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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Control System & Fuel System - 6.6L (LLY) - Introduction (2 Of 2)) >> Repair Instructions >> Engine Wiring Harness Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Engine Wiring Harness
    GM1731918Courtesy of GENERAL MOTORS CORP.
  1. Install the engine wiring harness.
    2. Fig 2: Identifying fuel rail pressure (FRP) sensor electrical connector
    GM1732190Courtesy of GENERAL MOTORS CORP.
  2. Connect the engine wiring harness electrical connector (1) to the fuel rail pressure sensor.
  3. Install the fuel rail pressure sensor wiring harness clip to the bracket.
    4. Fig 3: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
    GM1335540Courtesy of GENERAL MOTORS CORP.
  4. Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.
    5. Fig 4: View Of Fuel Injector Electrical Connectors
    GM1335536Courtesy of GENERAL MOTORS CORP.
    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.
  5. Connect the engine wiring harness electrical connectors to the right side fuel injectors.
    6. Fig 5: Identifying fuel pump electrical connector
    GM1734476Courtesy of GENERAL MOTORS CORP.
  6. Connect the engine wiring harness electrical connector to the fuel pressure regulator.
    7. NOTE: Refer to Fastener Notice .
  7. Position the right side main engine wiring harness connector to the bracket and install the connector bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  8. Connect the right side main engine wiring harness electrical connector.
    9. Fig 6: Identifying Glow Plug Nut, Glow Plug Harness Bracket Bolts And Nut
    GM1732769Courtesy of GENERAL MOTORS CORP.
  9. Install the engine wiring harness to the glow plugs and install the glow plug nuts (3).

    Tighten:  Tighten the nuts to 1.7 N.m (15 lb in).

  10. Position the right engine wiring harness bracket and install the bracket bolts (1) and nut (2).

    Tighten:  Tighten the bolts and nut to 10 N.m (89 lb in).

    11. Fig 7: View Of Crankshaft Position Sensor Electrical Connector
    GM1335470Courtesy of GENERAL MOTORS CORP.
  11. Connect the engine wiring harness electrical connector to the CKP sensor.
    12. Fig 8: View Of Camshaft Position Sensor Electrical Connector
    GM1334862Courtesy of GENERAL MOTORS CORP.
  12. Connect the engine wiring harness electrical connector to the CMP sensor.
  13. Install the engine wiring harness behind the clip attached to the engine block.
    14. Fig 9: Identifying Ground Bolt On Engine Block
    GM1662872Courtesy of GENERAL MOTORS CORP.
  14. Raise and support the vehicle.
  15. Position the engine wiring right side ground and install the bolt.

    Tighten:  Tighten the bolt to 41 N.m (30 lb ft).

    16. Fig 10: View Of Oil Level Sensor Harness Bolt
    GM1335549Courtesy of GENERAL MOTORS CORP.
  16. Position the engine wiring harness left side ground and install the bolt.

    Tighten:  Tighten the bolt to 40 N.m (29 lb ft).

  17. Install the engine wiring harness behind the clip secured to the front cover.
    18. Fig 11: View Of Oil Pressure Sensor Electrical Connector
    GM1335546Courtesy of GENERAL MOTORS CORP.
  18. Lower the vehicle.
  19. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
  20. Connect the engine wiring harness electrical connector to the oil level sensor.
    21. Fig 12: Identifying intake air temperature sensor
    GM1732300Courtesy of GENERAL MOTORS CORP.
  21. Connect the engine wiring harness electrical connector to the fuel temperature sensor.
    22. Fig 13: Identifying Glow Plug Controller
    GM1662873Courtesy of GENERAL MOTORS CORP.
  22. Connect the engine wiring harness electrical connector to the glow plug control module.
  23. Connect the engine wiring harness electrical connector to the IAT sensor.
  24. Position the left side engine wiring harness main electrical connector to the bracket and install the connector bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    25. Fig 14: View Of Fuel Injector Return Line Clip And Return Line Fitting At Injector
    GM1732359Courtesy of GENERAL MOTORS CORP.
    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.
  25. Install the engine wiring harness electrical connectors to the left fuel injectors.
    26. Fig 15: Identifying LH glow plug nuts
    GM1732768Courtesy of GENERAL MOTORS CORP.
  26. Install the engine wiring harness to the left glow plugs and install the glow plug nuts (2).

    Tighten:  Tighten the nuts to 1.7 N.m (15 lb in).

  27. Position the left engine wiring harness bracket and install the bracket bolts (1).

    Tighten:  Tighten the bolts to 10 N.m (89 lb ft).

  28. Install the turbocharger vane position sensor. Refer to Turbocharger Vane Position Sensor Replacement .
  29. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LLY, LBZ) or Thermostat Housing Crossover Replacement (LMM) .
  30. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
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