GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 786976  Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  3. Disconnect the fuel injection control module electrical connectors (1).

  4. Object Number: 877275  Size: SH
  5. Loosen the charged air cooler outlet duct clamp (1).
  6. 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.

  7. Remove the charged air cooler outlet duct.

  8. Object Number: 786973  Size: SH
  9. Disconnect the following electrical connectors:
  10. • Water-in-fuel sensor (1)
    • Fuel heater (2)

    Object Number: 786980  Size: SH
  11. Disconnect the right rear fuel injector electrical connector (1).

  12. Object Number: 788836  Size: SH
  13. Disconnect the exhaust gas recirculation (EGR) valve solenoid electrical connector (1).

  14. Object Number: 788837  Size: SH
  15. Disconnect the EGR valve vent solenoid electrical connector (1).

  16. Object Number: 788835  Size: SH
  17. Disconnect the EGR valve vacuum sensor electrical connector (1).

  18. Object Number: 788838  Size: SH
  19. Disconnect the EGR throttle valve solenoid electrical connector.

  20. Object Number: 788839  Size: SH
  21. Remove the right side glow plug electrical nuts.
  22. Remove the right side engine harness from the glow plug (1).

  23. Object Number: 788844  Size: SH
  24. Disconnect the right front fuel injector electrical connector (1).

  25. Object Number: 788842  Size: SH
  26. Disconnect the turbocharger boost sensor electrical connector (1).

  27. Object Number: 786983  Size: SH
  28. Remove the sight shield hold-down bolt and bracket (1).

  29. Object Number: 740506  Size: SH
  30. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).

  31. Object Number: 668427  Size: SH
  32. Reposition the turbocharger water inlet hose clamp.
  33. Remove the turbocharger water inlet hose.

  34. Object Number: 687052  Size: SH
  35. Remove the turbocharger coolant bypass valve.
  36. Remove the glow plug relay. Refer to Glow Plug Relay Replacement .

  37. Object Number: 674653  Size: SH
  38. Disconnect the engine harness electrical connectors.

  39. Object Number: 674680  Size: SH
  40. Remove the bulk connector bolts from the bracket (1).

  41. Object Number: 877281  Size: SH
  42. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
  43. 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.

  44. Remove the charged air cooler inlet duct from the turbocharger.

  45. Object Number: 687021  Size: SH
  46. Reposition the positive crankcase ventilation (PCV) hose clamp.
  47. Remove the PCV hose from the left valve cover.

  48. Object Number: 786986  Size: SH
  49. Disconnect the left front fuel injector electrical connector (1).

  50. Object Number: 786988  Size: SH
  51. Disconnect the left rear fuel injector electrical connector (1).

  52. Object Number: 786977  Size: SH
  53. Disconnect the fuel rail temperature sensor electrical connector (1).

  54. Object Number: 788841  Size: SH
  55. Disconnect the glow plug controller electrical connectors (1).

  56. Object Number: 788847  Size: SH
  57. Remove the fuel pipe retainer nut at the valve cover.
  58. Remove the fuel pipe retainer (2).

  59. Object Number: 788840  Size: SH
  60. Remove the left front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  61. Remove the left side glow plug electrical nuts.
  62. Remove the left side engine harness from the glow plugs (1).

  63. Object Number: 788846  Size: SH
  64. Disconnect the oil level electrical connector (1).

  65. Object Number: 739503  Size: SH
  66. Disconnect the barometric pressure (BARO) sensor electrical connector (1).

  67. Object Number: 786994  Size: SH
  68. Disconnect the fuel rail pressure sensor electrical connector (1).
  69. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  70. Object Number: 349061  Size: SH
  71. Remove the engine shield bolts and shield.

  72. Object Number: 786970  Size: SH
  73. Disconnect the crankshaft position (CKP) sensor electrical connector.

  74. Object Number: 742170  Size: SH
  75. Disconnect the camshaft position (CMP) sensor electrical connector (1).

  76. Object Number: 786972  Size: SH
  77. Remove the engine harness ground bolts (1).
  78. Lower the vehicle.

  79. Object Number: 786996  Size: SH
  80. Unroute and lift up the engine wiring harness for access to fuel pressure regulator.
  81. Disconnect the fuel pressure regulator electrical connector (1).

  82. Object Number: 660421  Size: SH
  83. Remove the engine wiring harness.

Installation Procedure


    Object Number: 660421  Size: SH
  1. Install the engine wiring harness.

  2. Object Number: 786996  Size: SH
  3. Connect the fuel pressure regulator electrical connector (1).
  4. Route the engine wiring harness to the engine.
  5. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 786972  Size: SH
  6. Raise the vehicle.
  7. Install the engine wiring harness ground bolts (1).
  8. Tighten
    Tighten the bolts to 34 N·m (25 lb ft).


    Object Number: 742170  Size: SH
  9. Connect the CMP sensor electrical connector (1).

  10. Object Number: 786970  Size: SH
  11. Connect the CKP sensor electrical connector.

  12. Object Number: 349061  Size: SH
  13. Install the engine shield and bolts.
  14. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  15. Lower the vehicle.

  16. Object Number: 786994  Size: SH
  17. Connect the fuel rail pressure sensor electrical connector (1).

  18. Object Number: 739503  Size: SH
  19. Connect the BARO sensor electrical connector (1).

  20. Object Number: 788846  Size: SH
  21. Connect the oil level sensor electrical connector (1).

  22. Object Number: 788840  Size: SH
  23. Install the left side engine harness to the glow plugs (1).
  24. Install the glow plug electrical nuts.
  25. Tighten
    Tighten the nuts to 2 N·m (18 lb in).

  26. Install the left inner wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.

  27. Object Number: 788847  Size: SH
  28. Install the fuel pipe retainer (2).
  29. Install the fuel pipe retainer nut at the valve cover.
  30. Tighten
    Tighten the nut to 8 N·m (70 lb in).


    Object Number: 788841  Size: SH
  31. Connect the glow plug controller electrical connectors (1).

  32. Object Number: 786977  Size: SH
  33. Connect the fuel rail temperature sensor electrical connector (1).

  34. Object Number: 786988  Size: SH
  35. Connect the left rear fuel injector electrical connector (1).

  36. Object Number: 786986  Size: SH
  37. Connect the left front fuel injector electrical connector (1).

  38. Object Number: 687021  Size: SH
  39. Install the PCV hose to valve cover.
  40. Position the PCV hose clamp.

  41. Object Number: 877281  Size: SH
  42. Install the charged air cooler inlet duct to the turbocharger.
  43. Align the mark on the duct (2) with the mark on the turbocharger.
  44. Position the clamp (1) as shown for proper clearance.
  45. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 674680  Size: SH
  46. Install the bulk connector bolts (1) to the bracket.
  47. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).


    Object Number: 674653  Size: SH
  48. Connect the engine harness electrical connectors.
  49. Install the glow plug relay. Refer to Glow Plug Relay Replacement .

  50. Object Number: 687052  Size: SH
  51. Install the turbocharger coolant bypass valve.
  52. Tighten
    Tighten the valve to 60 N·m (44 lb ft).


    Object Number: 668427  Size: SH
  53. Install the turbocharger water inlet hose.
  54. Position the turbocharger water inlet hose clamp.

  55. Object Number: 740506  Size: SH
  56. Connect the ECT sensor electrical connector (1).

  57. Object Number: 786983  Size: SH
  58. Install the engine sight shield hold-down bracket (1) and bolt.
  59. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 788842  Size: SH
  60. Connect the turbocharger boost sensor electrical connector (1).

  61. Object Number: 788844  Size: SH
  62. Connect the right front fuel injector electrical connector (1).

  63. Object Number: 788839  Size: SH
  64. Install the right side engine harness to the glow plugs (1).
  65. Install the right side glow plug electrical nuts.
  66. Tighten
    Tighten the nuts to 2 N·m (18 lb in).


    Object Number: 788838  Size: SH
  67. Connect the EGR throttle valve solenoid electrical connector (1).

  68. Object Number: 788835  Size: SH
  69. Connect the EGR vacuum sensor electrical connector (1).

  70. Object Number: 788837  Size: SH
  71. Connect the EGR vent solenoid electrical connector (1).

  72. Object Number: 788836  Size: SH
  73. Connect the EGR valve solenoid electrical connector (1).

  74. Object Number: 786980  Size: SH
  75. Connect the right rear fuel injector electrical connector (1).

  76. Object Number: 786973  Size: SH
  77. Connect the following electrical connectors:
  78. • Water-in-fuel sensor (1)
    • Fuel heater (2)

    Object Number: 877275  Size: SH
  79. Install the charged air cooler outlet duct to the intake.
  80. Tighten the charged air cooler outlet duct clamp (1).
  81. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 786976  Size: SH
  82. Connect the fuel injection control module electrical connectors (1).
  83. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
  84. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.