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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Controls - 6.6L - 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.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  3. Remove both front wheelhouse panels. Refer to Wheelhouse Panel Replacement .
  4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  5. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  6. Remove the charged air cooler outlet duct from the intake.
    Fig 1: Removing Charged Air Cooler Outlet Duct
    GM1653035Courtesy of GENERAL MOTORS CORP.
  7. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
    Fig 2: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  8. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
  9. Disconnect the intake air heater (IAH) electrical connector (1).
    Fig 3: Disconnecting IAH And MAP Sensor Electrical Connectors
    GM1602064Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
  11. Remove the engine harness clip from the side of the air inlet tube.
    12. Fig 4: View Of Left Glow Plug Harness Bracket Bolts
    GM1335443Courtesy of GENERAL MOTORS CORP.
  12. Remove the left glow plug harness bracket bolts.
    13. Fig 5: View Of Right Glow Plug Harness Bracket Bolts
    GM1335450Courtesy of GENERAL MOTORS CORP.
  13. Remove the right glow plug harness bracket bolts.
  14. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
    15. Fig 6: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    16. Fig 7: View Of EGR Valve Electrical Connector
    GM1335463Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    17. Fig 8: View Of Camshaft Position Sensor Electrical Connector
    GM1334862Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the camshaft position (CMP) sensor electrical connector.
    18. Fig 9: View Of Ground Bolts
    GM1335467Courtesy of GENERAL MOTORS CORP.
  18. Remove the 2 ground bolts.
    19. Fig 10: View Of Crankshaft Position Sensor Electrical Connector
    GM1335470Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the crankshaft position (CKP) sensor electrical connector.
    20. Fig 11: Removing Electrical Harness Bolts
    GM1602057Courtesy of GENERAL MOTORS CORP.
  20. Remove the electrical harness bolts.
    21. Fig 12: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  22. Open the harness clip (2).
  23. Remove the main engine electrical harness connectors.
    24. Fig 13: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  24. Remove the main engine electrical harness connector bolts.
    25. Fig 14: View Of Fuel Pressure Control Valve Electrical Connector
    GM1335482Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the fuel pressure control valve electrical connector.
    26. Fig 15: View Of Oil Level Sensor Electrical Harness Connector
    GM1335526Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the oil level sensor electrical harness connector.
    27. Fig 16: View Of Fuel Temperature Sensor Electrical Connector
    GM1335528Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the fuel temperature sensor electrical connector.
    28. Fig 17: Disconnecting Glow Plug Module Electrical Connectors
    GM1653265Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the glow plug control module electrical connectors (1, 2).
    29. IMPORTANT: Note the wire routing prior to removal.
    Fig 18: View Of Turbocharger Vane Position Sensor And Electrical Connector
    GM1334926Courtesy of GENERAL MOTORS CORP.
  29. Disconnect and remove the turbocharger vane position sensor.
    30. Fig 19: Disconnecting IAT Sensor Electrical Connector
    GM1602068Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the intake air temperature (IAT) sensor electrical connector (1).
    31. Fig 20: 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.
  31. Disconnect the fuel injector electrical connectors.
    32. Fig 21: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
    GM1335540Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the turbocharger vane control solenoid valve.
    33. Fig 22: View Of Fuel Rail Pressure Sensor And Electrical Connector
    GM1335543Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the fuel rail pressure sensor electrical connector.
    34. Fig 23: View Of Oil Pressure Sensor Electrical Connector
    GM1335546Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the oil pressure sensor electrical connector.
    35. Fig 24: View Of Oil Level Sensor Harness Bolt
    GM1335549Courtesy of GENERAL MOTORS CORP.
  35. Remove the oil level sensor harness bolt.
    36. Fig 25: Removing Glow Plug Module Bolts
    GM1602069Courtesy of GENERAL MOTORS CORP.
  36. Remove the glow plug control module bolts.
  37. Remove the glow plug control module.
    38. Fig 26: View Of Fuel Injector Control Module Harness
    GM1335560Courtesy of GENERAL MOTORS CORP.
  38. Remove the engine wiring harness.
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