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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying LH glow plug nuts
    GM1732768Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  3. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LLY, LBZ) or Thermostat Housing Crossover Replacement (LMM) .
  4. Remove the turbocharger vane position sensor. Refer to Turbocharger Vane Position Sensor Replacement .
  5. Remove the left engine wiring harness bracket bolts (1).
  6. Remove the left glow plug nuts (2).
    7. Fig 2: 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.
  7. Remove the engine wiring harness electrical connectors from the left fuel injectors.
    8. Fig 3: Identifying Glow Plug Controller
    GM1662873Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the engine wiring harness electrical connector from the glow plug control module.
  9. Disconnect the engine wiring harness electrical connector from the intake air temperature (IAT) sensor.
  10. Disconnect the left side engine wiring harness main electrical connector.
  11. Remove the left side engine wiring harness main connector bolt from the bracket.
    12. Fig 4: Identifying intake air temperature sensor
    GM1732300Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the engine wiring harness electrical connector from the fuel temperature sensor.
    13. Fig 5: View Of Oil Pressure Sensor Electrical Connector
    GM1335546Courtesy of GENERAL MOTORS CORP.
  13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  14. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
  15. Disconnect the engine wiring harness electrical connector from the oil level sensor.
    16. Fig 6: View Of Oil Level Sensor Harness Bolt
    GM1335549Courtesy of GENERAL MOTORS CORP.
  16. Remove the engine wiring harness left side ground bolt.
  17. Remove the engine wiring harness from the clip secured behind one of the front cover bolts.
    18. Fig 7: Identifying Ground Bolt
    GM1662872Courtesy of GENERAL MOTORS CORP.
  18. Remove the engine wiring right side ground bolt.
  19. Lower the vehicle.
    20. Fig 8: View Of Camshaft Position Sensor Electrical Connector
    GM1334862Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the engine wiring harness electrical connector from the camshaft position (CMP) sensor.
  21. Remove the engine wiring harness from behind the clip attached to the engine block.
    22. Fig 9: View Of Crankshaft Position Sensor Electrical Connector
    GM1335470Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the engine wiring harness electrical connector from the crankshaft position (CKP) sensor.
    23. Fig 10: Identifying Glow Plug Nut, Glow Plug Harness Bracket Bolts And Nut
    GM1732769Courtesy of GENERAL MOTORS CORP.
  23. Remove the right engine wiring harness bracket bolts (1) and nut (2).
  24. Remove the glow plug nuts (3).
    25. Fig 11: Identifying fuel pump electrical connector
    GM1734476Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the engine wiring harness electrical connector from the fuel pressure regulator.
  26. Disconnect the right side main engine wiring harness electrical connector.
  27. Remove the right side main engine wiring harness connector bolt.
    28. Fig 12: 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.
  28. Disconnect the engine wiring harness electrical connectors from the right side fuel injectors.
    29. Fig 13: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
    GM1335540Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.
    30. Fig 14: Identifying fuel rail pressure (FRP) sensor electrical connector
    GM1732190Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the engine wiring harness electrical connector (1) from the fuel rail pressure sensor.
  31. Remove the fuel rail pressure sensor wiring harness clip from the bracket.
    32. Fig 15: View Of Engine Wiring Harness
    GM1731918Courtesy of GENERAL MOTORS CORP.
  32. Remove the engine wiring harness.
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