1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

4. 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.

5. Remove the charged air cooler inlet duct connector (4) from the turbocharger.



6. Remove the battery cable to generator nut.
7. If equipped, remove the battery cable to auxiliary generator nut.
8. Remove the battery cable harness clip from the bracket.
9. Remove the battery cable junction block bolt (1) from the power steering pump.
10. Move and secure the battery cables out of the way.



11. Disconnect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
12. Remove the fuel line bracket nut.
13. Remove the fuel line bracket from the stud.



14. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
15. Open the harness clip (2).
16. Remove the main engine electrical harness connectors.



17. Remove the engine harness main electrical connectors bolts.



18. Disconnect the barometric sensor electrical connector.
19. Remove the engine harness main connector bracket bolts.
20. Remove the water outlet tube. Refer to Water Outlet Tube Replacement .
21. Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement .



22. Disconnect the glow plug controller electrical connector.



23. Disconnect the glow plug controller battery feed electrical connector (1).
24. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .



25. 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.
26. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.

Notice: 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 the fuel injector.

27. Remove the left fuel injector pipes.

Notice: 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.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the fuel injector pipes.

Tighten
Tighten the fittings to 41 N·m (30 lb ft).

2. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .



3. Connect the glow plug controller battery feed electrical connector (1).



4. Connect the glow plug controller electrical connectors.
5. Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement .
6. Install the water outlet tube. Refer to Water Outlet Tube Replacement .



7. Install the engine harness main connector bracket bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).

8. Connect the barometric sensor electrical connector.



9. Install the engine harness main electrical connectors bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




10. Connect the main engine electrical harness connectors.
11. Push down on the latches (1) in order to connect the connectors.
12. Close the harness clip (2).



13. Install the fuel line bracket from the stud.
14. Install the fuel line bracket nut.

Tighten
Tighten the nut to 21 N·m (15 lb ft).

15. Connect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .



16. Position the generator positive cable.
17. Install the generator positive cable in the clip on the engine front cover.
18. Install the generator positive cable and nut to the generator.

Tighten
Tighten the nut to 9 N·m (80 lb in).

19. Install the battery positive cable junction block bracket and bolt (1) to the power steering bracket.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




20. Remove the tape from the turbocharger openings.

Important: Lubricate the end of the duct prior to installation.

21. Install the charged air cooler inlet duct connector (4) to the turbocharger.
22. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

Tighten
Tighten the clamp to 6 N·m (53 lb in).

23. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
24. Fill the cooling system. Refer to Cooling System Draining and Filling .
25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
26. Prime the fuel system. Refer to Fuel System Priming .
27. Start the engine. If the engine stalls, repeat the above step.
28. Once the engine starts, inspect for fuel leaks.