GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 1653035  Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  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.

  7. Object Number: 1334380  Size: SH
  8. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
  9. 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.

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

  11. Object Number: 1602064  Size: SH
  12. Disconnect the intake air heater (IAH) electrical connector (1).
  13. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
  14. Remove the engine harness clip from the side of the air inlet tube.

  15. Object Number: 1335443  Size: SH
  16. Remove the left glow plug harness bracket bolts.

  17. Object Number: 1335450  Size: SH
  18. Remove the right glow plug harness bracket bolts.
  19. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .

  20. Object Number: 1335413  Size: SH
  21. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

  22. Object Number: 1335463  Size: SH
  23. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

  24. Object Number: 1334862  Size: SH
  25. Disconnect the camshaft position (CMP) sensor electrical connector.

  26. Object Number: 1335467  Size: SH
  27. Remove the 2 ground bolts.

  28. Object Number: 1335470  Size: SH
  29. Disconnect the crankshaft position (CKP) sensor electrical connector.

  30. Object Number: 1602057  Size: SH
  31. Remove the electrical harness bolts.

  32. Object Number: 1409327  Size: SH
  33. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  34. Open the harness clip (2).
  35. Remove the main engine electrical harness connectors.

  36. Object Number: 1334916  Size: SH
  37. Remove the main engine electrical harness connector bolts.

  38. Object Number: 1335482  Size: SH
  39. Disconnect the fuel pressure control valve electrical connector.

  40. Object Number: 1335526  Size: SH
  41. Disconnect the oil level sensor electrical harness connector.

  42. Object Number: 1335528  Size: SH
  43. Disconnect the fuel temperature sensor electrical connector.

  44. Object Number: 1653265  Size: SH
  45. Disconnect the glow plug control module electrical connectors (1, 2).

  46. Object Number: 1334926  Size: SH

    Important: Note the wire routing prior to removal.

  47. Disconnect and remove the turbocharger vane position sensor.

  48. Object Number: 1602068  Size: SH
  49. Disconnect the intake air temperature (IAT) sensor electrical connector (1).

  50. Object Number: 1335536  Size: SH

    Notice: 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.

  51. Disconnect the fuel injector electrical connectors.

  52. Object Number: 1335540  Size: SH
  53. Disconnect the turbocharger vane control solenoid valve.

  54. Object Number: 1335543  Size: SH
  55. Disconnect the fuel rail pressure sensor electrical connector.

  56. Object Number: 1335546  Size: SH
  57. Disconnect the oil pressure sensor electrical connector.

  58. Object Number: 1335549  Size: SH
  59. Remove the oil level sensor harness bolt.

  60. Object Number: 1602069  Size: SH
  61. Remove the glow plug control module bolts.
  62. Remove the glow plug control module .

  63. Object Number: 1335560  Size: SH
  64. Remove the engine wiring harness.

Installation Procedure


    Object Number: 1335560  Size: SH
  1. Install the engine wiring harness.
  2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1602069  Size: SH
  3. Install the glow plug electrical connector nuts.
  4. Tighten
    Tighten the nuts to 2 N·m (18 lb in).

  5. Install the glow plug control module.
  6. Install the glow plug control module bolts.
  7. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1335549  Size: SH
  8. Install the oil level sensor harness bolt.
  9. Tighten
    Tighten the bolt to 40 N·m (30 lb ft).


    Object Number: 1335546  Size: SH
  10. Connect the oil pressure sensor electrical connector.

  11. Object Number: 1335543  Size: SH
  12. Connect the fuel rail pressure sensor electrical connector.

  13. Object Number: 1335540  Size: SH
  14. Connect the turbocharger vane control solenoid valve.

  15. Object Number: 1335536  Size: SH
  16. Connect the fuel injector electrical connectors.

  17. Object Number: 1602068  Size: SH
  18. Connect the IAT sensor electrical connector (1).

  19. Object Number: 1334926  Size: SH
  20. Install and connect the turbocharger vane position sensor.

  21. Object Number: 1653265  Size: SH
  22. Connect the glow plug control module electrical connectors (1, 2).

  23. Object Number: 1335528  Size: SH
  24. Connect the fuel temperature sensor electrical connector.

  25. Object Number: 1335526  Size: SH
  26. Connect the oil level sensor electrical harness connector.

  27. Object Number: 1335482  Size: SH
  28. Connect the fuel pressure control valve electrical connector.

  29. Object Number: 1334916  Size: SH
  30. Install the main engine electrical harness connector screws.
  31. Tighten
    Tighten the screws to 10 N·m (89 lb in).


    Object Number: 1409327  Size: SH
  32. Connect the main engine electrical harness connectors.
  33. Push down on the latches (1) in order to connect the connectors.
  34. Close the harness clip (2).

  35. Object Number: 1602057  Size: SH
  36. Install electrical harness bolts.
  37. Tighten
    Tighten the screws to 4 N·m (35 lb in).


    Object Number: 1335470  Size: SH
  38. Connect the CKP sensor electrical connector.

  39. Object Number: 1335467  Size: SH
  40. Install the 2 ground bolts.
  41. Tighten
    Tighten the bolts to 34 N·m (25 lb ft).


    Object Number: 1334862  Size: SH
  42. Connect the CMP sensor electrical connector.

  43. Object Number: 1335463  Size: SH
  44. Connect the EGR valve electrical connector.

  45. Object Number: 1335413  Size: SH
  46. Connect the ECT sensor electrical connector.
  47. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .

  48. Object Number: 1335450  Size: SH
  49. Install the right glow plug harness bracket bolts.
  50. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  51. Install the right glow plug connectors to the glow plugs.
  52. Tighten
    Tighten the glow plug connector nuts to 2 N·m (18 lb in).


    Object Number: 1335443  Size: SH
  53. Install the left glow plug harness bracket bolts.
  54. Tighten
    Tighten the bolts to 10 N·m (89 lb in.

  55. Install the left glow plug connectors to the glow plugs.
  56. Tighten
    Tighten the glow plug connector nuts to 2 N·m (18 lb in).


    Object Number: 1602064  Size: SH
  57. Install the engine harness clip to the side of the air inlet tube.
  58. Connect the MAP sensor electrical connector (2).
  59. Connect the IAH electrical connector (1).

  60. Object Number: 1334380  Size: SH
  61. Remove the tape from the turbocharger openings.
  62. Important: Lubricate the end of the duct prior to installation.

  63. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  64. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
  65. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 1653035  Size: SH
  66. Install a NEW quick connect fitting clip to the charged air cooler duct.
  67. Install the charged air cooler outlet duct to the intake.
  68. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  69. Install both front wheelhouse panels. Refer to Wheelhouse Panel Replacement .
  70. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  71. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .