolts.
MY
Tighten: Tighten the through-bolts to 75 N.m (55 lb ft).
5. Install the bolts holding the engine mount to the engine.
Tighten: Tighten the engine mount bolts to 58 N.m (43 lb ft).
6. Lower the engine.

7. If 4WD vehicle remove the chain from the front of the engine.
8. If 4WD vehicle, install the generator mounting bracket and the power steering mount
bracket bolt.
Tighten: Tighten the mounting bracket bolts to 50 N.m (37 lb ft).
MY

9. Install the 3 bolts holding the engine mount to the engine mount frame bracket.
Tighten: Tighten the engine mount to engine mount frame bracket bolts to 65 N.m (48 lb
ft).
MY

MY

11. Install the oil pan skid plate.
Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Remove the wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement -
MY
ENGINE MOUNT REPLACEMENT - RIGHT SIDE
Removal Procedure
Fig. 33: View Of Wheelhouse Panel & Push-In Retainers

1. Remove the starter motor. Refer to Starter Motor Replacement (6.6L) .

2. If RWD vehicle, raise the vehicle to a height to work through the front wheelhouse opening.
Refer to Lifting and Jacking the Vehicle .
MY
3. If 4-wheel drive (4WD) vehicle, raise the vehicle in order to remove the front tires and
wheels and support with jackstands.
4. Remove the right front tire and wheel, if necessary. Refer to Tire and Wheel Removal
and Installation .
5. Remove the pushpins holding the right front fender wheelhouse inner panel (1).
6. Remove the wheelhouse inner panel.
MY
Fig. 34: View Of Engine Mount To Engine Mount Frame Bracket Bolt (Right)
NOTE: Refer to ENGINE MOUNTING NOTICE
7. Working through the wheelhouse opening remove the 3 bolts retaining the engine mount to
MY
the engine mount frame bracket.

8. Remove the oil pan skid plate, if equipped.
MY

9. Remove the engine protection shield from the vehicle, if equipped.
MY
Fig. 37: View Of Transmission Oil Cooler Lines, Bracket & Bolt
10. If RWD vehicle and equipped with an automatic transmission, remove the bracket bolt for
the transmission oil cooler lines to the engine.
11. Move the transmission oil cooler lines aside.
NOTE: Refer to ENGINE LIFTING NOTICE
MY
Fig. 38: View Of Ground Wire Bolt Bosses (Right Side)

IMPORTANT: When raising the engine only raise enough to separate the
engine mount from the engine mount bracket. Raising any
further the fan shroud or the exhaust pipe will require
removal.
MY
12. If RWD vehicle, using a suitable jack on the ground wire bolt bosses, raise the engine.
13. If 4WD vehicle, attach a chain to the front of the engine. Use accessible mounting bolts for
the generator mounting bracket and the power steering pump mounting bracket.
14. Raise the engine with a suitable lifting device to remove the engine mount.

15. Remove the bolts holding the engine mount to the engine.
MY
Fig. 40: Identifying Frame Bracket

16. Remove the 2 through-bolts for the engine mount frame bracket.
17. Remove the engine mount frame bracket.
18. Remove the engine mount.
MY
Fig. 41: Identifying Frame Bracket

1. Position the engine mount frame bracket on the frame. Do not install the bolts.
2. Install the engine mount.
3. Perform the following procedure prior to installing the engine mount bracket bolts.
1. Remove all traces of the original adhesive patch.
2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the
bolts.
4. Install the 2 through-bolts.

MY

5. Install the bolts holding the engine mount to the engine.
6. Lower the engine.

7. If 4WD vehicle, remove the chain from the front of the engine.
8. If 4WD vehicle, install the generator mounting bracket and the power steering mount
bracket bolt.
Tighten: Tighten the mounting bracket bolts to 50 N.m (37 lb ft).

MY
Fig. 43: View Of Engine Mount To Engine Mount Frame Bracket Bolt (Right)
9. Install the 3 bolts holding the engine mount to the engine mount frame bracket.
Tighten: Tighten the engine mount to engine mount frame bracket bolts to 65 N.m (48 lb
MY
ft).
10. If RWD vehicle with an automatic transmission, install the bolt for the transmission oil
cooler line bracket.
Tighten: Tighten the transmission oil cooler line bracket bolt to 9 N.m (80 lb in).
MY

MY

12. Install the oil pan skid plate.
13. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation .
14. Install the front fender wheelhouse inner panel.
MY
15. Install the starter motor. Refer to Starter Motor Replacement (6.6L) .
POSITIVE CRANKCASE VENTILATION VALVE REPLACEMENT (DRIVER SIDE)
Removal Procedure
Fig. 47: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
IMPORTANT: After removing the charged air cooler duct, cover the
turbocharger opening with tape in order to prevent entry of
MY
objects.
1. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose.
The hose can be torn or damaged. Loosen the hose by
twisting.
2. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
MY
Fig. 48: View Of PCV Cover, Diaphragm & Spring

3. Remove the positive crankcase ventilation (PCV) cover screws.

4. Remove the PCV cover, diaphragm, and spring.
5. Clean and inspect the cover, diaphragm, and spring.
6. Discard the diaphragm if damage is found.
MY

1. Install the spring, diaphragm, and cover.

2. Install the PCV cover screws.
Tighten: Tighten the screws to 4 N.m (35 lb in).
MY
IMPORTANT: Lubricate the end of the duct prior to installation.
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).
POSITIVE CRANKCASE VENTILATION VALVE REPLACEMENT (PASSENGER SIDE)
Removal Procedure
MY
Fig. 51: Identifying Fuel Filter Bracket Bolts

1. Remove the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement .
2. Remove the fuel filter bracket bolts.
3. Position the fuel filter assembly out of the way.

MY
4. Remove the positive crankcase ventilation (PCV) cover screws.

6. Clean and inspect the cover, diaphragm and spring.
7. Discard the diaphragm if damage is found.

MY
1. Install the spring, diaphragm and cover.

Tighten: Tighten the screws to 4 N.m (35 lb in).

3. Position the fuel filter assembly to the engine.

MY
4. Install the fuel filter bracket bolts.
5. Install the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement .
POSITIVE CRANKCASE VENTILATION HOSE/PIPE/TUBE REPLACEMENT
Removal Procedure
MY
objects.
1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
The hose can be torn or damaged. Loosen the hose by
twisting.
4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
MY
Fig. 56: View Of PCV Hose Clamp

5. Reposition the positive crankcase ventilation (PCV) hose clamp.

6. Remove the PCV hose from the air inlet pipe.
7. Remove the PCV hose from the clip on the top of the turbocharger.
MY
Fig. 57: View Of Left PCV Hose/Pipe Bolt

8. Remove the left PCV hose/pipe bolt.
MY
Fig. 58: View Of Right PCV Hose/Pipe Bolt

9. Remove the right PCV hose/pipe bolt.

10. Remove the PCV hose/pipe.
MY

1. Install the PCV hose/pipe.

2. Install the right PCV hose/pipe bolt.
MY

3. Install the left PCV hose/pipe bolt.
MY

4. Install the PCV hose to the air inlet pipe.

5. Position the PCV hose clamp.
6. Install the PCV hose to the clip on the top of the turbocharger.
7. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
MY

MY
11. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.
INTAKE MANIFOLD TUBE REPLACEMENT
Removal Procedure
Fig. 63: View Of Electrical Harness Bolts

1. Remove the intake air valve. Refer to Intake Air Valve Replacement .
2. Remove the electrical harness bolts (1).
3. Reposition the harness clip from the intake manifold tube, as needed.
MY
Fig. 64: View Of Air Inlet Tube To Intake Manifold Tube Bolt & Nut
4. Remove the air inlet tube to intake manifold tube bolt and nut.
MY
Fig. 65: View Of Air Inlet Tube & Components

5. Disconnect the intake air heater electrical connector.

6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
7. Remove the engine harness clip from the air inlet tube.
8. Remove the air inlet tube nuts and bolt.
9. Remove the air inlet tube.
MY
Fig. 66: View Of Intake Manifold Tube

10. If necessary, remove the intake manifold tube.

11. If necessary, remove and discard the 2 O-ring seals from the tube.
12. Clean the gasket surfaces of the exhaust gas recirculation (EGR) cooler tube, intake
manifold tube and inlet tube.
MY

1. If necessary, install NEW O-ring seals onto the tube.

2. If necessary, install the intake manifold tube.
MY
Fig. 68: View Of Air Inlet Tube & Components

3. Install the air inlet tube and NEW gaskets.

4. Install the air inlet tube nuts and bolt.
Tighten: Tighten the nuts to 25 N.m (18 lb ft).
5. Connect the intake air heater electrical connector.

6. Connect the MAP sensor electrical connector.
7. Install the engine harness clip to the air inlet tube.
MY
Fig. 69: View Of Air Inlet Tube To Intake Manifold Tube Bolt & Nut
8. Install the air inlet tube to intake manifold tube bolt and nut.
Tighten: Tighten the bolt/nut to 10 N.m (89 lb in).
MY
Fig. 70: View Of Electrical Harness Bolts

9. Install the electrical harness bolts (1).
10. Install the intake air valve. Refer to Intake Air Valve Replacement .
CENTER INTAKE MANIFOLD REPLACEMENT
Removal Procedure
MY

1. Remove the exhaust gas recirculation (EGR) valve cooler tube. Refer to Exhaust Gas
Recirculation Valve Cooler Replacement .
2. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LMM) .
3. Remove the intake manifold tube.
4. Remove and discard the 2 intake manifold tube gaskets.
5. Remove the turbocharger. Refer to Turbocharger Replacement.
MY
Fig. 72: View Of IAT Sensor & Electrical Connector

6. Disconnect the intake air temperature (IAT) sensor electrical connector (1).
7. Remove the IAT sensor (2).
MY
Fig. 73: View Of Center Intake Manifold

8. Remove the center intake manifold bolts/nuts.

9. Pull-up the center intake manifold in order to remove.
10. Remove and discard the gaskets.
11. Clean the center intake manifold in cleaning solvent and air dry.
MY

1. Install NEW center intake manifold gaskets.

2. Install the center intake manifold.
3. Install the center intake manifold bolts/nuts.
Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).
MY
Fig. 75: View Of IAT Sensor & Electrical Connector

4. Install the IAT sensor (2).
Tighten: Tighten the sensor to 10 N.m (89 lb in).
5. Connect the IAT sensor electrical connector (1).

6. Install the turbocharger. Refer to Turbocharger Replacement.
MY

7. Install 2 NEW O-rings onto the intake manifold tube.

8. Lubricate the O-rings with clean engine oil to aid in the installation.
9. Install the intake manifold tube.
10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LMM) .
11. Install the EGR valve cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler
Replacement .
INTAKE MANIFOLD REPLACEMENT - LEFT SIDE
Removal Procedure
MY
Fig. 77: View Of Intake Manifold (Right)

1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
2. Remove the right fuel rail. Refer to Fuel Rail Fuel Feed Pipe Replacement - Right
Side .
3. Remove the intake manifold bolts/nuts.
IMPORTANT: The intake manifold uses sealer. Pry at the area by the fuel
rail bolt holes in order to avoid damage to the sealing
surfaces.
4. Remove the intake manifold.

MY
5. To prevent entry of debris in the cylinder head tape the openings.

6. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and
Inspection .
Fig. 78: Determining Sealant Bead Dimensions

1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake
manifold. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
MY

2. Install the intake manifold.

3. Install the intake manifold bolts/nuts.
MY
Fig. 80: Intake Manifold Bolt Tightening Sequence (Right)

4. Tighten the intake manifold bolts/nuts in the sequence shown.
Tighten: Tighten the bolts/nuts to 21 N.m (15 lb ft).
5. Install the right fuel rail. Refer to Fuel Rail Fuel Feed Pipe Replacement - Right Side .
6. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
INTAKE MANIFOLD REPLACEMENT - RIGHT SIDE
Removal Procedure
MY

1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
2. Remove the right fuel rail. Refer to Fuel Rail Fuel Feed Pipe Replacement - Right
Side .
3. Remove the intake manifold bolts/nuts.
IMPORTANT: The intake manifold uses sealer. Pry at the area by the fuel
rail bolt holes in order to avoid damage to the sealing
surfaces.
4. Remove the intake manifold.

MY
5. To prevent entry of debris in the cylinder head tape the openings.

6. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and
Inspection .

1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake
manifold. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
MY


3. Install the intake manifold bolts/nuts.
MY

4. Tighten the intake manifold bolts/nuts in the sequence shown.
5. Install the right fuel rail. Refer to Fuel Rail Fuel Feed Pipe Replacement - Right Side .
6. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
OIL FILLER TUBE REPLACEMENT
Removal Procedure
MY
Fig. 85: View Of Upper Oil Fill Tube Bolt

1. Remove the fan and clutch assembly. Refer to Cooling Fan and Shroud Replacement
(Non-HP2) .
3. Remove the upper oil fill tube bolt (1).
MY
Fig. 86: View Of Oil Fill Tube Bracket & Bolts

4. Remove the oil filler tube bracket bolts.

5. Remove the oil fill tube bracket.
MY
Fig. 87: View Of Lower Oil Fill Tube Bolt

6. Remove the lower oil fill tube bolt (1).
MY
Fig. 88: View Of Oil Filler Tube

7. Remove the oil fill tube.

8. Remove and discard the oil fill tube O-ring seal.
MY

1. Install a NEW O-ring seal onto the oil fill tube.

2. Install the oil fill tube.
MY
Fig. 90: View Of Lower Oil Fill Tube Bolt

3. Install the lower oil fill tube bolt (1).

MY
Fig. 91: View Of Oil Fill Tube Bracket & Bolts

4. Install the oil fill tube bracket.

5. Install the oil filler tube bracket bolts.
MY
Fig. 92: View Of Upper Oil Fill Tube Bolt

6. Install the upper oil fill tube bolt (1).

MY
8. Install the fan and clutch assembly. Refer to Cooling Fan and Shroud Replacement
(Non-HP2) .
OIL LEVEL INDICATOR AND TUBE REPLACEMENT
Removal Procedure
MY
Fig. 93: View Of Oil Level Indicator Tube & Bolt

1. Remove the oil level indicator.

2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side
MY
(6.6L) .
3. Remove the starter motor. Refer to Starter Motor Replacement (6.6L) .
4. Remove the oil level indicator tube bolt at the indicator tube bracket.
5. Remove the oil level indicator tube and O-ring seals.
6. Remove and discard the O-ring seals.
MY
Fig. 94: View Of Oil Level Indicator Tube & Bolt

1. Install NEW O-ring seals onto the oil level indicator tube.
2. Lightly lubricate the O-ring seals with engine oil.
MY
3. Install the oil level indicator tube.
4. Install the oil level indicator tube bolt at the indicator tube bracket.
5. Install the starter motor. Refer to Starter Motor Replacement (6.6L) .

6. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side
(6.6L) .
7. Install the oil level indicator.
VALVE ROCKER ARM COVER REPLACEMENT - UPPER LEFT SIDE
Removal Procedure
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or
Cooling System Draining and Filling (Static Fill) .
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection
and Connection (w/Single Battery) or Battery Negative Cable Disconnection and
Connection (w/Auxiliary Battery) or Battery Negative Cable Disconnection and
Connection (w/Dual Batteries) .
objects.
4. Remove the charged air cooler inlet duct. Refer to Charge Air Cooler Inlet Pipe
Replacement .
MY
Fig. 95: View Of Battery Cable Junction Block Bolt At Power Steering Pump
Bracket
5. Remove the battery cable to generator nut.

6. If equipped, remove the battery cable to the auxiliary generator.
7. Remove the battery cable harness clip from the bracket.
8. Remove the battery cable junction block bolt (1) from the power steering pump.
9. Move and secure the battery cables out of the way.
MY
Fig. 96: View Of Fuel Line Bracket & Nut

10. Disconnect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
11. Remove the fuel hose bracket nut.
MY
Fig. 97: View Of Main Engine Electrical Harness Connector Latches & Clips
12. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order
to disconnect the connectors.
13. Open the harness clip (2).
14. Remove the main engine electrical harness connectors.
MY
Fig. 98: View Of Turbocharger Vane Position Sensor Electrical Connector

15. Disconnect the turbocharger vane position sensor electrical connector (1).
MY
Fig. 99: View Of Main Engine Electrical Harness Connectors & Latches
16. Unclip the main engine electrical harness connectors from the main electrical connector
harness bracket.
MY
Fig. 100: View Of Main Electrical Harness Bracket & Bolts

17. Remove the main electrical connector harness bracket bolts (1).
18. Remove the main electrical connector harness bracket (2).
19. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LMM) .
20. Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement
(6.6L) .
21. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase
Ventilation Hose/Pipe/Tube Replacement.
MY
Fig. 101: View Of Left Fuel Injector Pipes

22. 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.
23. Spray lithium grease between the fuel injector line and fittings to assist in containing any
debris during removal. Refer to Sealers, Adhesives, and Lubricants for the correct part
number.
NOTE: DO NOT use compressed air to clean debris from the fuel
injector inlet after the fuel line is removed. Using compressed
air can allow debris to enter the fuel injector inlet and damage
MY
the fuel injector.
24. Remove the left fuel injector pipes.
Fig. 102: View Of Upper Valve Rocker Arm Cover & Gasket
25. Remove the upper valve rocker arm cover bolts.

26. Remove the upper valve rocker arm cover.
27. Remove the upper valve rocker arm cover gasket.
28. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise
reuse the old gasket.
MY
29. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker
Arm Cover Cleaning and Inspection - Upper .
1. Install the valve rocker arm cover gasket.

2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts.
MY
Fig. 104: Upper Valve Rocker Arm Cover Bolts Tightening Sequence
4. Tighten the upper valve rocker arm cover bolts in the sequence shown.
MY

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.
5. Install the left fuel injector pipes.
Tighten: Tighten the pipes to 41 N.m (30 lb ft).

MY
6. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LMM) .
7. Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement
(6.6L) .
8. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement.
Fig. 106: View Of Main Electrical Harness Bracket & Bolts

9. Install the main electrical connector harness bracket (2).

10. Install the main electrical connector harness bracket bolts (1).
MY
Fig. 107: View Of Main Engine Electrical Harness Connectors & Latches
11. Clip the main engine electrical harness connectors to the main electrical connector harness
bracket.
MY
Fig. 108: View Of Turbocharger Vane Position Sensor Electrical Connector

12. Connect the turbocharger vane position sensor electrical connector (1).
MY
13. Connect the main engine electrical harness connectors.

14. Push down on the latches (1) in order to connect the connectors.
15. Close the harness clip (2).
MY

16. Connect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
17. Install the fuel hose bracket nut.
Tighten: Tighten the nut to 21 N.m (15 lb ft).
MY
Bracket
18. Position the generator positive cable.

19. Install the generator positive cable in the clip on the engine front cover.
20. Install the generator positive cable and nut.
Tighten: Tighten the nut to 9 N.m (80 lb in).
21. Install the positive battery cable junction block bracket and bolt (1) to the power steering
MY
pump.
Tighten: Tighten the bolt to 9 N.m (80 lb in).

23. Install the charged air cooler inlet duct. Refer to Charge Air Cooler Inlet Pipe
Replacement .
24. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or
25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection (w/Single Battery) or Battery Negative Cable Disconnection and
VALVE ROCKER ARM COVER REPLACEMENT - UPPER RIGHT SIDE
Removal Procedure
3. Remove the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe
Replacement .
4. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas
Recirculation Valve Cooler Replacement .
5. Remove the heater outlet hose bolt from the bracket.
6. Position the heater outlet hose out of the way.
MY
Fig. 112: View Of Oil Level Indicator Tube Bolts & Bracket Bolts
7. Remove the wiring harness retainer from the bracket.

8. Remove the oil level indicator tube bolt (1).
9. Remove the oil level indicator tube bracket bolts (2).
10. Remove the bracket.
MY


12. Reposition the fuel filter with bracket.
MY
Fig. 114: View Of Engine Harness Bracket Bolt

14. Remove the engine harness bracket bolt.

15. Position engine harness brackets aside.
MY
Fig. 115: View Of Fuel Injector Pipes

16. 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.
17. Spray lithium grease between the fuel injector line and fittings to assist in containing any
debris during removal. Refer to Sealers, Adhesives, and Lubricants for the correct part
number.
MY
the fuel injector.
18. Remove the right fuel injector pipes.
19. Remove the upper valve rocker arm cover bolts.

20. Remove the upper valve rocker arm cover.
21. Remove the upper valve rocker arm cover gasket.
22. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise
MY

23. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker
Arm Cover Cleaning and Inspection - Upper .
1. Install the upper valve rocker arm cover gasket.

MY
4. Tighten the upper valve rocker arm cover bolts in the sequence shown.
MY

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.
5. Install the fuel injector pipes.
Tighten: Tighten the pipes to 41 N.m (30 lb ft).

MY
Fig. 120: View Of Engine Harness Bracket Bolt

6. Position engine harness brackets.

7. Install the engine harness bracket bolt.

Replacement.
MY

9. Position the fuel filter with bracket to the rocker cover.

11. Position the heater outlet hose.

12. Install the heater hose bracket bolt to the bracket.
MY
13. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler
Replacement .
Fig. 122: View Of Oil Level Indicator Tube Bolts & Bracket Bolts
14. Install the bracket.

15. Install the oil level indicator tube bracket bolts (2).
16. Install the oil level indicator tube bolt (1).

MY
17. Install the wiring harness retainer to the bracket.

18. Install the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe
Replacement .
19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
VALVE ROCKER ARM COVER REPLACEMENT - LOWER LEFT SIDE
Removal Procedure
MY
Fig. 123: View Of Lower Valve Rocker Arm Cover (Left)

1. Remove the upper left valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Upper Left Side.
2. Remove the fuel injectors. Refer to Fuel Injector Replacement (Left) or Fuel Injector
Replacement (Right) .
3. Remove the lower valve rocker arm cover bolts.
4. Remove the lower valve rocker arm cover.
5. Remove the gasket from the lower valve rocker arm cover.
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6. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise
7. If required, clean and inspect the lower valve rocker arm cover. Refer to Valve Rocker
Arm Cover Cleaning and Inspection - Lower .

1. Install the lower valve rocker arm cover gasket.

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2. Install the lower valve rocker arm cover.

3. Install the lower valve rocker arm cover bolts.
Fig. 125: Lower Valve Rocker Arm Cover Bolts Tightening Sequence
4. Tighten the lower valve rocker arm cover bolts in the sequence shown.
5. Install the fuel injectors. Refer to Fuel Injector Replacement (Left) or Fuel Injector
6. Install the upper left valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Upper Left Side.
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VALVE ROCKER ARM COVER REPLACEMENT - LOWER RIGHT SIDE
Removal Procedure
Fig. 126: View Of Lower Valve Rocker Arm Cover (Right)

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1. Remove the upper right valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Upper Right Side.
2. Remove the fuel injectors. Refer to Fuel Injector Replacement (Left) or Fuel Injector
3. Remove the lower valve rocker arm cover bolts.
5. Remove the gasket from the lower valve rocker arm cover.
6. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise
7. If required, clean and inspect the lower valve rocker arm cover. Refer to Valve Rocker
Arm Cover Cleaning and Inspection - Lower .
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1. Install the lower valve rocker arm cover gasket.

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4. Tighten the bolts in the sequence shown.
5. Install the fuel injectors. Refer to Fuel Injector Replacement (Left) or Fuel Injector
6. Install the right upper valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Upper Right Side.
VALVE ROCKER ARM, SHAFT, AND PUSH ROD REPLACEMENT
Removal Procedure
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Fig. 129: View Of Valve Clearance Adjusting Screw

1. Remove the lower valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement - Lower Left Side or Valve Rocker Arm Cover Replacement - Lower
Right Side.
2. Loosen the valve clearance lock nuts on each rocker arm.
3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension
on the valvetrain.
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Fig. 130: Rocker Arm Shaft Bolts Loosening Sequence

4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the
rocker arm shaft brackets.
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Fig. 131: View Of Rocker Arm Shaft

5. Remove the rocker arm shaft assembly from the cylinder head.
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Fig. 132: View Of Pushrods, Valve Spring Caps & Valve Lifter Bridges
6. Remove the valve bridge pins.

7. Remove the valve bridges.
8. Remove the pushrods.
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Fig. 133: View Of Rocker Arm Components

9. Remove the rocker arm shaft bracket bolts (1), if necessary.

10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary.
11. Remove the remaining rocker arms, springs, and brackets, if necessary.
12. If required, clean and inspect the valve rocker arm and shaft. Refer to Valve Rocker Arm
and Shaft Cleaning and Inspection .
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Fig. 134: View Of Rocker Arm Components

1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if
necessary.
2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if
necessary.
3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12)
with bolt (1). Continue in the same sequence to the last bracket, if necessary.
4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary.
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5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve
spring caps with clean engine oil.
6. Install the valve bridge.
7. Install the valve bridge pins.
8. Lubricate the valve lifter end of the pushrod with clean engine oil.
9. Install the pushrods.
To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should
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be felt from the pushrod trying to lift the valve lifter.

NOTE: The pushrods must be correctly seated in the valve lifter and
valve rocker arms before the rocker arm shaft assembly is
torqued into place. Improper seating of the pushrods can cause
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damage to the pushrods or the valve rocker arm shaft

assembly components.
10. Install the rocker arm shaft assembly.
Fig. 137: Rocker Arm Shaft Bolts Tightening Sequence

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11. Tighten the rocker arm shaft bolts in the sequence shown.
12. Adjust the valve clearance. Refer to Valve Lash Adjustment .

13. Install the lower valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement - Lower Left Side or Valve Rocker Arm Cover Replacement - Lower
Right Side.
VALVE CLEARANCE ADJUSTMENT
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Fig. 138: View Of Crankshaft Balancer Mark Aligned With Engine Mark
1. Remove the fan clutch. Refer to Fan Clutch Replacement (Diesel) .

2. Remove the upper valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement - Upper Left Side and Valve Rocker Arm Cover Replacement - Upper
Right Side.
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3. Rotate the crankshaft in order to bring the number 1 cylinder to top dead center (TDC) of
the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The
mark on the crankshaft balancer should be aligned with the mark on the engine.
Fig. 139: View Of Feeler Gage Between Tip Of Rocker Arm & Valve Lifter Bridge
4. Loosen the valve adjusting screws.

5. Insert a feeler gage between the tip of the rocker arm and the valve bridge.
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Fig. 140: View Of Rocker Arm Intake & Exhaust Valves 1, 2, 3, 5, 6, 7 & 8
6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment
Specifications to determine which valves can be adjusted when the engine is at TDC.
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7. Tighten the lock nut.
Tighten: Tighten nut to 22 N.m (16 lb ft).
8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the
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exhaust stroke.

10. Insert a feeler gage between the tip of the rocker arm and the valve bridge.
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Fig. 143: View Of Rocker Arm Intake & Exhaust Valves 2, 3, 4, 5, 6, 7 & 8
11. Adjust the valve clearance to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment
Specifications to determine which valves can be adjusted when the engine is at TDC.
12. Tighten the lock nut.
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Tighten: Tighten nut to 22 N.m (16 lb ft).
13. Install the upper valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement - Upper Left Side and Valve Rocker Arm Cover Replacement - Upper
Right Side.
14. Install the fan clutch. Refer to Fan Clutch Replacement (Diesel) .
TURBOCHARGER REPLACEMENT
Removal Procedure
NOTE: If a turbocharger has failed, clean any turbocharger debris or

excessive oil from the charge air cooler system before installing
the new turbocharger. Failure to clean debris from the charge air
cooler system will cause severe turbocharger and engine damage
upon startup. Failure to clean excessive oil from the charge air
cooler system may cause an engine runaway condition on startup,
resulting in severe engine damage.
IMPORTANT: If a turbocharger failure is thought to be caused due to lack of oil,

the camshaft bearing should be checked. The number 4 camshaft
bearing bore feeds the turbocharger oil supply (feed) pipe. If this
camshaft bearing spins in the bore, the turbocharger will be
starved for oil. This will cause a failure of the turbocharger.
Failure to diagnosis this condition will result in repeat
turbocharger failures.
1. Remove the transmission. Refer to Transmission Replacement .

2. Remove the left and right wheelhouse liners. Refer to Front Wheelhouse Liner
Replacement - Right Side (GMC) or Front Wheelhouse Liner Replacement - Right
Side (Chevrolet) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) or
Front Wheelhouse Liner Replacement - Left Side (GMC) .
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Fig. 144: View Of Turbocharger Exhaust Pipe & Clamp

3. Loosen the exhaust pipe clamp. Slide the clamp onto the exhaust pipe.
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Fig. 145: View Of Fill Tube To Bellhousing Nuts

4. If equipped with an automatic transmission, remove the transmission fill tube to bellhousing
nuts.
5. Lift the fill tube up from the studs and reposition the tube to the right side of the vehicle.
The tube does not require removal from the transmission.
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Fig. 146: View Of Left Exhaust Pipe Heat Shield & Bolts
6. Remove the left exhaust pipe heat shield bolts.

7. Remove the heat shield.
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Fig. 147: View Of Left Exhaust Pipe

IMPORTANT: Do not bend the exhaust pipe at the expansion area.
8. Remove the left exhaust pipe to exhaust manifold bolts.

9. Remove and discard the exhaust manifold gasket.
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Fig. 148: View Of Right Exhaust Pipe

IMPORTANT: Do not bend the exhaust pipe at the expansion area.
10. Remove the right exhaust pipe to exhaust manifold bolts.

11. Remove and discard the exhaust manifold gasket.
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Fig. 149: View Of Exhaust Outlet Shield

12. Remove the lower bolt for the exhaust outlet shield.
15. Remove the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe
Replacement .
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objects.
The hose can be torn or damage. Loosen the hose by
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twisting.
Fig. 151: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant

Bypass
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18. Remove the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
Fig. 152: View Of Turbocharger Outlet Coolant Pipe

IMPORTANT: Use care not to damage this hose during the procedure.
19. Reposition the hose clamp and remove the turbocharger outlet coolant hose from the
turbocharger.
20. Remove the turbocharger outlet coolant pipe banjo bolt and washers.
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Fig. 153: Identifying Upper EGR Cooler Pipe Bolt

22. Remove the EGR cooler pipe bolt.
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Fig. 154: View Of Turbocharger Heat Shield & EGR Cooler Pipe
23. Reposition the EGR cooler pipe (4) out of the way.
24. Remove the EGR valve adapter pipe bracket bolts (1).
25. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
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Fig. 155: View Of Exhaust Outlet Heat Shield & Bolts

26. Remove the remaining exhaust outlet heat shield bolts.

27. Remove the exhaust outlet heat shield.
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Fig. 156: View Of Exhaust Outlet Clamp

28. Loosen the exhaust outlet clamp.
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Fig. 157: View Of Exhaust Outlet

29. Remove the exhaust outlet.
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30. Remove the right exhaust pipe to turbocharger bolts.

31. Remove the right exhaust pipe.
32. Remove and discard the gasket.
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33. Remove the left exhaust pipe to turbocharger bolts.

34. Remove the left exhaust pipe.
35. Remove and discard the gasket.
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Fig. 160: View Of Turbocharger Oil Feed Pipe Banjo Bolt

NOTE: Do not twist the turbocharger oil feed pipe. Twisting of the feed
pipe will result in the collapse and deformation of the plastic
pipe, restricting oil flow and causing turbocharger damage.
During turbocharger replacement, gently push the oil feed pipe
towards the front of the engine to clear the turbocharger.
Assistance may be required to keep the pipes clear of the
turbocharger during removal or installation.
36. Remove the turbocharger oil feed pipe banjo bolt and washer.
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37. Reposition the oil feed pipe out of the way.

38. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
Fig. 161: View Of Turbocharger W/Oil Return Pipe

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39. Remove the turbocharger bolts.

40. Remove the turbocharger (with the oil return pipe).
41. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.
Fig. 162: View Of Oil Feed Pipe Bolt, Washer & Pipe
42. Remove the turbocharger lower heat shield, if necessary.

43. Remove the oil feed pipe bolt, washer, and pipe, if necessary.
44. If the turbocharger has failed, perform the following steps the verify the condition of the
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number 4 camshaft bearing before installing a new turbocharger:

1. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole
through the turbocharger oil supply hole in the block.
2. Turn the engine over by hand 1/2 turn and inspect for camshaft bearing movement,
indicating a spun camshaft bearing.
3. If the bearing is spun the engine MUST be replaced.
Fig. 163: View Of Oil Return Pipe Bolts

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45. If replacing the turbocharger, remove the oil return pipe bolts, pipe and gasket. Discard the
gasket.
46. Clean all turbocharger to engine gasket mating surfaces.
47. If required, clean and inspect the turbocharger. Refer to Turbocharger Cleaning and
Inspection
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1. If the turbocharger was replaced, install the oil return pipe, bolts, and a NEW gasket.
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IMPORTANT: Lubricate the washer with diesel fuel prior to installing.
2. Install the oil feed pipe, washer, and bolt, if necessary.
3. Install the turbocharger lower heat shield, if necessary.
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4. Install a NEW turbocharger oil return pipe gasket at the flywheel housing.
5. Install the turbocharger (with the oil return pipe).
6. Install the turbocharger bolts.
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7. Install the turbocharger oil return pipe nuts at the top of the flywheel housing.

8. If installing a NEW turbocharger, add about 120-150 cc (4-5 oz) of clean engine oil in the
turbocharger oil feed pipe opening while rotating the impeller.
9. Position the oil feed pipe to the turbocharger.
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10. Install a NEW turbocharger oil feed pipe washer and the banjo bolt.

11. Install the left exhaust pipe and a NEW gasket.

12. Install the left exhaust pipe to turbocharger bolts.
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13. Install the right exhaust pipe and a NEW gasket.

14. Install the right exhaust pipe to turbocharger bolts.
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15. Install the exhaust outlet.
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16. Tighten the exhaust outlet clamp.
Tighten: Tighten the clamp to 15 N.m (11 lb ft).
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Fig. 172: View Of Exhaust Outlet Heat Shield & Bolts

17. Install the exhaust outlet heat shield.

18. Install the remaining exhaust outlet heat shield bolts.
Replacement.
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Fig. 173: View Of Cooling Outlet Hose Eye Bolts

20. If the cooling outlet hose eye bolts were removed, install the longer bolt (1) with 2 holes, in
the top location. Install the shorter bolt (2) in the lower location.
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21. Install the turbocharger outlet coolant pipe banjo bolt and washers.
22. Install the turbocharger outlet coolant hose to the turbocharger and position the hose clamp.
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Fig. 175: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant

Bypass
23. Install the turbocharger inlet coolant hose to the turbocharger coolant bypass valve.
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Fig. 176: View Of Turbocharger Heat Shield & EGR Cooler Pipe
24. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
25. Install the EGR valve adapter pipe bracket bolts (1).

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26. Position the EGR cooler pipe (4).
Fig. 177: Identifying Upper EGR Cooler Pipe Bolt

27. Install the EGR cooler pipe bolt.
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31. Install the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe
Replacement .

33. Install the lower bolt for the exhaust outlet shield.
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34. Install a NEW exhaust manifold gasket.

35. Install the right exhaust pipe to exhaust manifold bolts.
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36. Install a NEW exhaust manifold gasket.

37. Install the left exhaust pipe to exhaust manifold bolts.
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38. Install the heat shield.

39. Install the left exhaust pipe heat shield bolts.
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40. If equipped with an automatic transmission, position the fill tube to the studs.
41. Install the transmission fill tube to bellhousing nuts.
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42. Slide the clamp onto the exhaust pipe. Tighten the exhaust pipe clamp.

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43. Install the left and right wheelhouse liners. Refer to Front Wheelhouse Liner
44. Install the transmission. Refer to Transmission Replacement .
45. If a NEW turbocharger was installed, perform the turbocharger learn procedure. Refer to
Turbocharger Learn .
46. Road test the vehicle for normal operation.
47. Inspect for coolant, oil, or exhaust leaks. Correct as necessary.
TURBOCHARGER OIL FEED PIPE REPLACEMENT
Removal Procedure
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1. Remove the turbocharger. Refer to Turbocharger Replacement.

2. Remove the turbocharger oil feed pipe bolt.
3. Remove the oil feed pipe and washer.
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IMPORTANT: Lubricate the NEW washer with diesel fuel before installing.
1. Position the oil feed pipe and a NEW washer into place.
2. Install the oil feed pipe bolt.
3. Install the turbocharger. Refer to Turbocharger Replacement.
AIR CONDITIONING (A/C) COMPRESSOR AND POWER STEERING PUMP BRACKET

REPLACEMENT
Removal Procedure
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Fig. 187: View Of Left Side Idler Pulley & Bolt (Dual Generators)
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2. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement
(Non-HP2) .
4. If equipped, remove the auxiliary generator. Refer to Auxiliary Generator Replacement
(6.6L) .
5. If equipped with dual generators, remove the bolt from the left side idler pulley (smooth
pulley).
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Fig. 188: View Of A/C Compressor & Bolts

7. Disconnect the air conditioning (A/C) compressor clutch electrical connector.

8. Disconnect the A/C cut out switch electrical connector.
9. Remove the A/C compressor bolts.
10. Move the A/C compressor with the hoses attached to the right side of the engine
compartment.
Bracket
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11. Remove the positive cable junction block to power steering pump bolt (1).
12. Secure the junction block out of the way.
Fig. 190: View Of Rear Power Steering Pump, Bracket & Bolts
13. Remove the rear power steering pump bracket bolts (1).
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Fig. 191: View Of Power Steering Pump Front Bracket & Bolts
14. Remove the power steering pump front bracket bolt.

15. Move and secure the power steering pump out of the way. The hoses and battery cables can
remain attach to pump.
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Fig. 192: A/C Compressor And Power Steering Pump Bracket

16. Remove the A/C compressor and power steering pump bracket bolts.
17. Remove the A/C compressor and power steering pump bracket.
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Fig. 193: A/C Compressor And Power Steering Pump Bracket

1. Position the A/C compressor and power steering pump bracket.
2. Install the A/C compressor and power steering pump bracket bolts.
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3. Install the power steering pump and loosely install the front bracket bolts.
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Fig. 195: View Of Rear Power Steering Pump, Bracket & Bolts
IMPORTANT: Tighten the front bracket bolts before the rear bracket bolts
to ensure pulley alignment.
4. Loosely install the rear power steering pump bracket bolts (1).
Tighten:
1. Tighten the front bracket bolts to 50 N.m (37 lb ft).
2. Tighten the rear bracket bolts to 50 N.m (37 lb ft).
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Fig. 196: View Of Left Side Idler Pulley & Bolt (Dual Generators)
5. If equipped with dual generators, install the left side idler pulley and bolt.
Tighten: Tighten the bolt to 43 N.m (32 lb ft)
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6. Install the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) .
Bracket
7. Install the battery cable junction block and bolt (1).
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Fig. 198: View Of A/C Compressor & Bolts

8. Position the A/C compressor.

9. Install the A/C compressor bolts.
10. Connect the A/C cut out switch electrical connector.

11. Connect the A/C clutch electrical connector.
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13. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-
HP2) .
CYLINDER HEAD REPLACEMENT - LEFT SIDE
Tools Required
J 45059 Angle Meter

Removal Procedure
Fig. 199: Cylinder Head Bolt Removal Sequence

1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover

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Replacement (LMM) .
2. Remove the intake manifold. Refer to Intake Manifold Replacement - Left Side.
3. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side
(6.6L) .
4. Remove the bolt and ground straps from the rear of the cylinder head.
5. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker
Arm, Shaft, and Push Rod Replacement.
6. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 2 .
7. Remove the cylinder head bolts in the sequence shown.
8. Discard the large M12 bolts.
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Fig. 200: View Of Left Cylinder Head Gasket

9. Remove the cylinder head.

10. Remove and discard the cylinder head gasket.
11. Clean the sealing surface of the engine block and the cylinder head.
NOTE: Clean all dirt, debris, and coolant from the engine block
cylinder head bolt holes. Failure to remove all foreign material
may result in damaged threads, improperly tightened fasteners
or damage to components.
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12. Clean the cylinder head bolt holes in the engine block.
13. For service to the cylinder head refer to the following:
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Cylinder Head Assemble

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NOTE: The left and right cylinder head gaskets are not
interchangeable. Improper placement of the cylinder head
gasket will block coolant and oil passages. Blocked coolant
and oil passages will cause severe engine damage.
1. Install the cylinder head gasket of the correct grade. Refer to Cylinder Head Gasket
Selection Specifications .
2. Install the cylinder head.
Fig. 202: Cylinder Head Bolt Installation Sequence

NOTE: This component uses bolts with a preapplied molybdenum

disulfide coating for thread lubrication. Do not remove the
coating or use any additional lubricant. Improperly lubricated
threads will adversely affect the bolt torque and clamp load.
Improper bolt torque and clamp load can lead to engine
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damage.
3. Install NEW M12 cylinder head bolts.

4. Reuse the M8 cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown:
Tighten:
1. Tighten the M12 bolts a first pass to 50 N.m (37 lb ft).
2. Tighten the M12 bolts a second pass to 80 N.m (59 lb ft)
3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059 .
4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059 .
5. Tighten the M8 bolts to 25 N.m (18 lb ft).
6. Position the ground straps to the rear of the cylinder head, and install the bolt.
7. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 .

8. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker
9. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side
(6.6L) .
10. Install the intake manifold. Refer to Intake Manifold Replacement - Left Side.
11. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover
Replacement (LMM) .
13. Inspect for coolant, oil, or exhaust leaks.
CYLINDER HEAD REPLACEMENT - RIGHT SIDE
Tools Required
J 45059 Angle Meter

Removal Procedure
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1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover

Replacement (LMM) .
2. Remove the intake manifold. Refer to Intake Manifold Replacement - Right Side.
3. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side
(6.6L) .
4. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker
5. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 .
6. Remove the cylinder head bolts in the sequence shown.
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Fig. 204: View Of Cylinder Head & Gasket (Right)

8. Remove the cylinder head.

9. Remove and discard the cylinder head gasket.
10. Clean the sealing surface of the engine block and the cylinder head.
NOTE: Clean all dirt, debris, and coolant from the engine block
cylinder head bolt holes. Failure to remove all foreign material
may result in damaged threads, improperly tightened fasteners
or damage to components.
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11. Clean the cylinder head bolt holes in the engine block.
12. For service to the cylinder head refer to the following:
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Cylinder Head Assemble

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1. Install the cylinder head gasket of the correct grade. Refer to Cylinder Head Gasket
Selection Specifications .
2. Install the cylinder head.
Fig. 206: Cylinder Head Bolt Installation Sequence


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damage.
3. Install the NEW M12 cylinder head bolts.

4. Reuse the M8 cylinder head bolts.
5. Tighten the cylinder head bolts in the following steps using the sequence shown:
Tighten:
1. Tighten the M12 bolts a first pass to 50 N.m (37 lb ft).
2. Tighten the M12 bolts a second pass to 80 N.m (59 lb ft)
3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059 .
4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059 .
5. Tighten the M8 bolts to 25 N.m (18 lb ft).
6. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker
7. Install the glow plugs. Refer to Glow Plug Replacement - Bank 1 .
8. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side
(6.6L) .
9. Install the right intake manifold. Refer to Intake Manifold Replacement - Right Side.
10. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover
Replacement (LMM) .
VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Tools Required
J 26999 Compression Gage. See Special Tools .

J 26999-20 Compression Gage Adapter
J 44646 Valve Spring Compressor. See Special Tools .
J 44640 Valve Stem Seal Installer. See Special Tools .
Removal Procedure
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Fig. 207: View Of J 26999-20 & J 26999

1. Remove the upper and lower fan shroud. Refer to Engine Coolant Fan Lower Shroud
Replacement (Mechanical) and Engine Coolant Fan Upper Shroud Replacement
2. Remove the valve rocker arm shaft, valve bridges, and pushrods for the cylinder head being
serviced. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement.
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3. Remove the glow plug for the cylinder requiring service. Refer to Glow Plug Replacement
- Bank 1 or Glow Plug Replacement - Bank 2 .
4. In order to apply shop air to the cylinders use the following procedures to modify J 26999-
20 (1) and J 26999 (2):. See Special Tools .
1. Remove the valve core from J 26999-20 to allow air to flow.
2. Remove the quick connect fitting from J 26999 . See Special Tools .
3. Adapt the quick connect fitting in order to use for shop air.
4. Connect the quick connect fitting to J 26999-20 .
IMPORTANT: Rotate the cylinder to be serviced to the bottom of the stroke.

This is to ensure that the engine does not rotate when the
compressed air is applied to the cylinder being serviced.
5. Install J 26999-20 into the glow plug hole for the cylinder being serviced.
6. Apply compressed air to hold the valves in place. If the compressed air is released, the
valves can drop into the cylinder.
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Fig. 208: Compressing Valve Spring Using J 44646

CAUTION: Compressed valve springs have high tension against the

valve spring compressor. Valve springs that are not
properly compressed by or released from the valve spring
compressor can be ejected from the valve spring
compressor with intense force. Use care when
compressing or releasing the valve spring with the valve
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spring compressor and when removing or installing the

valve stem keys. Failing to use care may cause personal
injury.
7. Install J 44646 to the rocker arm bosses on the cylinder head. See Special Tools .
J 44646 should be installed in the rocker arm boss next to the cylinder being serviced. See
Special Tools . The pivot pin can be removed from the stand to allow the stand to be
installed. The lever has different locating holes for the pivot pin depending on available
clearance. The lever is also notched for different locations of the compressor.
8. Using J 44646 compress the valve spring. See Special Tools .
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Fig. 209: View Of Valve Stem Oil Seal & Valve Spring
9. Remove the valve keys (1) from the valve stem.

10. Carefully release the valve spring tension.
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11. Remove the valve spring upper seat (2) and the valve spring (3).
12. Remove the valve stem oil seal (4).
13. Remove the valve spring lower seat (5).
14. Continue removing the remaining valve stem seals for the cylinder using the above
procedure.
Fig. 210: Installing Valve Stem Using J 44640

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NOTE: Air pressure should remain applied to the cylinder for

installation.
1. Install the valve spring lower seat.

2. Install the valve stem seal using J 44640 . See Special Tools .
MY
3. Install the valve spring (3), the painted end of the valve spring goes toward the cylinder
head.
MY
4. Install the valve spring upper seat (2).

CAUTION: Compressed valve springs have high tension against the

valve spring compressor. Valve springs that are not
properly compressed by or released from the valve spring
compressor can be ejected from the valve spring
MY
compressor with intense force. Use care when

compressing or releasing the valve spring with the valve
spring compressor and when removing or installing the
valve stem keys. Failing to use care may cause personal
injury.
5. Using J 44646 compress the valve spring. See Special Tools .

6. Install the valve keys to the valve stem.
NOTE: The valve stem keys must correctly seat in the valve spring
cap. Engine damage may occur by not installing properly.
7. Carefully release the valve spring pressure. Make sure the valve keys stay in place.
8. Continue to install the 3 remaining valve stem seals for the cylinder.
MY
Fig. 213: View Of J 26999-20 & J 26999

9. Release the compressed air holding the valves in place.

10. Remove J 26999-20 (1) from the glow plug hole.
11. Continue to replace the valve stem seals on the remaining cylinders using the above
procedures.
12. Install the glow plug. Refer to Glow Plug Replacement - Bank 1 or Glow Plug
Replacement - Bank 2 .
MY
13. Install the valve rocker arm shaft, the valve bridges, and the push rods. Refer to Valve
Rocker Arm, Shaft, and Push Rod Replacement.
14. Install the upper and lower fan shroud. Refer to Engine Coolant Fan Lower Shroud
Replacement (Mechanical) and Engine Coolant Fan Upper Shroud Replacement
VALVE LIFTER REPLACEMENT
Removal Procedure
MY
Fig. 214: View Of Valve Lifter, Guides, Retainers & Bolts

1. Remove the cylinder head. Refer to Cylinder Head Replacement - Left Side or Cylinder
Head Replacement - Right Side.
2. Loosen the valve lifter guide retainer bolts.
3. Remove the valve lifter guide retainers.
4. Remove the valve lifter guides.
5. Remove the valve lifters.
6. If required, clean and inspect the lifters. Refer to Valve Lifters Cleaning and Inspection .
MY

1. Apply clean engine oil to the roller and outside of the valve lifter.
2. Install the valve lifter.
3. Install the valve lifter guides.
4. Install the valve lifter guide retainer.
MY
5. Install the valve lifter guide retainer bolt.
6. Install the cylinder head. Refer to Cylinder Head Replacement - Left Side or Cylinder
Head Replacement - Right Side.
CRANKSHAFT BALANCER REPLACEMENT
Tools Required
J 44643 Flywheel Holding Tool. See Special Tools .

Removal Procedure
MY
Fig. 216: View Of Starter

2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement -
Right Side (GMC) or Front Wheelhouse Liner Replacement - Right Side
(Chevrolet) .
3. Remove the starter motor bolts. Reposition the starter aside. The wiring to the starter does
not require removal.
MY
Fig. 217: Locking Flywheel Using J 44643

4. Install J 44643 in order to hold the flywheel. See Special Tools .

5. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud
Replacement (Mechanical) .
MY
Fig. 218: View Of Crankshaft Balancer & Bolt

6. Remove the crankshaft balancer bolt.

7. Remove the crankshaft balancer.
8. If required, clean and inspect the crankshaft balancer. Refer to Crankshaft Balancer
Cleaning and Inspection .
MY

1. Lubricate the crankshaft balancer internal hub with clean engine oil.
2. Install the crankshaft balancer on the crankshaft.
3. Lubricate the crankshaft balancer bolt with clean engine oil.
4. Install the crankshaft balancer bolt and washer.

MY

5. Remove J 44643 . See Special Tools .
MY

6. Position the starter motor.

7. Install the starter motor bolts.
8. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement -
(Chevrolet) .
9. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement
MY
(Mechanical) .
CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Tools Required
J 44644 Crankshaft Front Oil Seal Remover. See Special Tools .

J 44645 Crankshaft Front Oil Seal Installer. See Special Tools .
Removal Procedure
MY
Fig. 222: Removing Crankshaft Front Oil Seal Using J 44644

1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.

2. Install J 44644 to the crankshaft front oil seal. See Special Tools . The jaws of the J 44644
fit into the inner sleeve. See Special Tools .
3. Using J 44644 , remove the crankshaft front oil seal. See Special Tools .
Fig. 223: Pressing Crankshaft Front Oil Seal On Using J 44645

MY
1. Clean the front crankshaft seal bore and the crankshaft.

2. Lubricate the crankshaft sealing surface with clean engine oil.
3. Place the crankshaft front oil seal onto the crankshaft.
4. Install J 44645 to the crankshaft. See Special Tools .
5. Press the crankshaft front oil seal onto the crankshaft using J 44645 until the tool bottoms
out. See Special Tools .
Fig. 224: Measuring Distance Between Crankshaft End & Oil Seal
7. Measure the distance between the end of the crankshaft and the oil seal.
8. The service measurement is 43.45-44.05 mm (1.7106-1.7342 in).
MY
9. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
ENGINE FRONT COVER REPLACEMENT
Tools Required
J 37228 Seal Cutter. See Special Tools .

Removal Procedure
Fig. 225: View Of Crankshaft Position Sensor Electrical Connector

MY

2. Remove the water pump. Refer to Water Pump Replacement (LMM) .
3. Remove the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement.
4. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement -
(Chevrolet) .
5. Disconnect the crankshaft position (CKP) sensor electrical connector.
Fig. 226: View Of CKP Sensor & Bolt

MY
6. Remove the CKP sensor bolt and sensor.

7. Remove the CKP sensor spacer bolts and spacer.
8. Remove and discard the O-rings from the sensor and the spacer.
Fig. 227: View Of Upper Oil Pan To Engine Front Cover Bolts
9. Remove the upper oil pan to engine front cover bolts.
MY
Fig. 228: View Of Engine Front Cover

10. Remove the engine front cover bolts.

11. Separate the engine front cover from the cylinder block and upper oil pan using J 37228 .
See Special Tools .
IMPORTANT: Do not bend the turbocharger coolant pipe.
12. Remove the engine front cover.
MY
Fig. 229: View Of Pressure Relief Valve O-Ring

13. If necessary, remove the pressure relief valve O-ring.

14. Clean and inspect the front cover. Refer to Engine Front Cover Cleaning and
Inspection .
MY

MY
1. If necessary, install a NEW pressure relief valve O-ring.

2. Lubricate the O-ring with engine oil.
Tighten: Tighten the valve to 39 N.m (29 lb ft).

3. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant to the engine
front cover sealing surface to the engine block. Refer to Sealers, Adhesives, and
Lubricants for the correct part number.
4. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant to the engine
front cover sealing surface to the upper oil pan. Refer to Sealers, Adhesives, and
MY

5. Install the engine front cover.

6. Install the engine front cover bolts.
MY
Fig. 233: View Of Upper Oil Pan To Engine Front Cover Bolts
7. Install the upper oil pan to engine front cover bolts.
MY

8. Install a NEW O-ring to the CKP sensor spacer.

9. Lubricate the O-ring with clean engine oil.
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.
10. Install the CKP sensor spacer and bolts.

MY
11. Install a NEW O-ring to the CKP sensor.

12. Lubricate the O-ring with clean engine oil.
13. Install the CKP sensor and bolt.

14. Connect the CKP sensor electrical connector.

15. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement -
MY
(Chevrolet) .
16. Install the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement.
17. Install the water pump. Refer to Water Pump Replacement (LMM) .
CAMSHAFT RELUCTOR REPLACEMENT
Removal Procedure
MY
Fig. 236: View Of Oil Pump Driven Gear & Nut

1. Remove the engine front cover. Refer to Engine Front Cover Replacement.
2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement.
NOTE: Do not use an impact driver to remove or install the oil pump
driven gear nut. Use of an impact driver may shear the oil pump
drive gear pin in the crankshaft.
3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven
MY
gear nut.
4. Remove the oil pump driven gear.
Fig. 237: View Of Oil Pump Drive Gear

IMPORTANT: DO NOT remove the reluctor from the oil pump drive gear.
The reluctor is timed to the gear and once removed the
correct timing will be lost.
5. Remove the oil pump drive gear and crankshaft sensor reluctor.
MY
Fig. 238: View Of Camshaft Reluctor & Bolts

6. Remove the camshaft reluctor screws.

7. Remove the camshaft reluctor.
8. Clean and inspect the camshaft reluctor for damage. Replace the reluctor if damage is found.
MY

1. Position the camshaft reluctor to the camshaft gear.

2. Install the camshaft reluctor bolts.

MY

IMPORTANT: Do not damage the teeth on the reluctor.
3. Install the oil pump drive gear and reluctor to the crankshaft.
MY

4. Install the oil pump driven gear.
5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven
gear nut.
MY
6. Install the upper oil pan. Refer to Upper Oil Pan Replacement.
7. Install the engine front cover. Refer to Engine Front Cover Replacement.
CRANKSHAFT RELUCTOR AND OIL PUMP DRIVE GEAR REPLACEMENT
Removal Procedure

MY
gear nut.

MY
4. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the
crankshaft reluctor teeth.
Fig. 244: View Of Crankshaft Reluctor & Oil Pump Drive Gear Bolts
IMPORTANT: Do not remove the reluctor from the oil pump drive gear
unless replacing the reluctor or the oil pump drive gear. The
reluctor is timed to the gear and once removed the correct
timing will be lost.
5. Remove the crankshaft reluctor to oil pump drive gear bolts.

6. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped.
7. Inspect the oil pump drive gear for damaged or worn teeth.
8. Inspect the oil pump drive gear crankshaft pin for wear.
9. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear.
10. Replace any parts that are damaged or worn.
MY
Fig. 245: View Of Knock Pins Proper Installation Position In Oil Pump Drive Gear
IMPORTANT: The crankshaft reluctor and the oil pump drive gear are timed
at the factory. In order to re-establish proper timing, install
knock pins in the oil pump drive gear if the crankshaft
reluctor was removed from the oil pump drive gear. The
knock pins are available through the parts department.
MY
1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in)
Fig. 246: View Of Crankshaft Reluctor & Oil Pump Drive Gear Bolts
2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on
the knock pins.
3. Install the crankshaft reluctor bolts.
MY

IMPORTANT: Do not damage the teeth on the crankshaft reluctor.
MY


gear nut.
MY
CAMSHAFT REPLACEMENT
Tools Required

J 26900-13 Magnetic Base. See Special Tools .
J 26900-12 Dial Indicator. See Special Tools .
Removal Procedure
MY

1. Remove the valve lifters. Refer to Valve Lifter Replacement.

2. Remove the charged air cooler. Refer to Charge Air Cooler Replacement .
3. Remove the air conditioning (A/C) condenser. Refer to Condenser Replacement .
4. Remove the starter. Refer to Starter Motor Replacement (6.6L) .
5. Install J 44643 flush to the flywheel opening. See Special Tools .
MY

7. Remove the oil pump driven gear nut.

MY

IMPORTANT: The crankshaft reluctor and the oil pump drive gear are timed
together at the factory. Do not remove the crankshaft reluctor
from the oil pump drive gear.
9. Remove the oil pump drive gear and crankshaft reluctor.

Do not remove the crankshaft reluctor bolts.
Do not damage the reluctor teeth.
MY
Fig. 252: Measuring Camshaft End Play Using J 26900-12 & J 26900-13
10. Using J 26900-12 (1) and J 26900-13 (2), measure the camshaft end play. See Special
Tools .
The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20
mm (0.008 in).
Replace the camshaft gear or the camshaft thrust plate if measured value exceeds
service limit.
MY

11. Remove the camshaft reluctor screws.

12. Remove the camshaft reluctor.
MY
Fig. 254: View Of Camshaft Thrust Plate Bolts

13. In order to loosen the camshaft gear bolt use J 44643 in order to hold the engine from
turning. See Special Tools .
14. Loosen the camshaft gear bolt and leave the bolt finger tight.
15. Remove the camshaft thrust plate bolts through the holes in the camshaft gear.
MY
Fig. 255: View Of Camshaft & Camshaft Gear

16. Remove the camshaft with the camshaft gear attached.
MY
Fig. 256: View Of Camshaft, Camshaft Gear & Camshaft Thrust Plate
17. Remove the camshaft gear bolt and discard.

18. Remove the camshaft gear.
19. Remove the camshaft thrust plate.
20. Clean and inspect the camshaft and bearings. Refer to Camshaft and Bearings Cleaning
and Inspection .
If the camshaft bearings are worn or damaged the engine will require removal in order to
replace the camshaft bearings. Refer to Engine Replacement.
MY
1. Install the camshaft thrust plate to the camshaft.

2. Install the camshaft driven gear.
3. Install a NEW camshaft driven gear bolt.
Leave the bolt finger tight.
MY
Fig. 258: View Of Camshaft Gear Aligned With Crankshaft Gear

4. Install the camshaft into the cylinder block, align the camshaft gear to the crankshaft gear as
shown.
MY
Fig. 259: View Of Camshaft Thrust Plate Bolts

5. Apply threadlock to the threads of the camshaft thrust plate bolts. Refer to Sealers,
Adhesives, and Lubricants for the correct part number.
MY
6. Install the camshaft thrust plate bolts.

7. Install the camshaft reluctor to the camshaft gear.

8. Install the camshaft reluctor bolts.
MY
Tighten: Tighten the bolts in a cross-bolt pattern to 9 N.m (80 lb in).

9. Reinstall J 44643 in the starter opening, if removed. See Special Tools .

10. Install a NEW camshaft gear bolt.
MY
Fig. 262: Measuring Camshaft End Play Using J 26900-12 & J 26900-13
11. Using J 26900-12 (1) and J 26900-13 (2) measure the camshaft end play. See Special
Tools .
mm (0.008 in).
Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the
service limit.
MY

IMPORTANT: Do not damage the teeth on the crankshaft reluctor.
MY


14. Install the oil pump driven gear nut.
16. Install the starter. Refer to Starter Motor Replacement (6.6L) .
17. Install the A/C condenser. Refer to Condenser Replacement .
MY
18. Install the charged air cooler. Refer to Charge Air Cooler Replacement .
19. Install the valve lifters. Refer to Valve Lifter Replacement.
CRANKSHAFT REAR OIL SEAL REPLACEMENT
Tools Required
J 44641 Crankshaft Rear Oil Seal Remover. See Special Tools .

J 44642 Crankshaft Rear Oil Seal Installer. See Special Tools .
Removal Procedure
MY
Fig. 265: Removing Crankshaft Rear Oil Seal Using J 44641

1. Remove the flywheel. Refer to Engine Flywheel Replacement.

2. Clean the area around the crankshaft rear oil seal.
3. Install J 44641 to the crankshaft rear oil seal. See Special Tools .
4. Remove the crankshaft rear oil seal using J 44641 . See Special Tools .
MY
Fig. 266: Pressing Crankshaft Rear Oil Seal In Using J 44642

1. Ensure that the crankshaft is free of oil and dirt.

2. Clean the seal bore in the flywheel housing.
3. Position the crankshaft rear oil seal onto the crankshaft.
IMPORTANT: J 44642 must be fully secured to the crankshaft to ensure

proper seal depth. See Special Tools .
4. Install J 44642 to the crankshaft. See Special Tools .

5. Press the crankshaft rear oil seal into position using J 44642 , the tool will bottom out when
the seal reaches the proper depth. See Special Tools .
MY

7. Install the flywheel. Refer to Engine Flywheel Replacement.
ENGINE FLYWHEEL HOUSING REPLACEMENT
Tools Required

Removal Procedure
MY
Fig. 267: View Of Turbocharger Oil Return Pipe Nuts

2. Remove the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement.
3. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing.
Fig. 268: View Of Oil Filter

MY
5. Remove the oil filter.
Fig. 269: View Of Engine Rear Cover Bolts & Flywheel Housing To Upper Oil Pan
Bolts
6. Remove the flywheel housing bolts, denoted by the black circles.

7. Separate the flywheel from the cylinder block using J 37228 . See Special Tools .
8. Remove the flywheel housing.
MY
Fig. 270: View Of Oil Cooler Adapter

9. Remove the turbocharger oil return pipe gasket from the flywheel housing.
10. Remove the oil cooler adapter bolts.
11. Remove the oil cooler adapter and gaskets.
12. If required, clean and inspect the flywheel housing. Refer to Engine Flywheel Housing
Cleaning and Inspection .
MY
Fig. 271: View Of Flywheel Housing O-Ring Seals

1. Install NEW O-ring seals to the flywheel housing, if necessary.
MY
Fig. 272: View Of Engine Rear Cover Sealing Surfaces Sealant Application Area
2. Apply a 2 mm (1/8 in) wide bead of sealant (3) to the flywheel housing sealing surfaces.
Refer to Sealers, Adhesives, and Lubricants for the correct part number.
MY

3. Install a NEW oil cooler adapter gasket.

4. Install a NEW oil cooler adapter to flywheel housing gasket.
5. Install the oil cooler adapter to the flywheel housing.
6. Install the oil cooler adapter bolts.

MY
Fig. 274: View Of Engine Rear Cover Bolts & Flywheel Housing To Upper Oil Pan
Bolts
7. Install the flywheel housing bolts, denoted by the black circles.
MY

8. Install the oil filter.

MY

10. Install a NEW gasket to the turbocharger oil return pipe.

11. Install the turbocharger oil return pipe to flywheel housing nuts.
12. Install the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement.
MY
ENGINE FLYWHEEL REPLACEMENT
Tools Required

J 45059 Angle Meter
Removal Procedure

MY
1. Remove the transmission. Refer to Transmission Replacement for the 4L60-E /4L65-
E/4L70-E transmission, Transmission Replacement for the 4L50/4L80/4L90
transmission, or Transmission Replacement for the Allison transmission.
2. Install J 44643 in order to hold the flywheel. See Special Tools .
Fig. 278: View Of Flywheel & Washer (Automatic)

CAUTION: When removing, handling or installing this component

wear protective gloves. The sharp edges on the
component may be very sharp and may cause injury.
3. Remove and discard the flywheel bolts.

4. Remove the flywheel washer and flywheel.
MY
CAUTION: When removing, handling or installing this component wear

protective gloves. The sharp edges on the component may be
very sharp and may cause injury.

IMPORTANT: When installing the flywheel, ensure that the tapered side of
the teeth are facing the starter.
1. Install the flywheel.

2. Install the flywheel washer with the beveled side facing the engine.

MY

damage.
3. Install NEW flywheel bolts.
MY
Fig. 280: Flywheel Bolt Tightening Sequence

4. Tighten the flywheel bolts in the proper sequence.
Tighten:
1. Tighten the bolts a first pass to 79 N.m (58 lb ft).
MY
2. Tighten the bolts a second pass to 60 degrees using J 45059 .

3. Tighten the bolts a final pass an additional 60 degrees using J 45059 .

5. Remove J 44643 from the flywheel. See Special Tools .

6. Install the transmission. Refer to Transmission Replacement for the 4L60-E/4L65-
E/4L70-E transmission, Transmission Replacement for the 4L50/4L80/4L90
transmission, or Transmission Replacement for the Allison transmission.
MY
LOWER OIL PAN REPLACEMENT
Tools Required

Removal Procedure
Fig. 282: View Of Engine Oil Drain Plug

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Place a suitable container under the engine in order to drain the oil.
MY
3. Remove the oil drain plug.

4. Drain the engine oil.

5. Remove the oil pan skid plate bolts and plate, if equipped.
MY
Fig. 284: View Of Crossbar Bolts & Bar (2WD)

6. If equipped with a 2-wheel drive (2WD) vehicle, remove the crossmember bolts and
crossmember.
MY
Fig. 285: View Of Crossmember Bolts & Bar (4WD Only)

7. If equipped with a 4-wheel drive (4WD) vehicle, remove the crossmember bolts and
crossmember.
MY
Fig. 286: View Of Oil Level Sensor Electrical Connector

8. Disconnect the oil level sensor electrical connector.
MY
Fig. 287: View Of Lower Oil Pan & Bolts/Nuts

IMPORTANT: DO NOT damage the sealing surfaces when separating the

lower oil pan from the upper oil pan.
9. Remove the lower oil pan bolts/nuts.

10. Separate the lower oil pan from the upper oil pan using J 37228 . See Special Tools .
11. Remove the lower oil pan.
12. If necessary, clean and inspect the lower oil pan. Refer to Lower Oil Pan Cleaning and
Inspection .
MY

1. Apply a 2-3 mm (0.79-0.118 in) by 0.5-1.5 mm (0.02-0.06 in ) wide bead of sealant to the
lower oil pan mating surface. Refer to Sealers, Adhesives, and Lubricants for the correct
part number.
MY

2. Install the lower oil pan.

3. Install the lower oil pan bolts/nuts.
MY
Fig. 290: Lower Oil Pan Bolts Tightening Sequence

4. Tighten the oil pan bolts/nuts in the sequence shown.
MY
Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).

5. Connect the oil level sensor electrical connector.
MY
Fig. 292: View Of Crossbar Bolts & Bar (2WD)

6. If equipped with a 2WD, install the crossmember and bolts.
MY
Fig. 293: View Of Crossmember Bolts & Bar (4WD Only)

7. If equipped with a 4WD, install the crossmember and bolts.
MY

8. Install the oil pan skid plate and bolts, if equipped.
9. Install NEW engine oil and a oil filter. Refer to Engine Oil and Oil Filter Replacement.
MY
UPPER OIL PAN REPLACEMENT
Tools Required

Removal Procedure
Fig. 295: Oil Level Indicator Tube

1. Remove the oil level indicator.

2. Remove the oil level indicator tube bolt from the indicator tube bracket.
3. If vehicle is a 4-wheel drive (4WD), remove the front differential carrier. Refer to
MY
Differential Carrier Assembly Replacement (1500 FWD) or Differential Carrier

Assembly Replacement (2500 4WD) .
4. If vehicle is a 2-wheel drive (2WD), disconnect the relay rod from the pitman arm and idler
arm. Refer to Relay Rod Replacement .
5. Remove the lower oil pan. Refer to Lower Oil Pan Replacement.
6. Remove the engine flywheel. Refer to Engine Flywheel Replacement.
Fig. 296: View Of Battery Cable Bracket Bolts At Lower Crankcase

7. Remove the battery cable bracket bolts.
MY
Fig. 297: View Of Battery Cable Bracket Nut

8. Remove the battery cable bracket nut.
MY
Fig. 298: View Of Flywheel Housing To Upper Oil Pan Bolts

9. Remove the two flywheel housing to upper oil pan bolts.
MY
Fig. 299: View Of Upper Oil Pan

10. Remove the upper oil pan bolts and any brackets. Mark the bolt location of the bracket.
11. Separate the upper oil pan from the engine block using J 37228 . See Special Tools .
12. Remove the upper oil pan. The oil level indicator tube needs to be removed while lowering
the upper oil pan.
13. If required, clean and inspect the upper oil pan. Refer to Upper Oil Pan Cleaning and
Inspection .
MY

1. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the
upper oil pan mating surfaces. Refer to Sealers, Adhesives, and Lubricants for the correct
part number.
2. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the
flywheel housing sealing surface. Refer to Sealers, Adhesives, and Lubricants for the
correct part number.
MY

3. Install the upper oil pan to the engine block. Ensure the oil level indicator tube is installed
into the upper oil pan.
MY
Fig. 302: Upper Oil Pan Bolts Tightening Sequence

4. Install any brackets and the upper oil pan bolts in the sequence shown.
MY

5. Install the two flywheel housing to upper oil pan bolts.
MY

6. Install the battery cable bracket bolts.
MY

7. Install the battery cable bracket nut.
MY
Fig. 306: Oil Level Indicator Tube

8. Install the engine flywheel. Refer to Engine Flywheel Replacement.

9. Install the lower oil pan. Refer to Lower Oil Pan Replacement.
10. If vehicle is a 4WD, install the front differential carrier. Refer to Differential Carrier
Assembly Replacement (1500 FWD) or Differential Carrier Assembly Replacement
(2500 4WD) .
11. If vehicle is a 2WD, Connect the relay rod to the pitman arm and idler arm. Refer to Relay
Rod Replacement .
13. Install the oil level indicator tube bolt to the indicator tube bracket.
MY
14. Install the oil level indicator.

15. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
OIL PUMP REPLACEMENT
Removal Procedure
Fig. 307: View Of Oil Pump Screen, Bolts, Nuts & Gasket
MY
1. If the vehicle is a 2-wheel drive (2WD), remove the flywheel housing. Refer to Engine
Flywheel Replacement.
4. Remove the oil pump screen bolts and nuts.
5. Remove the oil pump screen.
6. Remove and discard the oil pump screen gasket.
Fig. 308: Blocking Crankshaft From Turning Using Wooden Handle

MY
7. Block the crankshaft from turning with a wooden handle.
Fig. 309: Removing/Installing Secondary Oil Pump Driven Gear Nut While Holding
Oil Pump Shaft
IMPORTANT: Look for an "L" on the end of the oil pump shaft. If there is an
"L" present, the nut and shaft have left hand threads. Service
the nut accordingly.
MY
gear nut.

MY

IMPORTANT: Do not damage the crankshaft reluctor. Do not remove the

crankshaft reluctor to oil pump drive bolts.
10. Remove the oil pump drive gear and crankshaft reluctor.
Use a brass drift.
Tap on the back as close to the center of the reluctor.
MY
Fig. 312: View Of Oil Pump, O-Ring Seal & Bolt

11. Remove the hex head and the allen head bolt in order to remove the oil pump.
12. Remove the oil pump.
13. Remove the O-ring seal for the oil pump.
14. If required, clean and inspect the oil pump. Refer to Oil Pump Cleaning and Inspection .
MY
Fig. 313: View Of Oil Pump, O-Ring Seal & Bolt

1. Install a NEW oil pump O-ring seal.

2. Install the oil pump.
3. Install the oil pump bolts.
MY
4. Inspect the oil pump drive gear for wear.

5. Replace the oil pump drive gear pin if worn.

MY

MY
Oil Pump Shaft
gear nut.
MY
Fig. 317: View Of Oil Pump Screen, Bolts, Nuts & Gasket
9. Install a NEW oil pump screen gasket to the oil pump.

10. Install the oil pump screen.
11. Install the oil pump screen bolts and nuts.
13. If the vehicle is a 2WD, install the flywheel housing. Refer to Engine Flywheel
MY
Replacement.
OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY REPLACEMENT
Removal Procedure
Fig. 318: View Of Charge Air Inlet Pipe

1. Drain the engine coolant and the engine block. Refer to Cooling System Draining and
Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
2. Remove the charge air inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
3. Remove the cooling fan shroud bracket bolts (1).
4. Remove the cooling fan shroud bracket (2).
MY
Fig. 319: View Of Water Pump Outlet Pipe Nuts

5. Loosen the water pump outlet pipe nuts at the coolant pipe.
MY

6. If equipped, remove the oil pan skid plate bolts and plate.
MY

MY

8. Remove the oil cooler adapter nuts and studs from the flywheel housing.
MY
Fig. 323: View Of Oil Filter Adapter/Oil Cooler

9. Remove the oil cooler assembly bolts.
MY

10. Remove the oil cooler adapter bolts from the oil filter adapter/oil cooler.
11. Remove the oil cooler and adapter.
MY

12. Remove the coolant pipe nuts.
MY
Fig. 326: View Of Engine Coolant Pipe

13. Remove the coolant pipe.

14. Remove and discard the oil filter adapter/oil cooler O-ring seals.
15. Remove and discard the coolant pipe O-ring and gasket.
16. If required, clean and inspect the oil filter adapter/oil cooler. Refer to Oil Filter Adapter
and Oil Cooler Assembly Cleaning and Inspection .
MY

1. Install new coolant pipe O-ring and gasket.

2. Install new oil filter adapter/oil cooler O-ring seals.
3. Install the coolant pipe.
MY

4. Install the coolant pipe nuts.
Tighten: Tighten the coolant pipe nuts to 25 N.m (18 lb ft).
MY

5. Install the oil cooler and adapter.

6. Install the oil cooler adapter bolts to the oil filter adapter/oil cooler.
Tighten: Tighten the oil cooler adapter bolts to 25 N.m (18 lb ft).
MY

7. Install the oil cooler assembly bolts.
Tighten: Tighten the oil cooler assembly bolts to 25 N.m (18 lb ft).
MY

8. Install the oil cooler adapter nuts and studs to the flywheel housing.
Tighten:
Tighten the oil cooler adapter nuts to 25 N.m (18 lb ft).
Tighten the oil cooler adapter studs to 10 N.m (89 lb in).
MY

9. Install the oil filter.
MY

10. If removed, install the oil pan skid plate bolts and plate.
MY

11. Install the water pump outlet pipe nuts at the coolant pipe.
MY
Fig. 335: View Of Charge Air Inlet Pipe

12. Position the cooling fan shroud bracket (2).

13. Install the cooling fan shroud bracket bolts (1).
Tighten: Tighten the fan shroud bolt to 8 N.m (71 lb in).
Tighten: Tighten the fan shroud bracket to engine block bolts to 58N.m (63 lb ft).
14. Install the charge air inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
ENGINE OIL PRESSURE SENSOR AND/OR SWITCH REPLACEMENT

MY
Tools Required
J 41712 Oil Pressure Switch Socket

Removal Procedure
Fig. 336: View Of Oil Pressure Sensor Electrical Connector

IMPORTANT: Clean the area around the sensor. Do not allow debris to
enter the engine.
MY
1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement
- Left Side (Chevrolet) or Front Wheelhouse Liner Replacement - Left Side (GMC) .
2. Disconnect the oil pressure sensor electrical connector.
Fig. 337: View Of Oil Pressure Sensor

3. Using J 41712 , remove the oil pressure sensor (1).

MY

1. Apply sealant to the threads of the oil pressure sensor. Refer to Sealers, Adhesives, and
2. Using J 41712 , install the oil pressure sensor (1).
Tighten: Tighten the sensor to 49 N.m (36 lb ft).
MY

3. Connect the oil pressure sensor electrical connector.

4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement -
5. Check and add engine oil if necessary.
ENGINE OIL LEVEL SENSOR AND/OR SWITCH REPLACEMENT
Removal Procedure
MY
Fig. 340: View Of Oil Level Sensor, Clip, Bolt & Oil Pan Mating Surface
1. Remove the lower oil pan. Refer to Lower Oil Pan Replacement.
2. Remove the oil level sensor clip (3).
3. Remove the oil level sensor bolt (2) and sensor (1).
IMPORTANT: When routing the oil level sensor wire, ensure that the wire is
routed along the side of the oil pan.
MY
1. Install the oil level sensor (1) and bolt (2).
2. Install the oil level sensor clip (3).

3. Install the lower oil pan. Refer to Lower Oil Pan Replacement.
ENGINE REPLACEMENT
MY
Tools Required
J 36857 Engine Lift Brackets. See Special Tools .

J 43181 Quick Connect Connector Removal. See Special Tools .
Removal Procedure
IMPORTANT: In order to remove the engine the vehicle needs to be on a hoist.

The front wheels and tires will also require removal. The vehicle
will have to be supported by the frame when the tires are
removed.
Fig. 342: View Of Ground Strap & Nut

MY
1. Open the hood.

2. Remove the ground strap from the stud.
Fig. 343: View Of Hood Strut Rod, Grille End Caps & Hood Hinge Bolts
3. Assemble 2 sets of the following: an M6 bolt, 2 each 19.05 mm (0.75 in) flat washers and an
M6 nut.
4. Release the retainer securing the hood strut rod to the hood strut bracket stud.
MY
5. Remove the air inlet grille end caps (1), lift the end cap up in order to disengage the
retainers. (left side shown, right side similar).
6. Have an assistant support the hood.
7. Remove the hood hinge bolts (2) and set aside.
Fig. 344: View Of Service Piston Notch

IMPORTANT: There is a positive stop which limits the hood from being
opened too far.
8. Raise the hood until the service position notch (1) in the upper hinge is reached.
9. Install the 2 sets of the M6 bolts to both the left and right side service notches and tighten
MY
finger tight.
10. Lower the hood until the bolts rest against the lower hinge, tighten the bolts to secure the
hood.
11. The hood is now set in the service position.

12. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and
Recharging .
13. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection
MY
Fig. 345: View Of Engine Wire Harness Clips, A/C Pressure Cycling Switch & Surge
Tank Switch
15. Disconnect the following engine wire harness connectors:

Surge tank switch (1)
A/C pressure cycling switch (2)
Remove the engine wire harness clips from the wheelhouse inner panel (3).
16. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
17. Remove the surge tank. Refer to Radiator Surge Tank Replacement (Non-HP2) .
18. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
19. Remove both front tires and wheels. Refer to Tire and Wheel Removal and Installation .
MY
20. Remove both fender wheelhouse inner panels. Refer to Front Wheelhouse Liner
22. Remove the charged air cooler pipes. Refer to Charge Air Cooler Inlet Pipe
Replacement and Charge Air Cooler Outlet Pipe Replacement .
23. Remove the radiator inlet hose Radiator Inlet Hose Replacement (Non-HP2) .
24. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud
Replacement (Mechanical) or Engine Coolant Fan Upper Shroud Replacement
(Automatic Transmission - Diesel) .
25. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud
Replacement (Mechanical) .
MY
Fig. 346: View Of Radiator Outlet Hose & Outlet Heater Hose
26. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
27. Disconnect the outlet heater hose from the outlet radiator hose.
28. Remove the hose clips from the frame.
Fig. 347: View Of Radiator Outlet Hose At Engine

MY
29. Loosen the hose clamp and remove the radiator outlet hose from the engine.
30. Remove the outlet heater hose pipe bolt from the bracket.
31. Remove the outlet heater hose pipe nut.
32. Move the heater hose and secure aside.
33. Remove the upper radiator support. Refer to Radiator Support Replacement .
34. Remove the radiator. Refer to Radiator Replacement (LLM) .
35. Remove the charged air cooler. Refer to Charge Air Cooler Replacement .
36. Remove the A/C condenser. Refer to Condenser Replacement .
Fig. 348: View Of A/C & Generator Electrical Connectors

MY
37. Disconnect the following electrical connectors:

Generator connector (1)
A/C refrigerant switch (2)
Dual generator harness connector (3), if equipped
A/C compressor clutch (4)
38. Remove the harness clip from the A/C compressor bracket.
Bracket
MY
39. Remove the battery cable to the generator.

40. If equipped, remove the battery cable to the auxiliary generator.
41. Remove the battery cable harness clip from the bracket.
42. Remove the battery cable junction block bolt (1) from the power steering pump.
44. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order
to disconnect the connectors.
45. Open the harness clip (2).
MY

47. Disconnect the fuel lines at the engine. Refer to Metal Collar Quick Connect Fitting
Service .
48. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
49. Secure the fuel lines out of the way.
MY

51. Disconnect the suction hose from the accumulator. The compressor end can remain on the
compressor.
52. Remove the A/C compressor bolts.
53. Move the A/C compressor with the hoses attached to the right side of the engine
compartment.
54. Move the wiring harness to the left side of the vehicle and secure out to the way.
MY
55. Remove the bolts retaining the power steering pump front bracket to the power steering
pump and the air conditioner compressor mounting bracket.
56. Remove the air conditioning and power steering pump mounting bracket. Refer to Air
MY
Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement.
When the battery cables are removed from the engine the power steering pump can be
removed further out of the way.
57. Remove the right idler pulley bolt (1) and pulley.
MY
Fig. 354: View Of Generator Mounting Bracket

58. Remove the generator mounting bracket and secure to the side.
The generator does not require removal.
The drive belt tensioner does not require removal.
MY
Fig. 355: Identifying Heater Hose To Heater Core Fittings

59. Use the J 43181 in order to disconnect the inlet heater hose from the heater core inlet. See
Special Tools .
60. Remove the bolt and the ground wires at the rear of the left cylinder head.
61. Raise the vehicle.
62. Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/3500
with RPO NZZ) .
63. Remove the engine shield from the vehicle, if equipped. Refer to Engine Shield
Replacement .
MY
Fig. 356: View Of Engine Wiring Harness Ground Wire & Battery Negative Cable
(Left Side Of Engine)
64. Remove the bolt for the battery negative cable and the engine wiring harness ground wire
from the left side of the engine.
MY

65. Remove the bolts holding the battery cable channel retainer to the lower crankcase.
MY
Fig. 358: View Of Engine Coolant Heater Cord

66. Disconnect the cord for the engine coolant heater.

67. Remove the starter. Refer to Starter Motor Replacement (6.6L) .
MY

68. Remove the nut holding the battery cable bracket to the right side of the lower crankcase.
MY
Fig. 360: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness
Ground Wires Bolt (Right Side Of Engine)
69. Remove the bolt holding the auxiliary battery negative cable and the engine wiring harness
ground wires to the right side of the engine.
MY

71. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
72. Drain the engine oil.
73. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
MY
74. If vehicle is 4-wheel drive (4WD) remove the lower oil pan. Refer to Lower Oil Pan
Replacement.
Fig. 362: View Of Torque Convertor Bolt

75. If equipped with an automatic transmission, mark the flywheel and torque converter
relationship for assembly purposes.
76. Remove the torque convertor bolts through the starter opening.
MY
77. If equipped with an automatic transmission, remove the transmission oil line clip nut.
MY

78. If equipped with an automatic transmission, remove the nuts retaining transmission fluid fill
tube bracket.
MY
Fig. 365: View of Transmission To Engine Stud & Bolts

79. Remove the transmission to engine stud and bolts (automatic transmission shown). Note the
location of the studs and any brackets attached to the studs.
MY

80. Lower the vehicle to work through the wheelhouse opening.

81. Remove the engine mount to frame bracket bolts (left side shown).
MY
Fig. 367: View Of J 36857 & Bolt At Rear Of Left Cylinder Head
83. Install the J 36857 (1) to the rear of the left cylinder head with a suitable bolt. See Special
Tools .
MY
Fig. 368: View Of J 36857 & Bolt At Front Of Right Cylinder Head
84. Install the J 36857 (1) to the front of the right cylinder head with a suitable bolt. See
Special Tools .
85. Install a suitable lifting device. The engine will have to be angled in order to remove. Use a
MY
load positioning sling to assist in angling the engine.

86. Raise the vehicle off of the engine mounts.

87. Remove the left and right engine mount frame brackets.
88. Remove the engine from the vehicle.
89. In order to secure the engine to an engine stand remove the following and follow the special
procedures:
Refer to Engine Flywheel Removal (Automatic Transmission) or Engine
Flywheel Removal (Manual Transmission) .
Refer to Exhaust Outlet Removal .
Refer to Upper Oil Pan Removal .

MY
Refer to Engine Flywheel Housing Removal .

Refer to Engine Mounting to Stand .
Fig. 370: View Of J 36857 & Bolt At Rear Of Left Cylinder Head
MY
1. Install the J 36857 (1) to the rear of the left cylinder head with a suitable bolt. See Special
Tools .
Fig. 371: View Of J 36857 & Bolt At Front Of Right Cylinder Head
MY
2. Install the J 36857 (1) to the front of the right cylinder head with a suitable bolt. See
Special Tools .
3. Install a suitable lifting device. The engine will have to be angled in order to install. Use a
load positioning sling to assist in angling the engine.
4. Remove the engine from the stand. Refer to Engine Removal from Stand .
5. Install the following:
Refer to Engine Flywheel Installation (Automatic Transmission) or Engine
Flywheel Installation (Manual Transmission) .
Refer to Exhaust Outlet Installation .
Refer to Upper Oil Pan Installation .
Refer to Engine Flywheel Housing Installation .
6. Install the engine in the vehicle.
IMPORTANT: Do not draw the engine to the transmission using the

transmission bolts. If everything is aligned properly the
engine and transmission will come together.
7. Loosely install 2 transmission to engine bolts.
MY

8. Install the left and right side engine mount frame brackets.
MY

9. Install the engine mount to frame bracket bolts (left side shown).
10. Remove the J 36857 from the cylinder heads. See Special Tools .
11. Raise the vehicle.
MY
Fig. 374: View of Transmission To Engine Stud & Bolts

12. Install the transmission to engine bolts (automatic transmission shown).
Tighten: Tighten the studs and bolts to 50 N.m (37 lb ft).
MY
Fig. 375: View Of Torque Convertor Bolt

13. If equipped with an automatic transmission install the torque convertor bolts.
MY

14. If equipped with an automatic transmission, install the nuts retaining the transmission fluid
fill tube bracket.
15. If the vehicle is 4WD, install the lower oil pan. Refer to Lower Oil Pan Replacement.
MY
16. If equipped with an automatic transmission, install the nut retaining the transmission oil
cooler line clip.
MY

17. Install the exhaust pipe to the exhaust outlet.

18. Install the exhaust manifold pipe to the exhaust outlet clamp.
MY
19. Lower the vehicle to work through the front fender wheelhouse openings.
Fig. 379: View Of Engine Wiring Harness Ground Wire & Battery Negative Cable
(Left Side Of Engine)
20. Install the bolt retaining the battery negative cable and the engine wiring harness ground
MY
wire to the left side of the engine.

21. Install the bolts holding the battery cable channel retainer to the lower crankcase.
MY
Fig. 381: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness
Ground Wires Bolt (Right Side Of Engine)
22. Install the bolts holding the auxiliary battery negative cable and the engine wiring harness
ground wires to the right side of the engine.

MY

23. Install the nut holding the battery cable bracket to the right side of the lower crankcase.
24. Install the starter. Refer to Starter Motor Replacement (6.6L) .
MY
Fig. 383: View Of Engine Coolant Heater Cord

25. Connect the cord for the engine coolant heater.

26. Install the engine oil pan skid plate. Refer to Oil Pan Skid Plate Replacement
(2500/3500 with RPO NZZ) .
27. Install the engine shield. Refer to Engine Shield Replacement .
29. Install the bolt and the ground wires at the rear of the left cylinder head.
MY

30. Install the generator mounting bracket and bolts.
MY
31. Install the right idler pulley and bolt (1).
32. Install the air conditioning compressor and the power steering pump mounting bracket.
Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket
Replacement.
33. Position the engine wiring harness on the engine.
34. Position the A/C compressor.
35. Install the A/C compressor mounting bolts.
MY
36. Install the A/C suction hose to the accumulator.


38. Connect the fuel hoses at the engine.

39. Install the nut and the fuel hose bracket to the valve rocker arm cover stud.
MY
40. Connect the main engine electrical harness connectors.

41. Push down on the latches (1) in order to connect the connectors.
42. Close the harness clip (2).
MY
Bracket
43. Install the cable junction block and bolt (1) to the power steering pump.
44. If equipped, install the battery cable to the auxiliary generator.

45. Install the battery cable to the generator.
MY
46. Install the battery cable harness clip to the bracket.
Fig. 389: View Of A/C & Generator Electrical Connectors

47. Connect the following electrical connectors:

Generator connector (1)
A/C refrigerant switch (2)
Dual generator harness connector (3), if equipped
A/C compressor clutch (4)
MY
48. Install the harness clip to the A/C compressor bracket.

49. Install the upper radiator support. Refer to Radiator Support Replacement .
50. Install the A/C condenser. Refer to Condenser Replacement .
51. Install the charged air cooler. Refer to Charge Air Cooler Replacement .
52. Install the radiator. Refer to Radiator Replacement (LLM) .
Fig. 390: View Of Radiator Outlet Hose & Outlet Heater Hose
53. Install the outlet radiator hose to the radiator and tighten the hose clamp.
54. Install the hose clips to the frame.
MY
Fig. 391: View Of Radiator Outlet Hose At Engine

55. Install the outlet radiator hose to the engine and tighten the hose clamp.
56. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement
(Mechanical) .
57. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement
MY
Fig. 392: View Of Inlet Heater Hose

58. Connect the inlet heater hose (1) to the heater core inlet.
Firmly push to quick connector onto the heater core pipe until you hear an audible click.
59. Install the outlet heater hose to the outlet radiator hose.
60. Install the bolt retaining the heater hose pipe to the bracket.
MY
61. Install the radiator inlet hose Radiator Inlet Hose Replacement (Non-HP2) .
62. Install the charged air cooler pipes and hoses to the turbocharger and the charged air cooler.
Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet
Pipe Replacement .
63. Install both fender wheelhouse inner panels (1). Refer to Front Wheelhouse Liner
64. Install both front tires and wheels. Refer to Tire and Wheel Removal and Installation .
65. Install the surge tank. Refer to Radiator Surge Tank Replacement (Non-HP2) .
66. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
MY
Fig. 393: View Of Engine Wire Harness Clips, A/C Pressure Cycling Switch & Surge
Tank Switch
67. Connect the following engine wire harness connectors:

Install the engine wire harness clips to the wheelhouse inner panel (3).
A/c pressure cycling switch (2)
Surge tank switch (1)
68. Connect the batteries negative cables. Refer to Battery Negative Cable Disconnection
69. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) or
70. Prelube the engine. Refer to Engine Prelubing .
71. Operate the engine, inspect for coolant, oil, fuel, and exhaust leaks.
72. Inspect for proper oil pressure.
73. Inspect for proper engine operation.
MY
Fig. 394: View Of Service Piston Notch

IMPORTANT: There is a positive stop which limits the hood from being
opened too far.
74. With the aid of the assistant raise the hood slightly until the hood hinge bolts can be
removed from the service position notch (1).
MY
Fig. 395: View Of Hood Strut Rod, Grille End Caps & Hood Hinge Bolts
75. With the aid of an assistant lower the hood and install the hood hinge bolts (2) to the hood
hinges.
76. Install the air inlet grille end caps (1), push down the end cap in order to engage the
retainers. (left side shown, right side similar).
MY
Fig. 396: View Of Ground Strap & Nut

77. Install the ground strap to the hood stud.

78. Install the ground strap nut at the hood stud.
79. Close the hood.

ENGINE OIL AND OIL FILTER REPLACEMENT

MY
Removal Procedure
Fig. 397: View Of Oil Drain Plug

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Position a suitable drain pan under the oil pan drain plug.
3. Remove the oil drain plug.
4. Allow the oil to drain completely.
5. Clean and inspect the oil pan drain plug, replace if necessary.
6. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary.
7. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until
snug.
MY

8. Position a suitable drain pan under the oil filter

10. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket
from the adapter.
MY

1. Apply clean engine oil to the NEW oil filter gasket.

2. Install the NEW oil filter.
Tighten: Tighten the filter after contact plus 1 to 11/4 turn.
MY
Fig. 400: View Of Oil Drain Plug

3. Tighten the oil pan drain plug.
Tighten: Tighten the plug to 84 N.m (62 lb ft).
4. Remove the oil drain pan from under the vehicle.

6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities and Fluid
and Lubricant Recommendations .
7. Start the engine.
8. Inspect for oil leaks after engine start up.
9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan.
MY
10. Remove the oil level indicator from the oil level indicator tube.
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator
handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the
oil level indicator down.
14. Check the level of the engine oil on the oil level indicator.
15. If necessary, adjust the oil level be adding or draining oil.
16. Check for oil leaks.
OIL PUMP REMOVAL
MY
Oil Pump Shaft
MY
gear nut.
Fig. 402: View Of Oil Pump Driven Gear

MY

IMPORTANT: Do not damage the crankshaft sensor reluctor teeth.
3. Remove the oil pump drive gear and crank sensor reluctor assembly.
MY
Fig. 404: View Of Oil Pump, Bolts & O-Ring

4. Remove the oil pump bolts.

5. Remove the oil pump.
6. Remove the O-ring and discard.
OFF-VEHICLE REPAIR INSTRUCTIONS

DRAINING FLUIDS AND OIL FILTER REMOVAL
MY
Fig. 405: View Of Fuel Filter

1. Drain the fuel from the fuel filter.

1. Attach drain tube to fuel filter drain tap.
2. Place open end of drain tube into a suitable container.
3. Open fuel filter drain, and allow fuel to drain.
4. Close fuel filter drain.
5. Remove drain tube.
6. Properly dispose of used fuel.
MY
Fig. 406: View Of Engine Oil Drain Plug

2. Remove the oil drain plug and gasket, and allow engine oil to drain.
3. Discard the oil drain plug gasket.
MY

MY
Fig. 408: View Of Engine Block Coolant Plugs

5. Remove the engine block coolant plugs, and allow coolant to drain.
STARTER REMOVAL
MY

1. Remove the starter motor bolts.

2. Remove the starter motor assembly.
CRANKSHAFT BALANCER REMOVAL
Tools Required
J 44643 Flywheel Hold Tool. See Special Tools .

Removal
MY

1. Install J 44643 to lock the flywheel. See Special Tools .
MY

2. Remove the crankshaft balancer bolt.

3. Remove the crankshaft balancer.
MY
2008 ENGINE
OFF-VEHICLE REPAIR INSTRUCTIONS (CONT.)

ENGINE FLYWHEEL REMOVAL (AUTOMATIC TRANSMISSION)
Tools Required

Removal

1. Remove the flywheel mounting bolts and discard.

MY
2. Remove the flywheel washer.

3. Remove the J 44643 . See Special Tools .
4. Remove the flywheel assembly.
ENGINE FLYWHEEL REMOVAL (MANUAL TRANSMISSION)
Tools Required

Removal
MY

1. Install the J 44643 to the starter opening in order to hold the flywheel. See Special Tools .
Fig. 3: Accessing Flywheel To Crankshaft Bolts

IMPORTANT: Do not use the clutch pressure plate bolts. Use a bolt of the
correct thread and a length that protrudes enough to use a
pry bar.
2. Install two bolts into the clutch pressure plate mounting holes 180 degrees apart.
3. Using a long pry bar, turn the secondary ring of the dual mass flywheel clockwise until the
flywheel mounting bolts can be accessed. It may require to turn the secondary ring past the
bolt holes in order to compensate the spring tension.
MY
Fig. 4: View Of Flywheel & Mounting Bolts (Manual)

4. Remove the flywheel mounting bolts and discard.


6. Remove the flywheel.
CRANKSHAFT REAR OIL SEAL REMOVAL

MY
Tools Required
J 44641 Crankshaft Rear Oil Seal Remover. See Special Tools .

Removal
Fig. 5: Removing Crankshaft Rear Oil Seal Using J 44641

1. Install the J 44641 to the crankshaft rear oil seal. See Special Tools .
MY
2. Remove the crankshaft rear oil seal using J 44641 . See Special Tools .
EXHAUST OUTLET REMOVAL

1. Remove the exhaust outlet heat shield bolts.

2. Remove the exhaust outlet heat shield.
3. Remove the exhaust outlet to right exhaust pipe bracket bolt.
MY

4. Loosen the exhaust outlet holding clamp.
MY

5. Remove the exhaust outlet.
EXHAUST PIPE REMOVAL - LEFT SIDE
MY

1. Remove the left exhaust pipe heat shield bolts.

2. Remove the left exhaust pipe heat shield.
MY
Fig. 10: Left Exhaust Pipe Bolts Removal Sequence

3. Remove the exhaust pipe bolts in the proper sequence.
MY

4. Remove the exhaust pipe and gaskets.
EXHAUST PIPE REMOVAL - RIGHT SIDE
MY
Fig. 12: Exhaust Pipe Bolts Removal Sequence

1. Remove the exhaust pipe bolts in the proper sequence.
MY

2. Remove the exhaust pipe, exhaust outlet bracket and gaskets.
LOWER OIL PAN REMOVAL
Tools Required

Removal
MY

1. Disconnect the oil level sensor.
MY

2. Remove the lower oil pan bolts.
IMPORTANT: Do not damage the sealing surfaces when separating the

lower oil pan from the upper oil pan.
3. Separate the lower oil pan from the upper oil pan using J 37228 . See Special Tools .
4. Remove the lower oil pan.
UPPER OIL PAN REMOVAL
MY
Tools Required

Removal
Fig. 16: View Of Oil Level Indicator

1. Remove the oil level indicator tube bracket bolt.

MY
2. Remove the oil level indicator tube.

3. Remove the two oil pan to flywheel housing bolts.
MY

4. Remove the 24 upper oil pan bolts using a long bit 6 mm hex driver.
5. Seperate the upper oil pan from the engine block using J 37228 . See Special Tools .
6. Remove the upper oil pan.
ENGINE FLYWHEEL HOUSING REMOVAL
Tools Required

MY
Removal

1. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing.
2. Remove the turbocharger oil return pipe studs.
MY
Fig. 20: View Of Flywheel Housing

IMPORTANT: The upper oil pan must be removed before removing the
flywheel housing.
3. Remove the flywheel housing bolts.

4. Separate the flywheel housing from the cylinder block using J 37228 . See Special Tools .
5. Remove the flywheel housing.
MY

6. Remove the turbocharger oil return pipe gasket from the flywheel housing.
7. Remove the oil cooler adapter bolts.
8. Remove the oil cooler adapter with gaskets.
ENGINE MOUNTING TO STAND
MY
Fig. 22: Mounting Engine Block To Suitable Engine Stand

CAUTION: Do not mount the engine to a engine stand by the flywheel

housing. The aluminum flywheel housing is not designed to
support the weight of the engine when mounted to a typical
rear-mount engine stand. Mounting the engine stand to the
aluminum flywheel housing may result in engine damage and
serious personal injury.
After the flywheel housing has been removed, mount the engine block to a suitable engine stand.
MY
COOLING FAN PULLEY REMOVAL
Fig. 23: View Of Camshaft Position Sensor Electrical Connector

1. Disconnect the camshaft position sensor connector.
MY
Fig. 24: View Of Cooling Fan Pulley

2. Remove the cooling fan pulley bolts and nuts.

3. Remove the cooling fan pulley.
MY
Fig. 25: View Of Camshaft Position Sensor

4. Remove the camshaft position sensor retaining bolt.

5. Remove the camshaft position sensor.
POWER STEERING PUMP MOUNTING BRACKET REMOVAL
MY
Fig. 26: View Of A/C Compressor & Power Steering Pump Bracket
1. Remove the power steering pump mounting bracket bolts.

2. Remove the power steering pump mounting bracket.
FUEL FILTER ASSEMBLY REMOVAL
MY
Fig. 27: View Of Fuel Hoses At Fuel Filter

1. Remove the fuel hoses.
MY
Fig. 28: View Of Fuel Filter Assembly Connectors

2. Disconnect the fuel filter assembly connectors.
MY

MY
Fig. 30: Identifying Fuel Filter Assembly

4. Remove the fuel filter assembly.
DRIVE BELT TENSIONER AND GENERATOR MOUNTING BRACKET REMOVAL
MY
Fig. 31: View Of Electrical Harness Clip Bolts

1. Remove the electrical harness clip bolts.
MY

2. Remove the drive belt tensioner bolt.

3. Remove the drive belt tensioner.
MY

4. Remove the drive belt tensioner and generator mounting bracket bolts.
5. Remove the drive belt tensioner and generator mounting bracket.
ENGINE COOLANT THERMOSTAT HOUSING REMOVAL
MY
Fig. 34: View Of Main Engine Electrical Harness Connector Bolts

1. Remove the main engine electrical harness connector hold down bolts.
MY
Fig. 35: View Of Barometric Pressure Sensor Electrical Connector


3. Disconnect and remove the barometric sensor.
MY
Fig. 36: View Of Turbocharger Vane Position Sensor And Electrical Connector
4. Disconnect and remove the turbocharger vane position sensor.
MY
Fig. 37: View Of Main Electrical Connector Harness Bracket & Bolts
5. Remove the main electrical harness bracket bolts.

6. Remove the main electrical harness bracket.
MY
Fig. 38: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
7. Disconnect the turbocharger coolant inlet hose.
MY
Fig. 39: View Of Electrical Harness Bracket Bolt

8. Remove the electrical harness bracket bolt.

9. Remove the electrical harness bracket.
MY
Fig. 40: View Of Water Outlet Bolts

10. Remove the water outlet bolts.
MY
Fig. 41: View Of Water Outlet

11. Remove the water outlet.
MY
Fig. 42: View Of Oil Filler Tube Bolts

12. Remove the oil fill tube bolts.
MY

13. Remove the oil fill tube.
MY
Fig. 44: View Of Engine Coolant Temperature Sensor And Electrical Connector
14. Disconnect the coolant temperature sensor.
MY
Fig. 45: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
15. Remove the EGR coolant pipe bolts.

16. Remove the EGR coolant pipe.
MY
Fig. 46: View Of Water Pump Inlet Pipe Bolts

17. Remove the water pump inlet pipe bolts.
MY
Fig. 47: View Of Turbocharger Coolant Outlet Hose & Clamps

18. Remove the turbocharger coolant outlet hose and clamps.
MY
Fig. 48: View Of Water Pump Inlet Pipe

19. Remove the water pump inlet pipe.
MY
Fig. 49: View Of Fuel Pipe Bracket Bolt

20. Remove the fuel pipe bracket bolt.
MY
Fig. 50: View Of Thermostat Housing

21. Remove the thermostat housing bolts.

22. Remove the thermostat housing.
ENGINE WIRING HARNESS ASSEMBLY REMOVAL
MY
Fig. 51: View Of Left Glow Plug Harness Bracket Bolts

1. Remove the left glow plug harness bracket bolts.
MY
Fig. 52: View Of Right Glow Plug Harness Bracket Bolts

2. Remove the right glow plug harness bracket bolts.
MY

3. Disconnect the positive crankcase ventilation (PCV) hose clamp.
MY

4. Remove the right PCV pipe bolt.
MY

5. Remove the left PCV pipe bolt.
MY
Fig. 56: View Of PCV Pipe

6. Remove the PCV pipe.
MY
Fig. 57: Identifying EGR Valve Electrical Connector

7. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
MY
Fig. 58: Identifying Ground Bolt On Engine Block

8. Remove the ground bolt.
MY

9. Disconnect the crankshaft postion sensor electrical connector.
MY
Fig. 60: View Of Fuel Pressure Control Valve Electrical Connector

10. Disconnect the fuel pressure control valve electrical connector.
MY
Fig. 61: View Of Oil Level Sensor Electrical Harness Connector

11. Disconnect the oil level sensor electrical harness connector.
MY
Fig. 62: View Of Fuel Temperature Sensor Electrical Connector

12. Disconnect the fuel temperature sensor connector.
MY
Fig. 63: Identifying Glow Plug Controller

13. Disconnect the glow plug controller electrical connector.
MY
Fig. 64: View Of Turbocharger Vane Position Sensor

14. Disconnect and remove the turbocharger vane positon sensor.
MY
Fig. 65: View Of Fuel Injector Electrical Connectors

NOTE: Label all the injector electrical connectors before the

connectors are removed in order to prevent reconnecting to the
wrong injector. Failure to properly connect the injectors in the
correct sequence will cause severe engine damage.
15. Disconnect the fuel injector electrical connections.
MY
Fig. 66: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
16. Disconnect the turbocharger vane control solenoid valve.
MY
Fig. 67: View Of Fuel Rail Pressure Sensor And Electrical Connector
17. Disconnect the fuel rail pressure sensor.
MY

18. Disconnect the oil pressure sensor electrical connector.
MY
Fig. 69: View Of Oil Level Sensor Harness Bolt

19. Remove the oil level sensor harness bolt.
MY
Fig. 70: Identifying glow Plug Controller Bolts

20. Remove the glow plug controller bolts.

21. Remove the glow plug controller.
22. Remove the glow plug controller shield bolts.
23. Remove the glow plug controller shield.
MY
Fig. 71: Glow Plug Controller Bracket Bolt

24. Remove the glow plug controller bracket bolts.
MY
Fig. 72: Identifying Glow Plug Controller Bracket

25. Remove the glow plug controller bracket.
MY
Fig. 73: View Of Left Glow Plugs

26. Remove the left glow plugs.
MY
Fig. 74: View Of Right Glow Plugs

27. Remove the right glow plugs.
MY
Fig. 75: View Of Fuel Injector Control Module Harness

28. Remove the engine wiring harness.
MY
Fig. 76: Identifying Engine Harness Bracket & Bolts

29. Remove the engine harness bracket bolts.

30. Remove the engine harness bracket.
EXHAUST GAS RECIRCULATION AND COOLER REMOVAL
MY
Fig. 77: Identifying Intake Pipe

1. Remove the intake pipe to air inlet tube bolts.

2. Remove the intake pipe.
3. Remove the intake heater.
MY
Fig. 78: View Of Air Inlet Tube Bolt And Nut

4. Remove the air inlet tube to intake manifold tube bolt and nut.
MY
Fig. 79: View Of Air Inlet Tube

5. Remove the air inlet tube nuts.

6. Remove the air inlet tube.
MY
Fig. 80: View Of EGR Cooler

7. Remove the rear EGR cooler bolts.
MY
Fig. 81: View Of EGR Mount Bolt

8. Remove the EGR mount bolt.
MY
Fig. 82: View Of EGR & Cooler

9. Remove the EGR and cooler.
MY
Fig. 83: Identifying EGR Cooler Bracket

10. Remove the EGR cooler bracket bolts.

11. Remove the EGR cooler bracket.
MY

12. Remove the intake manifold tube.
TURBOCHARGER REMOVAL
MY
Fig. 85: View Of Turbocharger Upper Heat Shield

1. Remove the turbocharger upper heat shield bolts.

2. Remove the turbocharger upper heat shield.
MY

3. Remove the eye bolt and washers from the oil supply hose at the top of the turbocharger.
MY

4. Loosen the hose clamp and remove the turbocharger cooling outlet hose.
MY

5. Remove the turbocharger mounting bolts.

6. Remove the turbocharger assembly with the oil return pipe.
MY
7. Remove the turbocharger lower heat shield from engine block.
MY
8. Remove the turbocharger oil supply hose eye bolt and washers.
9. Remove the turbocharger oil supply hose.
FUEL PIPES AND FUEL RAIL REMOVAL
Fig. 90: View Of Fuel Feed Pipe & Bolts

1. Remove the fuel feed pipe attaching nuts and bolts.

2. Remove the fuel feed pipe.
MY
Fig. 91: View Of Fuel Rail Balance Pipe & Bolts

3. Disconnect the fuel rail balance pipe from fuel rails.

4. Remove the fuel rail balance pipe bolts.
5. Remove the fuel rail balance pipe.
MY
Fig. 92: View Of Fuel Return Hose & Injectors

6. Remove the left fuel return hose.
MY
Fig. 93: View Of Right Fuel Return Hose & Injectors

7. Remove the right fuel return hose.
MY
Fig. 94: View Of Fuel Hose Connections

8. Disconnect the fuel hoses from the fuel injector pump.
MY
Fig. 95: View Of Distribution Block, Fuel Line Assembly & Bolts
9. Remove the distribution block and fuel line assembly bolts.

10. Remove the distribution block and fuel line assembly.
MY
Fig. 96: View Of Fuel Pipe Assembly Bracket

11. Remove the fuel pipe assembly bracket bolts.

12. Remove the fuel pipe assembly bracket.
MY
Fig. 97: View Of Coolant Pipe

13. Remove the coolant pipe bolt and nut.

14. Remove the coolant pipe.
MY
Fig. 98: View Of Left Fuel Rail At Pump Pipe

15. Remove the left fuel rail to pump pipe.
MY
Fig. 99: Identifying EGR Mounting Bracket & Bolts

16. Remove the EGR mounting bracket bolt and nut.

17. Remove the EGR mounting bracket.
MY
Fig. 100: View Of Fuel Injector Line Fittings

18. Using compressed air to blow away any debris between the fuel injector line and the fittings
(1, 2). Wipe clean the fittings (1) of debris.
the fuel injector.
MY
19. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and
fitting (1, 2) to contain any debris during removal.

20. Remove the left fuel injector pipes.
MY

21. Remove the right fuel injector pipes.
MY
Fig. 103: View Of Left Fuel Rail And Bracket

22. Remove the left fuel rail and bracket bolts.

23. Remove the left fuel rail and bracket.
MY
Fig. 104: View Of Right Fuel Rail

24. Remove the right fuel rail bolts.

25. Remove the right fuel rail.
FUEL INJECTORS REMOVAL
Tools Required
J-46594 Fuel Injector Remover

Removal
MY
Fig. 105: View Of Left Fuel Injector Bracket Bolts

1. Remove the left fuel injector bracket bolts.
MY
Fig. 106: View Of Right Fuel Injector Bracket Bolts

2. Remove the right fuel injector bracket bolts.
MY
Fig. 107: View Of Left Fuel Injectors W/Brackets

3. Install the J-46594 into the fuel injector brackets.

4. Pull back on J-46594 in one steady motion, until the fuel injector breaks free from its seat.
5. Remove the J-46594 .
6. Remove the left fuel injectors with brackets.
MY
Fig. 108: View Of Right Fuel Injectors W/Brackets

7. Remove the right fuel injectors with brackets.
MY
Fig. 109: View Of Left Injector Bracket Pins

8. Remove the left injector bracket pins.
MY
Fig. 110: Identifying Fuel Injector Copper Washers

9. Remove the right injector bracket pins.

10. Remove the copper washer from the injector bore and discard.
11. Remove the O-ring from the injector and discard.
VALVE ROCKER ARM COVER REMOVAL - UPPER LEFT SIDE
MY
1. Remove the left upper valve rocker arm cover bolts.

2. Remove the left upper valve rocker arm cover.
VALVE ROCKER ARM COVER REMOVAL - UPPER RIGHT SIDE
MY
1. Remove the right upper valve rocker arm cover bolts.

2. Remove the right upper valve rocker arm cover.
VALVE ROCKER ARM COVER REMOVAL - LOWER LEFT SIDE
MY

1. Remove the left lower valve rocker arm cover bolts.

2. Remove the left lower valve rocker arm cover.
VALVE ROCKER ARM COVER REMOVAL - LOWER RIGHT SIDE
MY

1. Remove the right lower valve rocker arm cover bolts.

INTAKE MANIFOLD CROSSOVER REMOVAL

MY

1. Remove the intake manifold crossover bolts and nuts.

2. Remove the intake manifold crossover.
INTAKE MANIFOLD REMOVAL - RIGHT SIDE
Tools Required

Removal
MY

1. Remove the right intake manifold bolts. Do not forget to remove the bolt inside the intake
manifold tube.
2. Separate the intake manifold from the cylinder head using J 37228 . See Special Tools .
3. Remove the right intake manifold.
INTAKE MANIFOLD REMOVAL - LEFT SIDE
Tools Required
MY
Removal
Fig. 117: View Of Intake Manifold (Left)

1. Remove the left intake manifold bolts. Do not forget to remove the bolt inside the intake
manifold tube.
2. Separate the intake manifold from the cylinder head using J 37228 . See Special Tools .
3. Remove the left intake manifold.
VALVE ROCKER ARM, SHAFT, AND PUSH ROD REMOVAL
MY
Fig. 118: View Of Valve Clearance Adjusting Screw

1. Loosen the valve clearance lock nuts on each rocker arm.

2. Loosen the valve clearance adjusting screw on each rocker arm to relieve tension on the
valve train.
MY
Fig. 119: Rocker Arm Shaft Bolts Loosening Sequence

3. Remove the rocker arm shaft assembly bolts in the proper sequence.
4. Remove the rocker arm shaft assembly from the cylinder head.
MY
5. Remove the valve bridge pins.

6. Remove the valve bridges.
7. Remove the pushrods.
EXHAUST MANIFOLD REMOVAL - LEFT SIDE
MY
Fig. 121: View Of Exhaust Manifold Heat Shield (Left)

1. Remove the exhaust manifold heat shield bolts.

2. Remove the exhaust manifold heat shield.
MY
Fig. 122: Left Exhaust Manifold Bolts & Nuts Removal & Installation Sequence
3. Remove the left exhaust manifold bolts and nuts in the proper sequence.
MY
Fig. 123: View Of Left Exhaust Manifold & Gasket

4. Remove the left exhaust manifold and gasket.
EXHAUST MANIFOLD REMOVAL - RIGHT SIDE

MY
Fig. 124: View Of Exhaust Manifold Heat Shield (Right)

1. Remove the exhaust manifold heat shield bolts.

2. Remove the exhaust manifold heat shield.
MY
Fig. 125: Right Exhaust Manifold Bolts And Nuts Removal & Installation Sequence
3. Remove the right exhaust manifold bolts and nuts in the proper sequence.
MY
Fig. 126: View Of Right Exhaust Manifold & Gasket

4. Remove the right exhaust manifold and gasket.
CYLINDER HEAD REMOVAL - LEFT SIDE
MY

1. Remove the cylinder head bolts in the proper sequence.

MY

3. Remove the left cylinder head assembly.

4. Remove the left cylinder head gasket.
CYLINDER HEAD REMOVAL - RIGHT SIDE
MY

1. Remove the cylinder head bolts in the proper sequence.

MY

3. Remove the right cylinder head assembly.

4. Remove the right cylinder head gasket.
VALVE LIFTER REMOVAL
MY

1. Loosen the valve lifter guide hold down bracket bolts.

2. Remove the valve lifter guide hold down brackets.
3. Remove the valve lifter guides.
4. Remove the valve lifters.
FUEL INJECTION PUMP REMOVAL
MY
Fig. 132: Locating Camshaft Gear Access Cover

1. Remove the camshaft gear access hole cover bolt.

2. Remove the camshaft gear access hole cover.
MY
Fig. 133: Aligning Camshaft Gear Tension Relief Hole

3. Rotate the crankshaft until the camshaft gear tension relief hole is in line with the front
cover access hole.
MY
Fig. 134: Unloading Spring Tension From Two Piece Cam Gear
4. Use a suitable tool to unload the spring tension from the two piece cam gear. Apply pressure
towards the right side of the engine while removing the injection pump.
MY
Fig. 135: View Of Fuel Injection Pump

5. Remove the four fuel injection pump bolts.

6. Remove the fuel injection pump.
WATER PUMP REMOVAL
MY

1. Remove the engine coolant pipe to water pump nuts.
MY
Fig. 137: View Of Engine Coolant Pipe & Gasket

2. Remove the water pump bolts.

3. Remove the water pump assembly.
4. Remove the water pump seal and discard.
5. Remove the engine coolant pipe gasket and discard.
OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY REMOVAL
MY

1. Remove the engine coolant pipe.

2. Remove the engine coolant pipe O-ring and discard.
MY

3. Remove the five oil filter adapter and oil cooler assembly bolts.
4. Remove the oil filter adapter and oil cooler assembly.
CRANKSHAFT FRONT OIL SEAL REMOVAL
Tools Required
J 44644 Crankshaft Front Oil Seal Remover. See Special Tools .

Removal
MY
Fig. 140: Removing Crankshaft Front Oil Seal Using J 44644

1. Install the J 44644 to the crankshaft front oil seal. See Special Tools .
2. Remove crankshaft front oil seal using J 44644 . See Special Tools .
ENGINE FRONT COVER REMOVAL
Tools Required

Removal
MY

1. Remove the crankshaft position sensor bolt.

2. Remove the crankshaft position sensor.
MY

3. Remove the engine front cover bolts.

4. Separate the engine front cover from the cylinder block using J 37228 . See Special Tools .
5. Remove the engine front cover.
OIL PUMP SUCTION PIPE AND SCREEN ASSEMBLY REMOVAL
MY
Fig. 143: View Of Oil Pump Pipe, Screen Assembly & Gasket
1. Remove the oil pump pipe and screen assembly bolts and nuts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly gasket and discard.
PISTON OIL COOLING NOZZLE REMOVAL
MY
Fig. 144: View Of Piston Oil Cooling Nozzle

1. Rotate crankshaft as necessary to obtain access to piston oil cooling nozzles.

2. Remove the piston oil cooling nozzle eye bolt.
3. Remove the piston oil cooling nozzle.
PISTON, CONNECTING ROD, AND BEARING REMOVAL
Tools Required
MY
J 24270 Ridge Reamer

Removal
Fig. 145: Removing Cylinder Bore Ring Ridge

1. Rotate the crankshaft to place the piston at the bottom of the piston stroke.
2. Place a cloth on top of the piston.
3. Use the J 24270 to remove the ridge at the top of the cylinder bore.
4. Remove cloth.
5. Remove cutting debris from the cylinder and piston.
MY
Fig. 146: View Of Connecting Rod Cap & Bearing Insert

6. Remove the connecting rod cap bolts. Set the bolts aside for use in plastic gauging if
needed. New bolts will be used for final assembly.
7. Remove the connecting rod cap.
8. Remove the bearing insert from connecting rod.
MY
Fig. 147: View Of Piston Assembly

9. Push piston assembly out of cylinder.

10. Reassemble the connecting rod bearing, cap, and bolts upon removal.
CAMSHAFT REMOVAL
Tools Required
J 7872 Dial Indicator Set

Removal
MY
Fig. 148: Measuring Camshaft End Play Using J 7872

1. Measure the camshaft end play using J 7872 .

mm (0.008 in).
Replace the camshaft or the camshaft thrust plate if the measured value exceeds the
service limit.
MY

2. Block the crankshaft from turning with a wooden handle.

3. Loosen the camshaft gear bolt and leave the bolt finger tight.
MY
Fig. 150: View Of Camshaft Exciter Ring, Bolts & Thrust Plate Bolts
4. Remove the camshaft exciter ring bolts.
IMPORTANT: The two piece cam gear must be bolted together to prevent
the spring tension from unloading upon removal.
5. Remove the camshaft exciter ring.
MY
Fig. 151: Using Exciter Ring Bolt To Secure Spring Tension

6. Align the threaded hole with a suitable tool and install an exciter ring bolt to secure the
spring tension.
7. Remove the camshaft thrust plate bolts through the holes in the camshaft gear.
MY
Fig. 152: View Of Camshaft With Camshaft Gear Attached

8. Remove the camshaft with the camshaft gear attached.
MY
9. Remove the camshaft gear bolt and washer.

10. Remove the camshaft gear.
11. Remove the camshaft thrust plate.
CRANKSHAFT AND BEARING REMOVAL
Tools Required

Removal
MY

1. Remove the oil pressure sensor.
MY
Fig. 155: Measuring Crankshaft End Play Using J 7872

2. Measure crankshaft end play using J 7872 . The production value is 0.04-0.205 mm
(0.0016-0.0081 in) and the service limit is 0.54 mm (0.0213 in). Replace the thrust bearings
upon reassembly if the measured value exceeds the service limit.
MY
Fig. 156: View Of Crankshaft Bearing Cap Side Bolts

3. Remove the crankshaft bearing cap side bolts.
MY
Fig. 157: View Of Crankshaft Bearing Cap & Bolts

4. Remove the crankshaft bearing cap bolts.

5. Remove the crankshaft bearing caps.
MY
6. Set the bolts aside for use in plastic gauging if needed.

7. Remove the crankshaft assembly.
8. Remove the crankshaft bearings from the engine block and the bearing caps.
9. Mark crankshaft bearings and caps so they may be installed in their original position.
ENGINE BLOCK CLEANING AND INSPECTION
IMPORTANT: All remanufactured cylinder blocks are steel stamped on both

sides of the fuel pressure pump boss. The stamp indicates
whether the cylinder is standard or over-bored, and if the deck is
standard or has been milled.
Stamped ID Cylinders Bore Size (in.) Top Deck (STD or Milled)

SS STD STD
01S 0.010 STD
02S 0.020 STD
03S 0.030 STD
SM STD Milled
01M 0.010 Milled
02M 0.020 Milled
03M 0.030 Milled
MY
Fig. 158: Stampings

IMPORTANT: If the block has no stampings, the block has a standard bore
and deck.
1. Inspect the block for stampings (1) indicating cylinder overbore or a milled deck.
MY
Fig. 159: View Of Engine Block Heater

2. Remove the engine block heater.

3. Remove the O-ring from the block heater and discard.
MY
Fig. 160: View Of Oil Gallery Plug

4. Remove the oil gallery plugs.
MY
Fig. 161: View Of Left Engine Mount & Bolts

5. Remove the left engine mount bolts.

6. Remove the left engine mount.
MY
Fig. 162: View Of Right Engine Mount & Bolts

7. Remove the right engine mount bolts.

8. Remove the right engine mount.
9. Clean the sealing material from the gasket mating surfaces of the block.
10. Clean the block in cleaning solvent.
11. Flush the engine block with clean water or steam.
12. Clean the oil passages.
13. Clean the cylinder bores.
MY
14. Inspect the block for cracks. Use the Magnaflux Spot check dye method, or the equivalent.
Inspect the cylinder walls.
Inspect the coolant jackets.
Inspect the crankshaft bearing webs.
Fig. 163: View Of Crankshaft Bearing Bores & Caps

15. Inspect the crankshaft bearing bores and caps. The crankshaft bearing bore inside diameters
should be round and uniform at all of the bearing supports.
MY
16. Inspect the area where the crankshaft bearing inserts contact the crankshaft bearing bore.
This area must be free of burrs and scratches.
17. Inspect the engine mount bosses.
18. Inspect the cylinder head gasket mating surfaces for pitting.
Fig. 164: Measuring Engine Block To Cylinder Head Gasket Surface Area
19. Inspect the engine block to cylinder head gasket surface area for warping. Use a straight
edge and feeler gauge. Replace the block if it is warped more than 0.15 mm (0.006 in)
longitudinally or more than 0.08 mm (0.003 in) transversely.
MY
20. Apply sealer to the oil gallery plugs.
Fig. 165: View Of Oil Gallery Plug

21. Install the oil gallery plugs.
Tighten: Tighten the oil gallery plugs to 53 N.m (39 lb ft).
MY
Fig. 166: View Of Left Engine Block Coolant Plugs

22. Install the left engine block coolant plugs.
Tighten: Tighten the left engine block coolant plugs to 18 N.m (13 lb ft).
MY
Fig. 167: View Of Right Engine Block Coolant Plugs

23. Install the right engine block coolant plugs.
Tighten: Tighten the right engine block coolant plugs to 18 N.m (13 lb ft).
MY
Fig. 168: View Of Left Engine Mount & Bolts

24. Install the left engine mount and engine mount bolts.
MY
Fig. 169: View Of Right Engine Mount & Bolts

25. Install the right engine mount and engine mount bolts.
Tighten: Tighten the right engine mount bolts to 58 N.m (43 lb ft).
MY
Fig. 170: View Of Engine Block Heater

26. Install a new O-ring to the block heater.

27. Lubricate the O-ring with engine coolant.
28. Install the engine block heater.
UPPER OIL PAN CLEANING AND INSPECTION
MY

1. Clean the upper oil pan.

2. Carefully clean the sealer from the threaded holes.
3. Inspect the upper oil pan for cracks.
4. Inspect the upper oil pan sealing surfaces for damage.
5. Replace the upper oil pan if any damage is found.
CAMSHAFT AND BEARINGS CLEANING AND INSPECTION
Tools Required

Inspection
MY
Fig. 172: View Of Camshaft Inspection Areas

1. Clean the camshaft.
IMPORTANT: The camshaft bearings are not serviceable. If the camshaft

bearings are damaged, the engine must be replaced.
2. Visually inspect the camshaft bearings in the engine block for the following conditions:
Scoring
Nicks
Damage caused by lack of lubrication
Misaligned oil feed holes
MY
Fig. 173: Measuring Camshaft Journal Diameter

3. Measure the camshaft journal diameter.

The production value is 60.932-60.962 mm (2.3990-2.4001 in) and service limit is
60.920 mm (2.3984 in).
Replace the camshaft if the measured value is less than service limit.
MY
Fig. 174: Measuring Camshaft Lobe Lift

4. Measure the camshaft lobe lift. The production value for intake is 7.273 mm (0.2863 in).
5. The production value for exhaust is 5.907 mm (0.2326 in).
6. Replace the camshaft if the measured value is less than the service limit.
MY
Fig. 175: Measuring Camshaft Runout

7. Measure the camshaft runout.

Mount the camshaft on the V-blocks.
Use J 7872 to measure the camshaft runout.
The runout service limit is 0.05 mm (0.0020 in).
8. Replace the camshaft if the run-out is over the service limit.
CRANKSHAFT AND BEARING CLEANING AND INSPECTION
MY
Special Tools

J 45059 Angle Meter
Inspection
Fig. 176: Measuring Crankshaft Run Out

1. Clean the crankshaft and bearings.

2. Inspect the crankshaft for the following conditions.
Excessive wear or damage on the surface of the crankshaft journals.
MY
Excessive wear or damage to the crankshaft gear.

Excessive wear or damage on the oil seal fitting surface.
Inspect the oil ports for obstructions.
Replace the crankshaft if there is excessive wear or damage to the journals, oil seal
fitting surface or to the crankshaft gear.
3. Measure the crankshaft run out.
Mount the crankshaft in wooden V-blocks.
Set J 7872 on the center of the crankshaft journal.
Turn the crankshaft in the normal direction of rotation.
Record readings. The production value is 0.05 mm (0.0020 in) and the service limit is
0.44 mm (0.0173 in).
Fig. 177: Measuring Crankshaft Journal Diameter

MY
4. Measure the crankshaft journal diameter across four points.

The crankshaft journal outside diameter is 79.905-79.925 mm (3.1459-3.1466 in) and
the service limit is 79.89 mm (3.1453 in).
Replace the crankshaft if the measured value is less than the service limit.
5. Measure the crankpin outside diameter across four points.

The crankpin outside diameter is 62.902-62.922 mm (2.4765-2.4772 in) and the
service limit is 62.88 mm (2.4756 in).
Replace the crankshaft if the measured value is less than the service limit.
Crankshaft Bearing Selection
There are two methods for selecting the proper size crankshaft bearings. The first one is to select
the bearing grade (color code) based on the cylinder block grade and the crankshaft journal grade
from the Crankshaft Bearing Grade chart. The second is the plastic gauge method.
Crankshaft Bearing Selection Grade Chart Method
Stamp ID Main Journal Conn. Rod Journal

No Stamp STD STD
M20 R20 0.020 in 0.020 in
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Fig. 178: Locating Crankshaft Stamping Marks (Undersized Main or Rod Journals)
IMPORTANT: All crankshafts that have been machined have a steel

stamping (1) on the 1st counterweight.
1. Inspect the crankshaft for stamping (1) indicating undersized main and/or rod journals.
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Fig. 179: View Of Cylinder Block Grade

2. The cylinder block grade is indicated on the right lower portion of the cylinder block.
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Fig. 180: View of Crankshaft Journal Grade

3. The crankshaft journal grade is indicated on the number 1 crankshaft counterweight.

4. Match the cylinder block grade and the crankshaft journal grade, refer to Crankshaft
Bearing Selection Specifications .
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5. From the Crankshaft Bearing Grade chart, determine which bearing grade (color code) is
required.
6. Verify the crankshaft bearing clearance using the plastic gage method.
Crankshaft Bearing Selection Plastic Gage Method
Special Tools
J 45059 Angle Meter
Fig. 181: View Of Crankshaft Upper & Lower Bearings

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1. Clean the cylinder block bearing fitting surfaces.

2. Clean the crankshaft and upper bearings (1) and lower bearings (2).
3. Install the bearings into the cylinder block and the bearing caps.
Fig. 182: View Of Crankshaft & Cylinder Block

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4. Install the crankshaft into the cylinder block.

5. Rotate the crankshaft approximately 30 degrees to seat the bearings.
Fig. 183: Installing Gaging Plastic

IMPORTANT: Do not allow the crankshaft to rotate at any time during

bearing cap installation and tightening or the plastic gauge
measurement will be inaccurate.
6. Place the plastic gage over the crankshaft journal across the full width of the bearing.
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Fig. 184: View Of Crankshaft Bearing Caps

7. Install the crankshaft bearing caps.
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Fig. 185: Crankshaft Bearing Cap Bolts Tightening Sequence

8. Install the crankshaft bearing cap bolts.

9. Tighten the crankshaft bearing cap bolts in the proper sequence.
Tighten:
1st step 98 N.m (72 lb ft).
2nd step 132 N.m (97 lb ft).
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3rd step 30 degrees using J 45059 .
Fig. 186: Crankshaft Bearing Cap Side Bolts Tightening Sequence

10. Install the crankshaft bearing cap side bolts.
Tighten: Tighten the crankshaft bearing cap side bolts in the proper sequence to 70 N.m
(52 lb ft).
11. Remove the crankshaft bearing cap bolts.

12. Remove the crankshaft bearing caps.
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Fig. 187: Measuring Compressed Width

13. Compare the width of the plastic gauge with the scale printed on the plastic gauge container.
14. Select the crankshaft bearing grade that provides the proper oil clearances. The production
specification for crankshaft bearing clearance is 0.039-0.070 mm (0.0015-0.0028 in) and
the service limit is 0.014 mm (0.0055 in).
CRANKSHAFT BALANCER CLEANING AND INSPECTION
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Fig. 188: View Of Crankshaft Balancer Inspection Area

1. Clean the crankshaft balancer.

2. Inspect the crankshaft balancer for damage to belt drive surface and to crankshaft balancer
hub.
3. Inspect the balancer hub groove for damage or wear.
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4. Replace the crankshaft balancer if any concerns exist.
ENGINE FLYWHEEL CLEANING AND INSPECTION
Fig. 189: View Of Engine Flywheel Inspection Areas

IMPORTANT: In order to maintain the proper component balance, contact

surface taper, and heat transfer, manual transmission
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flywheels are NOT to be machined.
1. Clean the flywheel assembly.

2. Inspect the flywheel assembly for cracks or excessive wear on the teeth.
3. Replace the flywheel assembly if any concerns exist.
PISTON AND CONNECTING ROD DISASSEMBLE
Tools Required
J 43654 Piston Pin Retainer Remover/Installer. See Special Tools .

Disassemble
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Fig. 190: Marking Orientation Of Piston To Connecting Rod

1. Mark orientation of the piston to the connecting rod.
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Fig. 191: View Of Piston Rings & Piston Expander

2. Remove the piston rings using a piston ring expander.
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Fig. 192: View Of Connecting Rod Bearing Inserts

3. Remove the connecting rod bearing inserts.
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Fig. 193: View Of Piston Pin Retaining Clips

4. Use J 43654 to remove the piston pin retainers. See Special Tools .
5. Remove the piston pin. The pin is a full-floating style and should slide from the piston.
6. Remove the piston from the connecting rod.
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2008 ENGINE

PISTON, CONNECTING ROD, AND BEARING CLEANING AND INSPECTION
Fig. 1: View of Connecting Rod, Bearing, Piston & Piston Pin

1. Clean the deposits from the following components:

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Connecting rod and bearings

Piston
Piston pin
Fig. 2: Identifying Piston Damage Inspection Areas

2. Inspect the piston for the following conditions:

Scoring on the piston skirt (2)
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Scoring in the piston pin area (3)

Cracks (1)
Broken ring groove lands
Fig. 3: Measuring Piston Ring End Gap

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3. Measure the piston ring end gap.

Use a piston to square the piston ring near the top of the cylinder.
Use a feeler gauge to measure the piston ring gap.
The 1st compression ring production gap is 0.30-0.45 mm (0.0118-0.0177 in) and the
The 2nd compression ring production gap is 0.50-0.65 mm (0.0197-0.0256 in) and the
The oil ring production gap is 0.15-0.35 mm (0.0059-0.0138 in) and the service limit
is 1.20 mm (0.0472 in).
Replace the piston ring if the measured value exceeds the service limit.
Fig. 4: Measuring Piston Ring Side Clearance

4. Measure the piston ring to piston ring groove clearance.
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Use a feeler gauge to measure the clearance between the piston ring and the piston ring
groove at several points around the piston.
The 1st compression ring production clearance is 0.08-0.17 mm (0.0030-0.0007 in)
and the service limit is 0.26 mm (0.0102 in).
The 2nd compression ring production clearance is 0.01-0.03 mm (0.0004-0.0012 in)
and the service limit is 0.10 mm (0.0039 in).
The oil ring production clearance is 0.01-0.03 mm (0.0004-0.0012 in) and the service
limit is 0.12 mm (0.0047 in).
Replace the piston ring if the measured value exceeds the service limit.
Fig. 5: Measuring Piston Pin Diameter

5. Measure the piston pin outside diameter.
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Measure the piston pin outside diameter at several points.

The production value is 34.495-34.50 mm (1.3581-1.3563 in) and the service limit is
34.450 mm (1.3563 in).
Replace the piston pin if the measured value is less than the service limit.
Fig. 6: Measuring Piston Pin Bore

6. Measure the piston pin to piston pin bore clearance.

Measure the piston pin bore.
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Subtract the piston pin measurement that was taken previously from the piston pin bore
measurement. The difference between these two measurements will be the piston pin to
piston pin bore clearance.
The production clearance is 0.004-0.017 mm (0.0002-0.0007 in) and the service limit
is 0.017 mm (0.0007 in).
If the piston pin to piston pin bore clearance is beyond specifications then replace the
piston.
Fig. 7: Measuring Piston Pin To Connecting Rod Small End Clearance

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7. Measure the piston pin to connecting rod small end clearance.

Measure the inside diameter of the connecting rod small end.
Subtract the piston pin measurement that was taken previously from the connecting rod
small end measurement. The difference between these two measurements will be the
piston pin to connecting rod clearance.
The production clearance is 0.012-0.027 mm (0.0005-0.0011 in) and the service limit
is 0.08 mm (0.0031 in).
Replace the connecting rod if the piston pin to connecting rod small end clearance is
beyond specifications. The connecting rod small end bushing is not serviceable.
PISTON AND CONNECTING ROD ASSEMBLE
Tools Required
J 43654 Piston Pin Retainer Remover/Installer. See Special Tools .

Assemble
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Fig. 8: View Of Piston Pin Retaining Clips

1. Apply engine oil to the connecting rod small end bushing and to the piston pin bore of the
piston.
2. Install the piston pin into the piston and connecting rod.
IMPORTANT: For the right bank piston and connecting rod

assemblies, reassemble so the grade mark on the
connecting rod faces the right side of the engine and the
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piston front mark faces the front of the engine.

For the left bank piston and connecting rod assemblies,
reassemble so the grade mark on the connecting rod
faces the left side of the engine and the piston front
mark faces the front of the engine.
3. Install the piston pin retaining rings.
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Fig. 9: View Of Piston Rings & Piston Expander

4. Apply engine oil to the piston ring grooves.

5. Install the piston rings using a piston ring expander.
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Fig. 10: Aligning Piston Ring End Gaps

IMPORTANT: The 2N mark on the 2nd compression ring must face

upwards. The piston has a groove between the 1st and the
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2nd compression rings to allow for expansion of blowby

gases. No ring is to be installed in this groove.
6. Orientate the piston ring end gaps as illustrated.
CYLINDER HEAD DISASSEMBLE
Tools Required
J 8062 Valve Spring Compressor
J 38820 Valve Stem Oil Seal Remover. See Special Tools .

Disassemble
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1. Use the J 8062 to compress the valve spring.
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2. Remove the valve keys (1).

3. Remove the J 8062 from the cylinder head.
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4. Remove the valve spring upper seat (2).

5. Remove the valve spring (3).
6. Remove the valve (6).
7. Remove the valve stem seal (4) using J 38820 . See Special Tools .
8. Remove the valve spring lower seat (5).
CYLINDER HEAD CLEANING AND INSPECTION
Tools Required
J 9666 Valve Spring Tester

EN-47909 Injector Bore and Sleeve Cleaning Kit
Inspection
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Fig. 13: Measuring Cylinder Head For Warpage

1. Clean the cylinder head of all foreign material. Do not use a motorized wire brush on any
gasket sealing surface.
2. Clean the threaded holes.
3. Clean the injector bores using EN-47909 .
4. Inspect the cylinder head for the following:
Damage to the gasket surfaces
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Damage to the threaded bolt holes

Cracks in the exhaust ports
External cracks in the water chamber
Cracks between the valve seats
Restrictions in the intake or exhaust passages
Restrictions in the cooling system passages
Rusted, damaged or leaking core plugs
5. Measure the cylinder head for warpage with a straight edge and a feeler gauge. A cylinder
head block deck with warpage in excess of 0.075 mm (0.0030 in) within a 516.5 mm (20.33
in) area must be replaced.
Fig. 14: Measuring Cylinder Head Exhaust Manifold Deck For Warpage
6. Measure the cylinder head exhaust manifold deck for warpage. A cylinder head exhaust
manifold deck with warpage in excess of 0.1 mm (0.0039 in) within a 453 mm (17.83 in)
area must be replaced.
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Fig. 15: Measuring Cylinder Head Intake Manifold Deck For Warpage
7. Measure the cylinder head intake manifold deck for warpage. A cylinder head intake
manifold deck with warpage in excess of 0.3 mm (0.011 in) within a 493 mm (19.41 in)
area must be replaced.
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Fig. 16: Measuring Valve Spring Tension Using J 9666

8. Measure the valve spring tension using J 9666 . Replace the valve spring if the valve spring
tension is less than 315.5 N (7.09 lb) at 41 mm (1.6142 in)
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Fig. 17: Measuring Valve Spring For Squareness

9. Measure the valve spring for squareness. Replace the valve spring if squareness is beyond
2.0 mm (0.0787 in).
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Fig. 18: Measuring Valve Spring Free Length

10. Measure the valve spring free length. The production free length is 56.6 mm (2.2283 in).
11. Measure the valve stem to guide clearance.
1. Set a dial indicator to the valve stem measuring point.
2. Move the valve stem from side to side while reading the total movement on the dial
indicator. If the measured valve exceeds 0.20 mm (0.0079 in), replace the cylinder
head.
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Fig. 19: Measuring Valve Stem To Guide Clearance

12. If the valve stem to guide clearance is over 0.25 mm (0.098 in) for the exhaust valve guides
or 0.20 mm (0.0079 in) for the intake valve guides, the cylinder head must be replaced.
13. Inspect the valves for the following:
Bent valve stem
Scored valve stem
Worn valve key grooves
Pitted surfaces
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Fig. 20: Measuring Valve Margin

14. Measure the valve margin. The intake valve production margin is 1.2 mm (0.0472 in) and
the service limit is 0.88 mm (0.0346 in). The exhaust valve production margin is 1.0 mm
(0.0394 in) and the service limit is 0.73 mm (0.0287 in). Replace the valve if the valve
margin is below the service limit.
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Fig. 21: Measuring Valve Depression

15. Measure the valve depression.

1. Insert a new valve into the cylinder head (1).
2. Use a depth gage or a straight edge to measure the valve depression from the cylinder
head gasket surface (2). The intake valve depression is 0.6 mm (0.0236 in) and the
service limit is 2.5 mm (0.0984 in). The exhaust valve depression is 0.9 mm (0.0354
in) and the service limit is 2.0 mm (0.0787 in). Recondition the valve seat if the valve
depression is above specifications.
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Fig. 22: Measuring Valve Contact Width

16. Measure the valve contact width.

Inspect the valve contact area for roughness or unevenness.
The intake valve contact width is 2.1 mm (0.0827 in) and the service limit is 2.5 mm
(0.0984 in).
The exhaust valve contact width is 2.1 mm (0.0827 in) and the service limit is 2.5 mm
(0.0984 in).
Recondition the valve seats to bring the contact width into specifications.
VALVE AND SEAT GRINDING
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Fig. 23: Grinding Valve

1. Remove the carbon from the valve guide and valve seat surface.
2. Resurface the valve face to 45 degrees. If valve margin falls below specifications after
resurfacing then discard valve.
3. Use a suitable tool to bring the valve contact width to the standard value. The valve seat
angle is 45 degrees.
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Fig. 24: Turning Valve Back & Forth

4. Apply valve lapping compound to the valve seat surface.

5. Insert the valve into the cylinder head.
6. Turn the valve back and forth in its seat to lap the valve face to the valve seat.
CYLINDER HEAD ASSEMBLE
Tools Required
J 44640 Valve Stem Seal Installer. See Special Tools .

J 8062 Valve Spring Compressor
Assemble
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Fig. 25: View Of Valves & Cylinder Head

IMPORTANT: Lubricate the valve stem with clean engine oil before
installing.
1. Install the valves into the cylinder head.

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2. Install the valve spring lower seat.
Fig. 26: Installing Valve Stem Using J 44640

3. Install the valve stem seal using J 44640 . See Special Tools .
4. Install the valve spring with the painted end towards the cylinder head.
5. Install the valve spring upper seat.
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6. Use the J 8062 to compress the valve spring.

7. Install the valve keys.
8. Remove the J 8062 from the cylinder head.
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Fig. 28: Measuring Valve Spring Installed Height

9. Measure the valve installed height using a ruler. Measure from the base of the valve spring
to the top of the valve. Refer to Engine Mechanical Specifications .
10. Install the remaining valves, springs, and other components.
VALVE LIFTERS CLEANING AND INSPECTION
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Fig. 29: View Of Distance Between Bottom Of Roller & Roller Lifter Body
1. Push the roller towards the roller lifter body and measure the distance between the bottom
of the roller and the roller lifter body. The production value is 0.989-1.0 mm (0.0389-
0.0394 in) and the service limit is 0.9 mm (0.0354 in).
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2. Replace the valve lifter if the measurement exceeds the service limit.
3. Inspect the valve lifters for the following:
The valve lifter body for scuffing and wear
The valve lifter roller assembly for wear
The valve lifter roller for smooth rotation
VALVE ROCKER ARM AND SHAFT CLEANING AND INSPECTION
Fig. 30: Measuring Rocker Arm Shaft Outside Diameter

1. Measure the rocker arm shaft outside diameter where the rocker arm is located. The
production value is 21.979-22.0 mm (0.8653-0.8661 in) and the service limit is 21.85 mm
(0.8602 in).
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2. Replace the rocker arm shaft if the measured value is less than the service limit.
Fig. 31: Measuring Rocker Arm Shaft Inside Diameter

3. Measure the rocker arm inside diameter. The production value is 22.01-22.035 mm (0.8665-
0.8675 in).
4. Calculate the rocker arm shaft to rocker arm clearance.
1. Subtract the rocker arm shaft outside diameter from the rocker arm inside diameter.
2. Replace the rocker arm if the rocker arm shaft to rocker arm clearance is over 0.2 mm
(0.0079 in).
5. Inspect the valve lash adjusting screw and lock nut for damage. Replace the valve lash
adjusting screw if any damage is found.
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Fig. 32: Measuring Pushrod For Warpage

6. Measure the pushrods for warpage.

7. Replace the pushrod if the warpage exceeds 0.8 mm (0.031 in).
PISTON OIL COOLING NOZZLE CLEANING AND INSPECTION
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Fig. 33: View Of Piston Oil Cooling Nozzle Inspection Areas

1. Inspect the piston oil cooling nozzle for damage.

2. Replace the piston oil cooling nozzle if any damage is found.
OIL PUMP CLEANING AND INSPECTION
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Fig. 34: View Of Oil Pump Gear Cover & Bolts

1. Remove the oil pump gear cover bolts.

2. Remove the oil pump gear cover.
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Fig. 35: Measuring Clearance Between Gear Teeth & Oil Pump Housing
3. Use a feeler gauge to measure the clearance between the gear teeth and the oil pump
housing. The production clearance is 0.125-0.221 mm (0.0049-0.0087 in) and the service
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limit is 0.221 mm (0.0087 in).

4. Replace the oil pump assembly if the clearance exceeds the service limit.
Fig. 36: Measuring Clearance Between Side Of Gear & Cover

5. Use a feeler gauge and a straightedge to measure the clearance between the side of the gear
and the cover. The production clearance is 0.064-0.109 mm (0.0025-0.0043 in) and the
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Fig. 37: View Of Driven Gear Shaft & Bushing Measurements

7. Calculate the driven gear shaft to bushing clearance.

1. Measure the driven gear shaft outside diameter. The production specification is
19.947-19.960 mm (0.7853-0.7858 in) and the service limit is 19.86 mm (0.7819 in).
2. Measure the driven gear bushing inside diameter. The production value is 20 mm
(0.7874 in).
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3. Calculate the driven gear shaft to bushing clearance. The service limit is 0.14 mm
(0.0055 in)
Fig. 38: View Of Oil Pump Gear Cover & Bolts

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9. Install the oil pump gear cover to the oil pump assembly.
10. Install the oil pump gear cover bolts.
Tighten: Tighten the oil pump gear cover bolts to 21 N.m (15 lb ft).
ENGINE FRONT COVER CLEANING AND INSPECTION
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Fig. 39: View Of Engine Front Cover O-Ring

1. Remove the O-ring (1) from the engine front cover.

2. Remove the oil pressure relief valve from the engine front cover.
3. Clean the engine front cover.
4. Clean the engine front cover mating surfaces.
5. Inspect the engine front cover mating surfaces for damage.
6. Inspect the engine front cover O-ring sealing surface for damage.
7. Inspect the crankshaft front oil seal bore for damage.
8. Replace the engine front cover if any damage is found.
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9. Install the oil pressure relief valve with a new O-ring.
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Tighten: Tighten the oil pressure relief valve to 39 N.m (29 lb ft).
LOWER OIL PAN CLEANING AND INSPECTION
1. Remove the oil level sensor (1) and retaining clip (3).
2. Clean the lower oil pan (4). Remove any sludge or other deposits.
3. Clean the lower oil pan mating surface.
4. Inspect the lower oil pan (4) for dents or distortion.
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5. Inspect the lower oil pan mating surface for damage.

6. Replace the lower oil pan (4) if any damage is found.
7. Install the oil level sensor (1) and retaining clip (3).
VALVE ROCKER ARM COVER CLEANING AND INSPECTION - LOWER
Fig. 42: Inspecting Lower Valve Rocker Arm Cover

1. Remove the grommets.

2. Clean the lower valve rocker arm cover. Remove any sludge or other deposits.
3. Clean the lower valve rocker arm cover mating surfaces.
4. Inspect the lower valve rocker arm cover for cracks or other damage.
5. Inspect the lower valve rocker arm cover mating surfaces for damage.
6. Replace the lower valve rocker arm cover if any damage is found.
7. Inspect the grommets for damage.
8. Replace the grommets if any damage is found.
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9. Install the grommets.
VALVE ROCKER ARM COVER CLEANING AND INSPECTION - UPPER

1. Remove the PCV cover screws.

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Fig. 44: View Of Upper Valve Rocker Arm Cover Components

3. Clean the upper valve rocker arm cover. Remove any sludge or other deposits.
4. Clean the upper valve rocker arm cover mating surface.
5. Inspect the upper valve rocker arm cover for cracks or other damage.
6. Inspect the upper valve rocker arm cover mating surfaces for damage.
7. Replace the upper valve rocker arm cover if any damage is found.
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8. Inspect the PCV cover, diaphragm, and spring for damage.

9. Install the PCV spring.
10. Install the PCV diaphragm.
11. Install the PCV cover.
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Tighten: Tighten the PCV cover screws to 4 N.m (35 lb in).
INTAKE MANIFOLD CLEANING AND INSPECTION
Fig. 46: View Of Intake Manifold Crossover Inspection Areas

1. Clean the intake manifold crossover.

2. Clean the intake manifold mating surfaces.
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Fig. 47: View Of Intake Manifold Inspection Areas

3. Clean the intake manifolds.

4. Clean the intake manifold mating surfaces.
5. Inspect the intake manifolds for cracks.
6. Inspect the intake manifold mating surfaces for damage.
7. Replace the intake manifolds if any damage is found.
OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY CLEANING AND INSPECTION
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Fig. 48: View Of Coolant Tube Inspection Areas

1. Clean the coolant tube.

2. Inspect the coolant tube for cracks.
3. Inspect the coolant tube mating surfaces for damage.
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Fig. 49: View Of Oil Filter Adapter Inspection Areas

4. Clean the oil filter adapter.

5. Inspect the oil filter adapter mating surfaces for damage.
6. Replace the O-rings.
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ENGINE COOLANT THERMOSTAT HOUSING CLEANING AND INSPECTION
Fig. 50: View Of Thermostat Housing Inspection Areas

1. Clean the thermostat housing.

2. Clean the thermostat housing mating surfaces.
3. Inspect the thermostat housing for cracks.
4. Inspect the thermostat housing mating surfaces for damage.
5. Replace the thermostat housing if any damage is found.
EXHAUST MANIFOLD CLEANING AND INSPECTION
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Fig. 51: View Of Exhaust Manifold Inspection Areas

1. Clean the exhaust manifold.

2. Clean the exhaust manifold mating surfaces.
3. Inspect the exhaust manifold for cracks.
4. Inspect the exhaust manifold mating surfaces for damage.
5. Replace the exhaust manifold if any damage is found.
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Fig. 52: Measuring Exhaust Manifold Flange For Warpage

6. Measure the exhaust manifold flange for warpage with feeler gauge and a straightedge.
Replace the exhaust manifold if the warpage is more than 0.3 mm (0.0118 in).
7. Install the exhaust manifold heat shield.
8. Install the exhaust manifold heat shield bolts.
Tighten: Tighten the exhaust manifold heat shield bolts to 8 N.m (71 lb in).
EXHAUST PIPE CLEANING AND INSPECTION
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Fig. 53: View Of Exhaust Pipe Inspection Areas

1. Clean the exhaust pipe.

2. Clean the exhaust pipe mating surfaces.
3. Inspect the exhaust pipe for dents or cracks.
4. Replace the exhaust pipe if any damage is found.
EXHAUST OUTLET CLEANING AND INSPECTION
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Fig. 54: View Of Exhaust Outlet Inspection Areas

1. Clean the exhaust outlet.

2. Clean the exhaust outlet mating surfaces.
3. Inspect the exhaust outlet for dents or cracks.
4. Replace the exhaust outlet if any damage is found.
FUEL INJECTION PUMP CLEANING AND INSPECTION
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Fig. 55: View Of Fuel Injection Pump Adapter & Bolts

1. Remove the fuel injection pump adapter bolts.

2. Remove the fuel injection pump adapter.
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Fig. 56: View Of Fuel Injection Pump & Adapter O-Rings

3. Remove the O-ring from the fuel injection pump and discard.
4. Remove the O-ring from the fuel injection pump adapter and discard.
5. Clean the fuel injection pump adapter mating surfaces.
6. Clean the fuel injection pump mating surfaces.
7. Inspect the fuel injection pump and adapter for damage.
8. Replace component if any damage is found.
9. Install a new O-ring onto fuel injection pump.
10. Install a new O-ring onto fuel injection pump adapter.
11. Lubricate the O-rings with engine oil.
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Fig. 57: View Of Fuel Injection Pump Adapter & Bolts

12. Install the fuel injection pump adapter to the fuel injection pump.
13. Install the fuel injection pump adapter bolts.
Tighten: Tighten the fuel injection pump adapter bolts to 21 N.m (15 lb ft).
FUEL INJECTOR CLEANING AND INSPECTION
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Fig. 58: View Of Fuel Injector Nozzle Tip & Copper Washer Sealing Area
1. Use a soft bristle non-metallic brush and top engine cleaner, GM P/N 1052626 or
equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing
area (2) before reinstallation.
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NOTE: The fuel injector must be cleaned with the proper cleaning
equipment. DO NOT use abrasive cleaning methods, such as a
metallic brush, to remove deposits. Cleaning an injector with
improper tools will damage the fuel injector.
2. Inspect the fuel injector nozzle tip (1) for cracks, dents, or other damage.
3. Inspect the nozzle tip (1) for any signs of discoloration - dark yellow, tan, or blue due to
excessive heat.
4. Replace the injector if any damage is found.
Fig. 59: View Of Fuel Injector Sealing Surfaces

5. Clean the fuel injector high pressure line.

6. Inspect the fuel injector high pressure line for excessive corrosion or damage to the sealing
surfaces (1, 2). Replace the line if any damage is found.
TURBOCHARGER CLEANING AND INSPECTION
Completely inspect the turbocharger and all other engine components that may cause similar
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conditions before replacing the turbocharger.
Use the following information to diagnose problems caused by the turbocharger.
The turbocharger is serviced as a complete unit.

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IMPORTANT: Oil residue on the turbocharger compressor wheel is normal

with a closed PCV system.
1. Remove the turbocharger oil return pipe bolts.

2. Remove the turbocharger oil return pipe and gasket.
3. Clean mating surfaces.
Fig. 61: View Of Compressor Wheel

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4. Inspect for damage to the compressor wheel, compared to a normal compressor wheel.
Fig. 62: View Of Damaged Compressor Wheel (Soft Object)

5. Inspect for damage to the compressor wheel, by a soft object.
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Fig. 63: View Of Damaged Compressor Wheel (Hard Object)

6. Inspect for damage to the compressor wheel, by a hard object.
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Fig. 64: View Of Compressor Blades (Heavy Rubbing)

7. Inspect compressor blades for heavy rubbing.
Ensure that the following conditions do not exist on the compressor wheel blades:
Cracks
Bends
Erosion of the blades
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Broken blades

8. Check the housing for signs of rubbing.

9. Install the turbocharger oil return pipe and new gasket.

10. Install the turbocharger oil return pipe bolts.
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Tighten: Tighten the turbocharger oil return pipe bolts to 21 N.m (15 lb ft).

IMPORTANT: If the cooling outlet hose eye bolts were removed, install the
longer bolt (1) with two holes, in the top location. Install the
shorter bolt (2) in the lower location.
11. Inspect the coolant outlet lines for damage.
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Fig. 67: View Of Turbocharger Inlet Duct Inspection Areas

12. Clean the turbocharger inlet duct.

13. Clean the turbocharger inlet duct mating surfaces.
14. Inspect the turbocharger inlet duct for cracks.
15. Inspect the turbocharger inlet duct mating surfaces for damage.
16. Replace the turbocharger inlet duct if any damage is found.
Tighten: Tighten the inlet duct clamp to 5 N.m (44 lb in).
MY
ENGINE FLYWHEEL HOUSING CLEANING AND INSPECTION
Fig. 68: View Of Flywheel Housing O-Ring Seals

1. Remove the O-rings from the flywheel housing and discard.

2. Clean the flywheel housing.
3. Clean the flywheel housing mating surfaces.
MY
4. Clean the flywheel housing O-ring sealing area.

5. Inspect the flywheel housing for cracks.
6. Inspect the flywheel housing mating surfaces for damage.
7. Inspect the crankshaft rear oil seal bore for damage.
8. Replace the flywheel housing if any damage is found.
WATER PUMP CLEANING AND INSPECTION
MY
Fig. 69: View Of Water Pump, Housing & O-Ring

1. Remove the O-ring from the water pump and discard.

2. Remove the water pump to water pump housing bolts.
3. Remove the water pump from the water pump housing.
MY
4. Remove the O-ring from the water pump housing and discard.
Fig. 70: View Of Water Pump Inspection Areas

5. Clean the water pump assembly.

MY
6. Clean the water pump mating surfaces.

7. Inspect the water pump gear for damage.
8. Inspect the water pump mating surfaces for damage.
9. Inspect the water pump shaft for looseness.
10. Inspect the water pump assembly for damage.
11. Replace the water pump if any damage is found.
MY
Fig. 71: View Of Water Pump, Housing & O-Ring

12. Install a new O-ring to the water pump housing.

13. Lubricate the O-ring with engine coolant.
14. Install the water pump to the water pump housing.
MY
15. Install the water pump to water pump housing bolts.
Tighten: Tighten the water pump to water pump housing bolts to 21 N.m (15 lb ft).
16. Install a new O-ring to the water pump.
EXHAUST GAS RECIRCULATION COOLER CLEANING AND INSPECTION
Fig. 72: EGR Cooling Hoses

1. Remove the exhaust gas recirculation (EGR) cooling hoses.

2. Clean and inspect the EGR gasket surfaces.
3. Clean and inspect the EGR and cooler.
4. Replace the EGR or cooler if damaged.
THREAD REPAIR
General purpose thread repair kits are available commercially.
MY
Fig. 73: Drilling & Tapping Damaged Threads

CAUTION: Refer to SAFETY GLASSES CAUTION .
IMPORTANT: Refer to the thread repair kit manufacturer's instructions

regarding the size of the drill and which tap to use.
Always avoid any buildup of chips. Back out the tap every
few turns and remove the chips.
1. Determine the size, the pitch, and the depth of the damaged thread.
MY
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required
depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
Fig. 74: Installing Thread Insert

8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the
MY
thread insert onto the end of the mandrel.
IMPORTANT: The thread insert should be flush to 1 turn below the surface.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and
install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert
installer, break off the tang using a drift punch.
FUEL LINE TORQUING
MY
Fig. 75: View Of Flare Nut Socket

The torque of a fuel line fitting is critical to prevent fuel leaks in a high pressure direct injection
fuel system. The preferred method is through the use of a flare nut socket. With the use of a flare
nut socket, the torque wrench can be set to the listed torque specification. Refer to Fastener
Tightening Specifications .
MY
If a crows foot is used to torque the fuel lines, then special attention to the position of the crows
foot in relation to the torque wrench is required.
Fig. 76: View Of Crows Foot (90 Degrees)

MY
If the crows foot is kept perpendicular (90 degrees) to the torque wrench during the entire
tightening procedure, then the torque wrench can be set to the listed torque specification.
Refer to Fastener Tightening Specifications .
Fig. 77: View Of Crows Foot (Straight)

MY
If the crows foot is positioned straight with the torque wrench, then the torque setting needs
to be corrected to compensate for the increased leverage.
If the crows foot is held at any position other than 90 degrees or inline to the wrench, more
complex corrections of the torque setting are required, and therefore, positioning the crows
foot in this manner is not recommended.
If it is necessary to position a crows foot in line with the torque wrench, the procedure for
adjusting the torque specification is as follows:
Fig. 78: Measuring Center Of Crows Foot Wrench End To Center Of Square Drive
MY
Hole
1. Measure the distance between the center of the crows foot wrench end to the center of the
square drive hole.
Fig. 79: Measuring Length Of Torque Wrench

MY
2. Measure the length of the torque wrench from the center of the square drive to the center of
the handle.
3. Divide the measurement of the crows foot length by the torque wrench length. This figure is
the percentage of additional torque, over the torque wrench setting, that will be applied to
the fitting.
4. Subtract the results of step 3 from the number 1. This figure is the percentage of the listed
torque specification that the torque wrench should be set to.
5. Multiply the results of step 4 by the listed torque setting. Refer to Fastener Tightening
Specifications . This figure is the proper setting the torque wrench should be set at when
using a crows foot in line with the torque wrench.
Example
1. Crows foot measurement = 25 mm (1.0 in)

2. Torque wrench measurement = 355 mm (14.0 in)
3. 25 mm / 355 mm (1.0 in / 14.0 in) = 0.07, or 7 %
4. 1 - 0.07 = 0.93, or 93 %
5. 0.93 x 41 N.m (30 lb ft) = 38 N.m (28 lb ft)
SERVICE PRIOR TO ASSEMBLY
Dirt will cause premature wear of the rebuilt engine. Clean all the components.
Use the proper tools to measure the components when checking for excessive wear.
Components not within the manufacturer's specification must be repaired or replaced.
When the components are reinstalled into an engine, return the components to their original
location, position, and direction.
During assembly, lubricate all the moving parts with clean engine oil (unless otherwise
specified). This will provide initial lubrication when the engine is first started.
CRANKSHAFT AND BEARING INSTALLATION
Tools Required
J 45059 Angle Meter

Installation
MY
Fig. 80: View Of Crankshaft Upper & Lower Bearings

1. Install the upper crankshaft bearings into the cylinder block. The bearing halves to be
inserted into the crankshaft main bearing saddle have a wide groove and oil hole in the
center of the bearing (1).
2. Install the lower crankshaft bearings into the crankshaft bearing caps. The bearing halves to
be inserted into the crankshaft main bearing caps do NOT have an oil hole or groove in the
bearing (2).
MY
Fig. 81: View Of View Of Thrust Bearings

3. Install the upper thrust bearings to the cylinder block. There are two thrust bearings (1 and
3) in the cylinder block and one lower thrust bearing in the No. 5 crankshaft bearing cap
(2).
4. Lubricate the crankshaft bearing surfaces with engine oil.
5. Install the crankshaft into the cylinder block.
6. Install the No. 5 crankshaft bearing cap with the lower thrust bearing (2).
MY
Fig. 82: View Of Crankshaft Bearing Cap & Bolts

7. Install the remaining four crankshaft bearing caps.
MY
Fig. 83: Main Bearing Bolt


damage.
IMPORTANT: There are two different length crankshaft bearing cap bolts in
MY
production depending on the counter bore of the threaded

hole/block. Using the wrong bolt may lead to improper thread
engagement, bottoming out or improper clamp load. Look at
the bolt head surface to determime which bolt was used in
production. The bolt head will have either a raised circle (1)
or it will be unmarked (2). Replace the bolt with the same
type.
8. Install the NEW crankshaft bearing cap bolts.

9. Tighten the crankshaft bearing cap bolts in the proper sequence.
Tighten:
2nd step 132 N.m (97 lb ft).
MY
Fig. 84: View Of Crankshaft Bearing Cap Side Bolts

10. Clean the crankshaft bearing side cap bolt threads, sealing flange and mounting holes with
GM P/N 12377981 (Canadian P/N 10953463) or equivalent. Dry the bolts and mounting
holes with compressed air.
11. Apply GM P/N 12346004 (Canadian P/N 10953480) to the threads and sealing flange of
the bolts.
12. Install the ten bolts.
Tighten: Tighten the crankshaft bearing cap side bolts to 70 N.m (52 lb ft).
MY

13. Install the oil pressure sensor.
Tighten: Tighten the oil pressure sensor to 41 N.m (30 lb ft).
CAMSHAFT INSTALLATION
Tools Required

Installation
1. Install the camshaft thrust plate to the camshaft.

2. Install the camshaft driven gear.
MY
3. Install a new camshaft driven gear bolt.
Leave the bolt finger tight.
Fig. 87: View Of Camshaft Gear Aligned With Crankshaft Gear

4. Install the camshaft and gear assembly into the cylinder block, aligning the camshaft gear to
the crankshaft gear as shown.
MY
5. Install the camshaft thrust plate bolts.
Tighten: Tighten the camshaft thrust plate bolts to 22 N.m (16 lb ft).
Fig. 88: Using Exciter Ring Bolt To Secure Spring Tension

IMPORTANT: Use a suitable tool to relieve the spring tension while

removing the locking bolt.
6. Remove the exciter ring bolt that was installed to hold the spring tension of the two piece
MY
cam gear.
Fig. 89: View Of Camshaft Exciter Ring, Bolts & Thrust Plate Bolts
7. Install the camshaft position sensor exciter ring to the camshaft gear.
8. Install the camshaft position sensor exciter ring bolts.
Tighten: Tighten the camshaft position sensor exciter ring bolts to 9 N.m (80 lb in).
MY

9. Block the crankshaft from turning using a wooden handle.

10. Install the new camshaft gear bolt.
Tighten: Tighten the new camshaft gear bolt to 234 N.m (173 lb ft).
MY
Fig. 91: Measuring Camshaft End Play Using J 7872

11. Measure the camshaft end play with J 7872 .

mm (0.0079 in).
Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the
service limit.
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
MY
Tools Required
J 8037 Piston Ring Compressor

J 45059 Angle Meter
Installation
MY
Fig. 92: View Of Connecting Rod Bearing & Connecting Rod Cap Bearing
IMPORTANT: The connecting rod bearing with the notch all the way out
against the edge of the bearing (2) is the connecting rod
bearing. The connecting rod bearing with the notch "in
board" (1) is the connecting rod cap bearing.
1. Select the connecting rod bearing according to the Connecting Rod Bearings Selection
Specifications chart.
2. Position the crankshaft so the connecting rod journal is opposite the piston and connecting
rod assembly being installed.
MY
Fig. 93: View Of Connecting Rod Cap & Bearing Insert

3. Install the connecting rod bearing inserts.

4. Lubricate the cylinder wall and piston rings with engine oil.
5. Install the J 8037 to the piston to compress the piston rings.
MY
Fig. 94: View Of Piston Assembly

6. Orientate the piston front mark and the piston inside mark to the engine block.
MY
Fig. 95: Pushing Piston & Connecting Rod Assembly Into Engine
NOTE: The chamfered side of the connecting rod large journal ends
must face away from each other on a common crankshaft
journal. Placement of the chamfered side of the connecting rod
large journal ends in any other direction or combination will
cause damage to the crankshaft, connecting rod and
connecting rod bearing.
7. Push the piston and connecting rod assembly into the engine.
MY
Fig. 96: View Of Connecting Rods

8. Install the gauging plastic onto the connecting rod journal. Install the gauging plastic the full
width of the journal.
9. Install the connecting rod cap with its stamped cylinder number aligned with the stamped
cylinder number on the connecting rod.
MY
10. Install the original connecting rod cap bolts for the plastic gauging. NEW bolts will be used
for final assembly.
11. Tighten the bolts in three steps.
Tighten:
1. 1st step 64 N.m (47 lb ft)
2. 2nd step 30 degrees using J 45059
3. 3rd step 30 degrees using J 45059
12. Remove the connecting rod cap bolts.

13. Compare the width of the gauging plastic with the scale printed on the gauging plastic
container. The connecting rod bearing clearance should be 0.10 mm (0.0039 in).
14. Discard the original connecting rod bolts once the plastic gauging is completed. NEW
connecting rod bolts will be used for final assembly.
15. Carefully clean the gauging plastic from the bearing surface and the crankpin.
16. Lubricate the connecting rod bearing inserts with engine oil.
17. Install the connecting rod caps with the stamped cylinder number aligned with the stamped
cylinder number on the connecting rods.

damage.
18. Install NEW connecting rod cap bolts.

19. Tighten the connecting rod cap bolts in three steps.
Tighten:
2. 2nd step 30 degrees using J 45059
3. 3rd step 30 degrees using J 45059
PISTON OIL COOLING NOZZLE INSTALLATION

MY
Fig. 97: View Of Piston Oil Cooling Nozzle

1. Install the piston oil cooling nozzle.
MY
Fig. 98: Aligning Oil Cooling Nozzle

NOTE: The piston oil cooling nozzle must be aligned to direct oil
towards the oil inlet hole on the bottom of the piston. Improper
MY
alignment of the piston oil cooling nozzle will allow insufficient

oil lubrication to the piston and cause severe engine damage.
2. Install the piston oil cooling nozzle bolt.
Tighten: Tighten the piston oil cooling nozzle bolts to 21 N.m (15 lb ft).
OIL PUMP INSTALLATION
Fig. 99: View Of Oil Pump, Bolts & O-Ring

MY
1. Install a new O-ring to the engine block.

3. Install the oil pump.
4. Install the oil pump bolts.
Tighten: Tighten the oil pump bolts to 21 N.m (15 lb ft).
MY

IMPORTANT: Do not damage the crankshaft sensor reluctor teeth.
5. Install the oil pump drive gear and crank sensor reluctor assembly.
MY
Fig. 101: View Of Oil Pump Driven Gear

MY
Oil Pump Shaft
MY
gear nut.
Tighten: Tighten the oil pump driven gear nut to 100 N.m (74 lb ft).
OIL PUMP SUCTION PIPE AND SCREEN ASSEMBLY INSTALLATION
Fig. 103: View Of Oil Pump Pipe, Screen Assembly & Gasket
MY
1. Install the oil pump pipe and screen gasket.

2. Install the oil pump pipe and screen.
3. Install the oil pump pipe and screen assembly bolts and nuts.
Tighten:
Tighten the oil pump pipe and screen assembly bolts to 25 N.m (18 lb ft).
Tighten the oil pump pipe and screen assembly nuts to 25 N.m (18 lb ft).
ENGINE FRONT COVER INSTALLATION
MY

1. Install the relief valve O-ring to the engine front cover.

MY

3. Apply a 2-3 mm wide and 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N
88901148) sealant to the mating surfaces of the engine front cover.
MY

4. Install the engine front cover.
5. Install the engine front cover bolts.
Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
MY

6. Install a new O-ring to the crankshaft position sensor spacer.

8. Install the crankshaft position sensor spacer.
9. Install the crankshaft position sensor spacer bolts.
Tighten: Tighten the crankshaft position sensor spacer bolts to 10 N.m (89 lb in).
10. Install a new O-ring to the crankshaft position sensor.

12. Install the crankshaft position sensor.
MY
13. Install the crankshaft position sensor bolt.
Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
CRANKSHAFT FRONT OIL SEAL INSTALLATION
Tools Required
J 44645 Crankshaft Front Oil Seal Installer. See Special Tools .

Installation
Fig. 108: Pressing Crankshaft Front Oil Seal On Using J 44645

MY
1. Lubricate the crankshaft sealing surface with engine oil.

2. Place the crankshaft front oil seal onto the crankshaft.
3. Install the J 44645 to the crankshaft. See Special Tools .
4. Press the crankshaft front oil seal onto the crankshaft with the J 44645 until the tool
bottoms out. See Special Tools .
OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY INSTALLATION
Fig. 109: Oil Cooler

MY
1. Install new O-rings (2) to the oil filter adapter and oil cooler assembly. Lubricate the O-
rings with engine oil.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) to the O-ring sealing area (1).

3. Install the oil filter adapter and oil cooler assembly.

MY
4. Install the five oil filter adapter and oil cooler assembly bolts (1).
Tighten: Tighten the oil filter adapter and oil cooler assembly bolts to 25 N.m (18 lb ft).

5. Install a new O-ring onto the engine coolant pipe.

6. Lubricate the O-ring with engine coolant. Do not use oil or grease.
7. Install the engine coolant pipe to the oil filter adapter and oil cooler assembly.
WATER PUMP INSTALLATION

MY
Fig. 112: View Of Engine Coolant Pipe & Gasket

1. Lubricate the water pump O-ring with engine oil.

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

MY

6. Install the water pump to coolant tube nuts.
Tighten: Tighten the water pump to coolant tube nuts to 25 N.m (18 lb ft).
FUEL INJECTION PUMP INSTALLATION
MY
Fig. 114: View Of Fuel Injection Pump

1. Lubricate the O-ring on the fuel injection pump adapter with engine oil.
MY
Fig. 115: Identifying Two Piece Cam Gear

2. Use a suitable tool to unload the spring tension from the two piece cam gear. Apply pressure
towards the right side of the engine while installing the fuel injection pump.
3. Install the fuel injection pump and adapter assembly.
4. Install the fuel injection pump bolts.
MY
Tighten: Tighten the fuel injection pump bolts to 25 N.m (18 lb ft).
VALVE LIFTER INSTALLATION

1. Install the valve lifter.

2. Install the valve lifter guides.
3. Install the valve lifter guide hold down bracket.
MY
4. Install the valve lifter guide hold down bracket bolt.
Tighten: Tighten the valve lifter guide hold down bracket bolt to 11 N.m (97 lb in).
CYLINDER HEAD GASKET SELECTION
Tools Required

Selection
1. If a reciprocating component (crankshaft, connecting rod, piston, or bearings) has not been
replaced, install the same grade head gasket that was removed.
MY
Fig. 117: View Of Cylinder Head Gasket Markings

2. The markings on the gasket are as follows:

Grade A (1)
Grade B (2)
Grade C (3)
Block over-bored 0.010-0.030 in (0.254-0.762 mm) (4)
Block over-bored 0.010-0.030 in (0.254-0.762 mm) and deck milled 0.008 in (0.203
MY
mm) (5)
3. The cylinder head gasket thickness is determined by the piston head projection from the
cylinder block deck surface. There are cylinder head gaskets available in three different
thicknesses. Follow the procedure below and refer to Cylinder Head Gasket Selection
Specifications to determine what gasket to use for each bank of cylinders.
4. Be sure the piston and cylinder deck are free of carbon, gasket material, or other objects
that may give you an erroneous measurement.
Fig. 118: Measuring Piston Projection Using J 7872

5. Use J 7872 to measure the piston projection across two different points on each piston.
1. Zero the dial indicator to the cylinder deck surface.
2. Place the dial indicator pointer on the piston top. Be sure the pointer is directly above
the piston pin centerline to prevent inaccurate readings from piston rocking.
MY
3. Rotate the engine to roll the piston through Top Dead Center while noting the
maximum reading on the dial indicator.
4. Repeat procedure at the second measuring point on the piston.
6. Calculate the average value of piston projection for each cylinder.
7. Obtain the maximum piston projection value for that bank of cylinders.
8. Determine the gasket grade by the maximum piston projection value using the chart.
9. If the difference between the highest measured piston head projection and the lowest
measured piston projection, within one bank of cylinders, exceeds 0.1 mm (0.0039 in), then
the following items need to be checked.
Connecting rod to piston pin clearance
Piston to piston pin clearance
If any of the above clearances are beyond specifications, then refer to the appropriate section for
repair. If all of the above clearances are within the service limits but the piston projection
variation is over 0.1 mm (0.0039 in), then replace the connecting rod and piston assembly.
CYLINDER HEAD INSTALLATION - LEFT SIDE
Tools Required
J 45059 Angle Meter

Installation
MY

IMPORTANT: The stamped letter, R or L, must face up. R is the right bank,
L is the left bank.
MY

Grade A (1)
Grade B (2)
Grade C (3)
mm) (5)
2. Install the left cylinder head gasket of the correct grade. The left and right cylinder head
gaskets are not interchangeable. Refer to Cylinder Head Gasket Selection.
MY

3. Install the left cylinder head.
Fig. 121: Cylinder Head Bolt Tightening Sequence


damage.
4. Install the NEW M12 cylinder head bolts.

MY
Tighten the M12 cylinder head bolts in three steps:
Tighten:
2. 2nd step 80 N.m (59 lb ft)
3. 3rd step tighten 60 degrees using J 45059
4. 4th step tighten 60 degrees using J 45059
5. Reuse the M8 bolts. Install the M8 bolts.
Tighten: Tighten the M8 cylinder head bolts to 25 N.m (18 lb ft).
CYLINDER HEAD INSTALLATION - RIGHT SIDE
Tools Required
J 45059 Angle Meter

Installation
MY

IMPORTANT: The stamped letter, R or L, must face up. R is the right bank,
L is the left bank.
MY

Grade A (1)
Grade B (2)
Grade C (3)
mm) (5)
2. Install the right cylinder head gasket of the correct grade. The left and right cylinder head
gaskets are not interchangeable. Refer to Cylinder Head Gasket Selection.

MY
3. Install the right cylinder head.
Fig. 124: Cylinder Head Bolt Tightening Sequence


damage.
4. Install the NEW M12 cylinder head bolts. Reuse the M8 bolts.
MY
Tighten the M12 cylinder head bolts in three steps:
Tighten:
2. 2nd step 80 N.m (59 lb ft)
3. 3rd step tighten 60 degrees using J 45059
4. 4th step tighten 60 degrees using J 45059
5. Install the M8 bolts.
Tighten: Tighten the M8 cylinder head bolts to 25 N.m (18 lb ft).
EXHAUST MANIFOLD INSTALLATION - LEFT SIDE
MY
Fig. 125: View Of Left Exhaust Manifold & Gasket

1. Install the exhaust manifold gasket.

2. Install the exhaust manifold.
MY
Fig. 126: Exhaust Manifold Bolt Tightening Sequence -- Left Side (6.6L)
3. Install the exhaust manifold bolts and nuts.
Tighten: Tighten the exhaust manifold bolts and nuts to 57 N.m (42 lb ft) in the proper
sequence.
Tighten: Tighten the center exhaust manifold bolts and nuts an additional pass to 57 N.m
(42 lb ft) in sequence.
MY
Fig. 127: View Of Exhaust Manifold Heat Shield (Left)


MY
EXHAUST MANIFOLD INSTALLATION - RIGHT SIDE
Fig. 128: View Of Right Exhaust Manifold & Gasket

1. Install the exhaust manifold gasket.

2. Install the exhaust manifold.
MY
Fig. 129: Exhaust Manifold Bolt Tightening Sequence -- Right Side (6.6L)
3. Install the exhaust manifold bolts and nuts.
Tighten: Tighten the exhaust manifold bolts and nuts to 57 N.m (42 lb ft) in the proper
sequence.
Tighten: Tighten the center exhaust manifold bolts and nuts an additional pass to 57 N.m
(42 lb ft) in sequence.
MY
Fig. 130: View Of Exhaust Manifold Heat Shield (Right)


VALVE ROCKER ARM, SHAFT, AND PUSH ROD INSTALLATION
MY
Fig. 131: View of Valve Bridge

IMPORTANT: Install the valve bridge with the expansion side of bridge
away from the injector.
MY
1. Install the valve bridge.
2. Install the valve bridge pins.

3. Install the pushrods.
MY

NOTE: The pushrods must be correctly seated in the valve lifter and
valve rocker arms before the rocker arm shaft assembly is
torqued into place. Improper seating of the pushrods can cause
damage to the pushrods or the valve rocker arm shaft
assembly components.
MY
4. Install the rocker arm shaft assembly.
Fig. 134: Rocker Arm Shaft Bolt Tightening Sequence

5. Install the rocker arm shaft assembly bolts.
Tighten: Tighten the rocker arm shaft assembly bolts in the proper sequence. Tighten the
MY
rocker arm shaft bolts to 41 N.m (30 lb ft).
VALVE LASH ADJUSTMENT
1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center of the
MY
compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark
on the crankshaft balancer should be aligned with the mark on the engine.

3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge.
MY
Fig. 137: Identifying Valves To Adjust When #1 Cylinder Is At TDC Of

Compression Stroke
Specifications to determine which valves that can be adjusted when the engine is at Top
MY
Dead Center.
Tighten: Tighten the valve lash lock nut to 22 N.m (16 lb ft).
5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of
MY
the exhaust stroke.
Fig. 139: Identifying Valves To Adjust When #1 Cylinder Is At TDC Of Exhaust

Stroke
MY
Specifications to determine which valves that can be adjusted when the engine is at Top
Dead Center.
Tighten: Tighten the valve lash lock nut to 22 N.m (16 lb ft).
INTAKE MANIFOLD INSTALLATION - LEFT SIDE

1. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N
88901148) sealant on the intake manifold mating surface.
MY
Fig. 141: View Of Intake Manifold (Left)

MY
Fig. 142: Intake Manifold Bolt Tightening Sequence (Left)

3. Install the intake manifold bolts and nuts.
Tighten: Tighten the intake manifold bolts and nuts to 25 N.m (18 lb ft).
INTAKE MANIFOLD INSTALLATION - RIGHT SIDE
MY

88901148) sealant on the intake manifold mating surface.
MY

MY

3. Install the intake manifold bolts and nuts.
Tighten: Tighten the intake manifold bolts and nuts to 25 N.m (18 lb ft).
MY
2008 ENGINE

INTAKE MANIFOLD CROSSOVER INSTALLATION

1. Install the intake manifold crossover gaskets.

2. Install the intake manifold crossover.

MY
3. Install the intake manifold crossover nuts and bolts in sequence.
Tighten: Tighten the intake manifold crossover nuts and bolts to 10 N.m (89 lb in).
VALVE ROCKER ARM COVER INSTALLATION - LOWER LEFT SIDE

IMPORTANT: The gasket may be reused if it is not torn, cracked, stretched,

or swollen.
MY

NOTE: Refer to Fastener Notice
Tighten:
Tighten the lower valve rocker arm cover bolts in the proper sequence to 10 N.m (89
lb in).
Retighten the lower valve rocker arm cover bolts in the proper sequence to the same
torque, 10 N.m (89 lb in).
VALVE ROCKER ARM COVER INSTALLATION - LOWER RIGHT SIDE
MY


or swollen.
MY

Tighten:
Tighten the lower valve rocker arm cover bolts in the proper sequence to 10 N.m (89
lb in).
Retighten the lower valve rocker arm cover bolts in the proper sequence to the same
torque, 10 N.m (89 lb in).
VALVE ROCKER ARM COVER INSTALLATION - UPPER LEFT SIDE
MY


or swollen.
MY

Tighten: Tighten the upper valve rocker arm cover bolts to 8 N.m (71 lb in).
VALVE ROCKER ARM COVER INSTALLATION - UPPER RIGHT SIDE
MY


or swollen.
MY

Tighten: Tighten the upper valve rocker arm cover bolts in the proper sequence to 8 N.m
(71 lb in).
FUEL INJECTORS INSTALLATION
MY
Fig. 10: Identifying Fuel Injector Copper Washers

1. Install a new O-ring onto the fuel injector.

3. Install a new copper washer into the fuel injector bore in the cylinder head.
4. Install the fuel injector right bracket pin.
MY
Fig. 11: View Of Left Injector Bracket Pins

5. Install the fuel injector left bracket pin.
MY
Fig. 12: View Of Right Fuel Injectors W/Brackets

6. Install the right fuel injector with fuel injector bracket.
MY
Fig. 13: View Of Left Fuel Injectors W/Brackets

7. Install the left fuel injector with fuel injector bracket.
MY
Fig. 14: View Of Right Fuel Injector Bracket Bolts

8. Install the right fuel injector bracket bolts.
Tighten: Tighten the right fuel injector bracket bolts to 30 N.m (22 lb ft).
MY
Fig. 15: View Of Left Fuel Injector Bracket Bolts

9. Install the left fuel injector bracket bolts.
Tighten: Tighten the left fuel injector bracket bolts to 30 N.m (22 lb ft).
FUEL PIPES AND FUEL RAIL INSTALLATION
MY
Fig. 16: View Of Right Fuel Rail

1. Install the right fuel rail.
2. Install the right fuel rail mounting bolts.
Tighten: Tighten the right fuel rail mounting bolts to 25 N.m (18 lb ft).
MY
Fig. 17: View Of Left Fuel Rail And Bracket

3. Install the left fuel rail.

4. Install the left fuel rail mounting bolts.
Tighten: Tighten the left fuel rail mounting bolts to 25 N.m (18 lb ft).
MY

CAUTION: Improper torque methods of the fuel lines will result in

fuel leaks and possible damage to the engine. Failure to
follow proper fuel line fitting torque methods could result
in serious personal injury.
5. Install the injection pipes to the right bank.
Tighten: Tighten the injection pipes to 41 N.m (30 lb ft).
MY

CAUTION: Improper torque methods of the fuel lines will result in

fuel leaks and possible damage to the engine. Failure to
follow proper fuel line fitting torque methods could result
in serious personal injury.
6. Install the injection pipes to the left bank.
Tighten: Tighten the injection pipes to 41 N.m (30 lb ft).
MY
Fig. 20: Identifying EGR Mounting Bracket & Bolts

7. Install the exhaust gas recirculation (EGR) mounting brackets.

8. Install the EGR mounting bracket bolts.
Tighten: Tighten the EGR mounting bracket bolts to 20 N.m (15 lb ft).
MY
Fig. 21: View Of Left Fuel Rail At Pump Pipe

9. Install the left fuel rail to pump pipe.
Tighten: Tighten the fuel rail to pump pipe nut to 41 N.m (30 lb ft).
MY
Fig. 22: View Of Coolant Pipe

10. Install the coolant pipe.

11. Install the coolant pipe bolt and nut.
Tighten: Tighten the coolant pipe bolt and nut to 25 N.m (18 lb ft).
MY
Fig. 23: View Of Distribution Block, Fuel Line Assembly & Bolts
12. Install the distribution block and fuel line assembly.

13. Install the distribution block and fuel line assembly bolts.
Tighten: Tighten the fuel line assembly bolts to 25 N.m (18 lb ft).
MY
Fig. 24: View Of Fuel Hose Connections

14. Connect the fuel hoses to the fuel injector pump.
MY
Fig. 25: View Of Right Fuel Return Hose & Injectors

15. Install the right fuel return hose.
MY
Fig. 26: View Of Fuel Return Hose & Injectors

16. Install the left fuel return hose.
MY
Fig. 27: View Of Fuel Rail Balance Pipe & Bolts

17. Install the fuel rail balance pipe.

18. Install the fuel rail balance pipe bolts.
Tighten: Tighten the fuel rail balance pipe bolts to 21 N.m (15 lb ft).
19. Connect the fuel rail balance pipe to the fuel rails.
Tighten: Tighten the fuel rail balance pipe nuts to 41 N.m (30 lb ft).
MY
Fig. 28: View Of Fuel Feed Pipe & Bolts

20. Install the fuel feed pipe.

21. Install the fuel feed pipe attaching nuts and bolts.
Tighten: Tighten the fuel feed pipe bolts and nut to 25 N.m (18 lb ft).
TURBOCHARGER INSTALLATION
MY
MY
1. Install the turbocharger oil supply line to the engine block.
IMPORTANT: Lubricate the washers with diesel fuel before installing.
2. Install the turbocharger oil supply line eye bolt and washers.
Tighten: Tighten the turbocharger oil supply line eye bolt to 26 N.m (19 lb ft).
3. Install the turbocharger lower heat shield to the engine block.
MY

4. Install the turbocharger assembly with the oil return pipe.

5. Install the turbocharger mounting bolts.
MY
Tighten: Tighten the turbocharger mounting bolts to 108 N.m (80 lb ft).

6. Install the turbocharger cooling outlet hose and tighten hose clamp.
MY

IMPORTANT: If the cooling outlet hose eye bolts were removed, install the
longer bolt (1) with two holes, in the top location. Install the
shorter bolt (2) in the lower location.
7. Install the cooling outlet hose eye bolts.
MY

8. Install the oil supply line eye bolt and washers to the turbocharger.
MY
Lubricate the washers with diesel fuel before installing.
Tighten: Tighten the oil supply hose eye bolt to 26 N.m (19 lb ft).
Fig. 34: View Of Turbocharger Upper Heat Shield

9. Install the turbocharger heat shield.

10. Install the turbocharger upper heat shield bolts.
Tighten: Tighten the turbocharger upper heat shield bolts to 10 N.m (89 lb in).
MY
EXHAUST GAS RECIRCULATION AND COOLER INSTALLATION

1. Install the intake manifold tube.
MY
Fig. 36: Identifying EGR Cooler Bracket

2. Install the exhaust gas recirculation (EGR) cooler bracket.
3. Install the EGR cooler bracket bolts.
Tighten: Tighten the EGR cooler bracket bolts to 25 N.m (18 lb ft).
MY
Fig. 37: View Of EGR & Cooler

4. Install the EGR and cooler.
MY
Fig. 38: View Of EGR Mount Bolt

5. Install the EGR mount bolt.
Tighten: Tighten the EGR mount bolt to 50 N.m (37 lb ft).
MY
Fig. 39: View Of EGR Cooler

6. Install the top EGR cooler bolts.
Tighten: Tighten the top EGR cooler bolts to 25 N.m (18 lb ft).
MY
Fig. 40: View Of Air Inlet Tube

7. Install the air inlet tube.

8. Install the air inlet tube nuts.
MY
Tighten: Tighten the air inlet tube nuts to 25 N.m (18 lb ft).
Fig. 41: View Of Air Inlet Tube Bolt And Nut

9. Install the air inlet tube to intake manifold tube bolt and nut.
Tighten: Tighten the air inlet tube to intake manifold tube bolt and nut to 25 N.m (18 lb ft).
ENGINE WIRING HARNESS ASSEMBLY INSTALLATION
MY
Fig. 42: View Of Fuel Injector Control Module Harness

1. Install the engine wiring harness assembly.
MY
Fig. 43: View Of Right Glow Plugs

2. Install the right glow plugs.
Tighten: Tighten the glow plugs to 18 N.m (13 lb ft).
MY
Fig. 44: View Of Left Glow Plugs

3. Install the left glow plugs.
Tighten: Tighten the glow plugs to 18 N.m (13 lb ft).
MY
Fig. 45: Identifying glow Plug Controller Bolts

4. Install the glow plug nuts.
Tighten: Tighten the glow plug nuts to 2 N.m (18 lb in).
5. Install the glow plug controller.

6. Install the glow plug controller bolts.
Tighten: Tighten the glow plug controller bolts to 10 N.m (89 lb in).
MY
Fig. 46: View Of Oil Level Sensor Harness Bolt

7. Install the oil level sensor harness bolt.
Tighten: Tighten the oil level sensor harness bolt to 40 N.m (29 lb ft).
MY

8. Connect the oil pressure sensor electrical connector.
MY
Fig. 48: View Of Fuel Rail Pressure Sensor And Electrical Connector
9. Connect the fuel rail pressure sensor.
MY
Fig. 49: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
NOTE: Label all the injector electrical connectors before the

connectors are removed in order to prevent reconnecting to the
wrong injector. Failure to properly connect the injectors in the
correct sequence will cause severe engine damage.
10. Connect the turbocharger vane control solenoid valve.
MY
Fig. 50: View Of Fuel Injector Electrical Connectors

11. Connect the fuel injector electrical connections.
MY
Fig. 51: View Of Turbocharger Vane Position Sensor

12. Connect and install the turbocharger vane position sensor.
Tighten: Tighten the turbocharger vane position sensor to 23 N.m (16 lb ft).
MY
Fig. 52: View Of Glow Plug Controller Electrical Connectors

13. Connect the glow plug controller electrical connector.
MY
Fig. 53: View Of Fuel Temperature Sensor Electrical Connector

14. Connect the fuel temperature sensor connector.
MY
Fig. 54: View Of Oil Level Sensor Electrical Harness Connector

15. Connect the oil level sensor electrical harness connector.
MY
Fig. 55: View Of Fuel Pressure Control Valve Electrical Connector

16. Connect the fuel pressure control valve electrical connector.
MY
Fig. 56: View Of Electrical Harness Tie Strap

17. Install the tie strap to the electrical harness.
MY

18. Connect the crankshaft position sensor electrical connector.
MY
Fig. 58: View Of Ground Bolts

19. Install the two ground bolts.
Tighten: Tighten the ground bolts to 41 N.m (30 lb ft).
MY
Fig. 59: View Of EGR Valve Electrical Connector

20. Connect the EGR valve electrical connector.
MY
Fig. 60: View Of PCV Pipe

21. Install the positive crankcase ventilation (PCV) pipe.
MY

22. Install the left PCV pipe bolt.
Tighten: Tighten the PCV pipe bolt to 25 N.m (18 lb ft).
MY

23. Install the right PCV pipe bolt.
Tighten: Tighten the PCV pipe bolt to 25 N.m (18 lb ft).
MY

24. Connect the PCV hose clamp.
MY
Fig. 64: View Of Right Glow Plug Harness Bracket Bolts

25. Install the right glow plug harness bracket bolts.
Tighten: Tighten the glow plug harness bracket bolt to 10 N.m (89 lb in).
MY
Fig. 65: View Of Left Glow Plug Harness Bracket Bolts

26. Install the left glow plug harness bracket bolts.
Tighten: Tighten the glow plug harness bracket bolt to 10 N.m (89 lb in).
ENGINE COOLANT THERMOSTAT HOUSING INSTALLATION
MY
Fig. 66: View Of Thermostat Housing

1. Install the thermostat housing.
2. Install the thermostat housing bolts and nuts.
Tighten: Tighten the thermostat housing bolts and nuts to 25 N.m (18 lb ft).
MY
Fig. 67: View Of Fuel Pipe Bracket Bolt

3. Install the fuel pipe bracket bolt.
Tighten: Tighten the fuel pipe bracket bolt to 25 N.m (18 lb ft).
MY
Fig. 68: View Of Water Pump Inlet Pipe

4. Install the water pump inlet pipe.
MY
Fig. 69: View Of Turbocharger Coolant Outlet Hose & Clamps

5. Install the turbocharger coolant outlet hose and clamps.
MY
Fig. 70: View Of Water Pump Inlet Pipe Bolts

6. Install the water pump inlet pipe bolts.
Tighten: Tighten the water pump inlet pipe bolts to 25 N.m (18 lb ft).
MY
Fig. 71: View Of Exhaust Gas Recirculation (EGR) Coolant Pipe, Hose & Bolts
7. Install the EGR coolant pipe.

8. Install the EGR coolant pipe bolts.
Tighten: Tighten the EGR coolant pipe bolts to 25 N.m (18 lb ft).
MY
Fig. 72: View Of Engine Coolant Temperature Sensor And Electrical Connector
9. Connect the coolant temperature sensor.
MY

10. Install the oil fill tube.
MY
Fig. 74: View Of Oil Filler Tube Bolts

11. Install the oil fill tube bolts.
Tighten: Tighten the oil fill tube bolts to 25 N.m (18 lb ft).
MY
Fig. 75: View Of Water Outlet

12. Install the water outlet.
MY
Fig. 76: View Of Water Outlet Bolts

13. Install the water outlet bolts.
Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).
MY
Fig. 77: View Of Electrical Harness Bracket Bolt

14. Install the electrical harness bracket.

15. Install the electrical harness bracket bolt.
Tighten: Tighten the electrical harness bracket bolt to 10 N.m (89 lb in).
MY
Fig. 78: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
16. Connect the turbocharger coolant inlet hose.
MY
Fig. 79: View Of Main Electrical Connector Harness Bracket & Bolts
17. Install the main electrical harness bracket.

18. Install the main electrical harness bracket bolts.
Tighten: Tighten the main electrical harness bracket bolts to 10 N.m (89 lb in).
MY
Fig. 80: View Of Turbocharger Vane Position Sensor And Electrical Connector
19. Connect and install the turbocharger vane position sensor.
MY
Fig. 81: View Of Barometric Pressure Sensor Electrical Connector

20. Connect and install the barometric sensor.
MY
Fig. 82: View Of Main Engine Electrical Harness Connector Bolts

21. Install the main engine electrical harness connector hold down bolts.
Tighten: Tighten the main electrical harness connector hold down bolts to 10 N.m (89 lb
in).
DRIVE BELT TENSIONER AND GENERATOR MOUNTING BRACKET INSTALLATION
MY

1. Install the drive belt tensioner and generator mounting bracket.
2. Install the drive belt tensioner and generator mounting bracket bolts.
Tighten: Tighten the drive belt tensioner and generator mounting bracket bolts to 50 N.m
(37 lb ft).
MY

3. Install the drive belt tensioner.

4. Install the drive belt tensioner bolt.
Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
MY
Fig. 85: View Of Electrical Harness Clip Bolts

5. Install the electrical harness clip bolts.
Tighten: Tighten the electrical harness clip bolts to 10 N.m (89 lb in).
FUEL FILTER ASSEMBLY INSTALLATION
MY
Fig. 86: Identifying Fuel Filter Assembly

1. Install the fuel filter assembly.
MY

Tighten: Tighten the fuel filter bracket bolts to 21 N.m (15 lb ft).
MY
Fig. 88: View Of Fuel Filter Assembly Connectors

3. Connect the fuel filter assembly connectors.
MY
Fig. 89: View Of Fuel Hoses At Fuel Filter

4. Install the fuel hoses.
POWER STEERING PUMP MOUNTING BRACKET INSTALLATION
MY
Fig. 90: View Of A/C Compressor & Power Steering Pump Bracket
1. Install the power steering pump mounting bracket.
2. Install the power steering pump mounting bracket bolts.
Tighten: Tighten the power steering pump mounting bracket bolts to 46 N.m (34 lb ft).
COOLING FAN PULLEY INSTALLATION
MY
Fig. 91: View Of Camshaft Position Sensor

1. Lubricate the camshaft position sensor O-ring with engine oil.

2. Install the camshaft position sensor.
3. Install the camshaft position sensor retaining bolt.
Tighten: Tighten the camshaft position sensor retaining bolt to 10 N.m (89 lb in).
MY
Fig. 92: View Of Cooling Fan Pulley

4. Install the cooling fan pulley.

5. Install the cooling fan pulley bolts and nuts.
Tighten: Tighten the cooling fan pulley bolts and nuts to 41 N.m (30 lb ft).
MY
Fig. 93: View Of Camshaft Position Sensor Electrical Connector

6. Connect the camshaft position sensor connector.
ENGINE REMOVAL FROM STAND
Tools Required
J 36857 Engine Lift Bracket. See Special Tools .

Removal
MY
Fig. 94: View Of J 36857 Installation Positions

1. Bolt J 36857 to the ends of the cylinder heads. See Special Tools .
MY
Fig. 95: Mounting Engine Block To Suitable Engine Stand

2. Lift the engine and the engine stand with a suitable hoist.
3. Remove the engine stand from the engine adapter.
4. Lower the engine to the floor. Support the engine with blocks.
5. Remove the engine adapter.
ENGINE FLYWHEEL HOUSING INSTALLATION
MY

1. Install the oil cooler adapter with gaskets to the oil cooler.
2. Install the oil cooler adapter to oil cooler bolts.
Tighten: Tighten the oil cooler adapter to oil cooler bolts to 21 N.m (15 lb ft).
MY
88901148) sealant to the engine block mating surface.
Fig. 97: View Of Flywheel Housing

4. Install the flywheel housing to the cylinder block.

5. Install the flywheel housing bolts.
Tighten: Tighten the flywheel housing bolts to 80 N.m (60 lb ft)
MY

6. Install a new gasket to the turbocharger oil return pipe.

7. Install the turbocharger oil return pipe to flywheel housing studs.
Tighten: Tighten the turbocharger oil return pipe to flywheel housing studs to 10 N.m (89
lb in).
8. Install the turbocharger oil return pipe nuts.
MY
Tighten: Tighten the turbocharger oil return pipe nuts to 25 N.m (18 lb ft).
UPPER OIL PAN INSTALLATION

1. Apply a 2-3 mm wide by 0.5-1.5 mm bead of GM P/N 12378521 (Canadian P/N

88901148) sealant to the upper oil pan mating surfaces.
MY

2. Install the upper oil pan to the engine block.
MY
Fig. 101: Upper Oil Pan Bolts Tightening Sequence

3. Install the upper oil pan bolts.
Tighten: Tighten the upper oil pan bolts in sequence to 20 N.m (15 lb ft).
MY

4. Install the two flywheel housing to upper oil pan bolts.
Tighten: Tighten the two flywheel housing to upper oil pan bolts to 50 N.m (37 lb ft)
MY
Fig. 103: View Of Oil Level Indicator

5. Install the oil level indicator tube.

6. Install the oil level indicator tube bracket bolt.
Tighten: Tighten the oil level indicator tube bracket bolt to 21 N.m (15 lb ft).
LOWER OIL PAN INSTALLATION

MY

88901148) sealant to the lower oil pan mating surface.
MY

2. Install the lower oil pan.
MY
Fig. 106: Lower Oil Pan Bolts Tightening Sequence

NOTE: Refer to Fastener Notice
3. Install the lower oil pan bolts and nuts.
MY
Tighten: Tighten the lower oil pan bolts and nuts in sequence to 10 N.m (89 lb in).

4. Connect the oil level sensor.
EXHAUST PIPE INSTALLATION - LEFT SIDE
MY

IMPORTANT: Position the exhaust pipe gaskets with the tabs as shown.
Failure to do so will cause improper alignment of the gaskets
and result in exhaust leaks.
1. Install the exhaust pipe with gaskets.

2. Install the exhaust pipe to turbocharger bolts.
MY
Fig. 109: Exhaust Pipe To Exhaust Manifold Bolt Tightening Sequence - Left Side
3. Install the exhaust pipe to exhaust manifold bolts.
Tighten: Tighten the exhaust pipe bolts to 53 N.m (39 lb ft) in the proper sequence.
MY
4. Install the exhaust pipe heat shield.

5. Install the exhaust pipe heat shield bolts.
Tighten: Tighten the exhaust pipe heat shield bolts to 10 N.m (89 lb in).
EXHAUST PIPE INSTALLATION - RIGHT SIDE
MY

IMPORTANT: Position the exhaust pipe gaskets with the tabs as shown.
Failure to do so will cause improper alignment of the gaskets
and result in exhaust leaks.
1. Install the exhaust pipe with gaskets.

2. Install the exhaust outlet bracket.
3. Install the exhaust pipe to turbocharger bolts.
MY
Fig. 112: Exhaust Pipe To Exhaust Manifold Bolt Tightening Sequence -- Right Side
4. Install the exhaust pipe to exhaust manifold bolts in sequence.
Tighten: Tighten the exhaust pipe bolts to 53 N.m (39 lb ft) in sequence.
Tighten: Tighten the exhaust pipe to EGR cooler nuts to 26 N.m (19 lb ft).
MY
EXHAUST OUTLET INSTALLATION

1. Install the exhaust outlet.
2. Install the exhaust outlet clamp.
MY
Tighten: Tighten the exhaust outlet clamp to 15 N.m (11 lb ft).
Fig. 114: View Of Exhaust Outlet Heat Shield

3. Install the exhaust outlet to right exhaust pipe bracket bolt.
Tighten: Tighten the exhaust outlet to right exhaust pipe bracket bolt to 34 N.m (25 lb ft).
4. Install the exhaust outlet heat shield.

5. Install the exhaust outlet heat shield bolts.
Tighten: Tighten the exhaust outlet heat shield bolts to 10 N.m (89 lb in).
MY
CRANKSHAFT REAR OIL SEAL INSTALLATION
Tools Required
Installation
J 44642 Crankshaft Rear Oil Seal Installer. See Special Tools .
Fig. 115: Pressing Crankshaft Rear Oil Seal In Using J 44642

1. Place the crankshaft rear oil seal onto the crankshaft.
IMPORTANT: The J 44642 must be fully secured to the crankshaft to

ensure proper seal depth. See Special Tools .
MY
2. Install the J 44642 to the crankshaft. See Special Tools .

3. Press the crankshaft rear oil seal into position using the J 44642 . See Special Tools . The J
44642 will bottom out when the seal reaches the proper depth. See Special Tools .
ENGINE FLYWHEEL INSTALLATION (AUTOMATIC TRANSMISSION)
Tools Required

J 45059 Angle Meter
Installation

MY
1. Install the flywheel to the crankshaft.

2. Install the flywheel washer to the flywheel with the beveled side facing the engine.

damage.
3. Install NEW flywheel bolts.
MY

4. Install the J 44643 to lock the flywheel. See Special Tools .
MY

5. Tighten the flywheel bolts in the proper sequence.
Tighten:
MY

2nd step 60 degrees using J 45059 .
ENGINE FLYWHEEL INSTALLATION (MANUAL TRANSMISSION)
Tools Required

J 45059 Angle Meter
Installation
Fig. 119: View Of Engine Flywheel Pilot Bearing

MY
1. Install the pilot bearing.
Fig. 120: View Of Flywheel & Mounting Bolts (Manual)


2. Install the flywheel.

MY

damage.
3. Loosely install NEW flywheel bolts.
MY
Fig. 121: Locking Flywheel Using J 44643 (Manual Transmission)

4. Install J 44643 to hold the flywheel from rotating. See Special Tools .

MY
5. Use the following steps and the proper sequence to tighten the flywheel bolts:
Tighten:
1. Tighten the flywheel bolts to 79 N.m (59 lb ft).
2. Tighten the flywheel bolts to 60 degrees using the J 45059 .
3. Tighten the flywheel bolts again to 60 degrees using the J 45059 .
CRANKSHAFT BALANCER INSTALLATION
Tools Required

Installation
MY

1. Lightly lubricate the crankshaft balancer internal hub with engine oil.
2. Install the crankshaft balancer to the crankshaft.
3. Lightly lubricate the crankshaft balancer bolt with engine oil.
4. Install the crankshaft balancer bolt and washer.
Tighten:
MY
1. Tighten the bolt to 100 N.m (74 lb ft) on the first pass.
2. Tighten the bolt an additional 105 degrees.
STARTER INSTALLATION

1. Install the starter motor to the flywheel housing.

MY
2. Install the starter motor bolts.
Tighten: Tighten the starter bolts to 78 N.m (58 lb ft).
ENGINE PRELUBING
Special Tools
J 45299 Engine Preluber

Prelube
Fig. 125: View Of Engine Assembly

MY
IMPORTANT: A constant/continuous flow of clean engine oil is required to

properly prime the engine. Be sure to use an approved
engine oil as specified in the owners manual.
1. Remove the engine oil filter, fill with clean engine oil, and reinstall.
Tighten: Tighten the oil filter to 24 N.m (18 lb ft).
2. Remove the oil pressure sensor.

3. Install the M16 x 1.5 adapter P/N 509375.
MY
Fig. 126: Identifying Engine Preluber J 45299

4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the
MY
flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the oil pressure sensor.
Tighten: Tighten the oil pressure sensor to 41 N.m (30 lb ft).
8. Top off the engine oil to the proper level.
MY

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2008 Chevrolet Silverado 1500

3rd Step 30 3rd Step 30

Fan Pulley Bracket Bolt 50 N.m 37 lb ft

Injector Bracket Bolt 23 N.m 16 lb ft

Torque Converter Bolt 60 N.m 44 lb ft

ENGINE MECHANICAL SPECIFICATIONS

Cylinder Bore Diameter - Service Limits

Production Value 34.512-34.522 mm 1.3587-1.3591 in

Surface Flatness- Production Value

Piston Ring End Gap-First Compression Ring - 0.3-0.45 mm 0.0118-0.0177 in

Valve Springs-Valve Spring Free Length - 56.6 mm 2.2283 in

SEALERS, ADHESIVES, AND LUBRICANTS

Camshaft Bearing Engine Oil 12345634 993297

CONNECTING ROD BEARINGS SELECTION SPECIFICATIONS

Connecting Rod Bearing Grade

CYLINDER HEAD GASKET SELECTION SPECIFICATIONS

Fig. 1: View Of Cylinder Head Gasket Selection Marks

Callout Component Name

Cylinder Head Ti Max (Piston Projection) Compressed Gasket Thickness

CRANKSHAFT BEARING SELECTION SPECIFICATIONS

Cylinder Block Crankshaft Identification Oil Clearance

VALVE CLEARANCE ADJUSTMENT SPECIFICATIONS

Adjust at No 1 Adjust at No 1 Exhaust

THREAD REPAIR SPECIFICATIONS

Cylinder Head - Exhaust View

Fig. 2: Cylinder Head (Exhaust View)

Cylinder Head - Exhaust View

Cylinder Head - Intake View

Fig. 3: Cylinder Head (Intake View)

Cylinder Head - Intake View

Cylinder Head - Top View

Fig. 4: Cylinder Head (Top View)

Cylinder Head - Top View

Cylinder Head - Rear View

Fig. 5: Cylinder Head (Rear View)

Cylinder Head - Rear View

Cylinder Head - Front View

Fig. 6: Cylinder Head (Front View)

Cylinder Head - Front View

Intake Manifold - Right Side View

Fig. 7: Intake Manifold (Right Side View)

Intake Manifold - Right Side View

Intake Manifold - Left Side View

Fig. 8: Intake Manifold (Left Side View)

Intake Manifold - Left Side View

Fig. 9: View Of Oil Cooler

EGR Cooler - Rear View

Fig. 10: EGR Cooler (Rear View)

EGR Cooler - Rear View

EGR Cooler - Front View

Fig. 11: EGR Cooler (Front View)

EGR Cooler - Front View

EGR - Top View

Fig. 12: EGR (Top View)

Courtesy of GENERAL MOTORS CORP.

EGR - Top View

Thermostat Housing - Top View

Fig. 13: Thermostat Housing (Top View)