AIR CONDITIONING
AUTOMATIC & MANUAL SYSTEM
HVAC System Service Specifications
HVAC SYSTEM SERVICE SPECIFICATIONSApplication Specification Accumulator Replacement (1) 2 ozs. Compressor Replacement (3) (2) 2 ozs. Condenser Replacement (2) 1 ozs. Evaporator Replacement (Front Or Rear) (2) 3 ozs. Total System PAG Oil Capacity 8 ozs. R-134a Refrigerant Charge 1.6 lbs. (1) Add PAG oil equal to amount of oil drained from component plus the specified additional amount. PAG Oil GM P/N 12378526 for U.S. & GM P/N 88900060 for Canada. (2) Add amount specified or amount drained, which ever is greater. (3) The Denso service compressor is precharged with 8.0 ozs. (237 ml) of PAG oil.
HVAC System Torque Specifications
HVAC SYSTEM TORQUE SPECIFICATIONSApplication Ft. Lbs. (N.m) A/C Refrigerant Filter Retaining Nuts 11 (15) Compressor Bracket Mounting Bolts 37 (50) Compressor Clutch Plate Retaining Bolt 13 (18) Compressor Discharge Hose Nut At Connector 12 (16) Compressor Hose Bolt At Compressor - Harrison (4.3L, 6.6L & 8.1L) 25 (34) Compressor Mounting Bolts - Denso (4.8L, 5.3L, 6.0L & 6.6L) 37 (50) Compressor Mounting Bolts - Harrison (4.3L, 6.6L & 8.1L) 37 (50) Compressor Suction/Discharge Hose Bolt 25 (34) Compressor Suction Hose Nut At Accumulator 12 (16) Compressor Suction Hose-To-Accumulator 30 (41) Discharge Hose Mounting Bolt - Denso (4.8L, 5.3L, 6.0L & 6.6L) 12 (16) Evaporator Tube Fitting At Orifice 18 (25) Evaporator Tube Nut At Condenser 12 (16) Evaporator Tube Nut At Evaporator 12 (16) Heater Hose Mounting Bolt (4.3L) 18 (25) Heater Hose Outlet Mounting Nut/Bolt 18 (25) Suction Hose Mounting Bolt - Denso (4.8L, 5.3L, 6.0L & 6.6L) 12 (16) In. Lbs. (N.m) A/C High Pressure Recirculation Switch 53 (6) A/C Low Pressure Switch 53 (6) Accumulator Bracket Nut 80 (9) Accumulator Clamp Bolt 88 (10) Air Distribution Duct Screw 14 (1.6) Air Outlet Mounting Screw 14 (1.6) Air Temperature Actuator Mounting Screw 14 (1.6) Blower Motor Control Processor Screw 14 (1.6) Blower Motor Insulating Cover Screw 14 (1.6) Blower Motor Relay/Resistor Screw 14 (1.6) Compressor Clutch Coil Connector Retaining Bracket Screw 80 (9) Condenser Upper Insulator Retainer Bolts 21 (2.4) Filter Access Door Screw 14 (1.6) Floor Air Outlet Duct Screw 14 (1.6) Heater Core Cover Screws 14 (1.6) Heater Ventilation Module Screws 14 (1.6) Heater/Ventilation Module Mounting Nuts 80 (9) Heater/Ventilation Module Mounting Screws 35 (4) HVAC Control Module Screw 17 (1.9) Insulator Retainers & Bolts 21 (2.4) Mode Actuator Mounting Screw 14 (1.6) Pressure Relief Valve 80 (9) Recirculation Actuator Mounting Screw 14 (1.6)
AXLE NUT/HUB NUT
AXLE NUT TORQUE SPECIFICATIONSApplication Specification Metric English Hub Nut 240 N.m 177 lb ft
BATTERY
Battery Service Specifications
BATTERY SERVICE SPECIFICATIONSStandard GM Part Number 19001810 Replacement Battery Number 78-6YR Cold Cranking Amperage (CCA) 600 Amps Reserve Capacity Rating 115 Minutes Optional (Dual) GM Part Number 19001814 Replacement Battery Number 78-7YR Cold Cranking Amperage (CCA) 770 Amps Reserve Capacity Rating 115 Minutes
BRAKES
BLEEDING SEQUENCE
BRAKE BLEEDING SEQUENCEApplication Sequence All Models Front Master Cylinder Port, Rear Master Cylinder Port, RR, LR, RF & LF
DISC BRAKES
Disc Brakes Service Specifications
DISC BRAKES SERVICE SPECIFICATIONSApplication In. (mm) Front Brakes (1) or (2) (6400 Lbs. GVWR) Rotor Discard Thickness (3) 1.082 (27.50) Rotor Minimum Allowable Thickness After Refinish 1.10 (28.0) Rotor Thickness (New) 1.14 (29.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Front Brakes (1) (7200 Lbs. GVWR) Rotor Discard Thickness (3) 1.082 (27.50) Rotor Minimum Allowable Thickness After Refinish 1.10 (28.0) Rotor Thickness (New) 1.14 (29.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Front Brakes (2) (9900 Lbs. GVWR) Rotor Discard Thickness (3) 1.437 (36.50) Rotor Minimum Allowable Thickness After Refinish 1.46 (37.0) Rotor Thickness (New) 1.50 (38.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Front Brakes (2) (12,300 Lbs. GVWR) Rotor Discard Thickness (3) 1.437 (36.50) Rotor Minimum Allowable Thickness After Refinish 1.46 (37.0) Rotor Thickness (New) 1.50 (38.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Rear Brakes (1) or (2)(6400 Lbs. GVWR) Rotor Discard Thickness (3) 0.728 (18.50) Rotor Minimum Allowable Thickness After Refinish 0.748 (19.0) Rotor Thickness (New) 0.787 (20.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Rear Brakes (1)(7200 Lbs. GVWR) Rotor Discard Thickness (3) 1.122 (28.50) Rotor Minimum Allowable Thickness After Refinish 1.142 (29.0) Rotor Thickness (New) 1.181 (30.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Rear Brakes (2)(9900 Lbs. GVWR) Rotor Discard Thickness (3) 1.082 (27.50) Rotor Minimum Allowable Thickness After Refinish 1.102 (28.0) Rotor Thickness (New) 1.141 (29.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.5) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) Rear Brakes (2)(12,400 Lbs. GVWR) Rotor Discard Thickness (3) 1.122 (28.5) Rotor Minimum Allowable Thickness After Refinish 1.142 (29.0) Rotor Thickness (New) 1.181 (30.0) Rotor Maximum Allowable Lateral Runout 0.005 (0.13) Rotor Maximum Allowable Scoring 0.059 (1.50) Rotor Maximum Allowable Thickness Variation 0.001 (0.025) (1) With vacuum assisted power brakes. (2) With hydraulic assisted power brakes. (3) All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing rotor, replace any rotor that does not meet the minimum thickness specifications.
Disc Brakes Torque Specifications
DISC BRAKES TORQUE SPECIFICATIONSApplication Ft. Lbs. (N.m) Backing Plate Bolts 100 (135) Brake Caliper Mounting Bolt Front 80 (108) Rear 15-Series 31 (42) 25/35-Series 80 (108) Brake Hose-To-Caliper Bolt Front 30 (40) Rear 30 (40) Brake Pedal Bolt 35 (47) Brake Pipe Fittings 18 (25) Cable Support Bracket Bolts 64 (85) Caliper Mounting Bracket Bolt - Rear 6400 & 7200 Lbs. GVWR 148 (200) 9900 Lbs. GVWR 122 (165) 12,300 Lbs. GVWR 221 (300) 4-Wheel Steering 148 (200) Caliper Mounting Bracket-To-Knuckle - Front 15-Series 129 (175) 25/35-Series 221 (300) EHCU Bracket Mounting Bolts 18 (25) Front Brake Pipe Fitting-To-BPMV 18 (25) Front Wheel Speed Sensor Mounting Bolt 13 (18) Hose Bracket-To-Anchor Plate Bolt 18 (25) Hose Bracket-To-Rear Axle Bolt 16 (22) Master Cylinder Brake Lines-To-BPMV 18 (25) Master Cylinder Mounting Nuts 27 (36) Negative Battery Cable Bolt 13 (17) Park Brake Cable Bracket-To-Knuckle Bolt (4-Wheel Steering) 45 (61) Park Brake Cable-To-Rear Axle Clip Bolt 18 (25) Park Brake Cable-To-Shock Absorber Bracket Bolt 18 (25) Park Brake Lever Mounting Bolts 18 (25) Power Brake Booster Nuts (Hydraulic) 24 (33) Power Brake Booster Nuts (Vacuum) 24 (33) Quarter Shaft Shield 18 (25) Rear Brake Pipe Fitting-To-BPMV 18 (25) In. Lbs. (N.m) Brake Caliper Bleeder Valve Front 115 (13) Rear 97 (11) Brake Pressure Modulator Bleeder Valves 80 (9) EBCM-To-BPMV Torx Bolts 44 (5) EHCU-To-Bracket Bolts 80 (9) Hose Bracket-To-Frame Bolt 106 (12) Hose Bracket-To-Knuckle Bolt 106 (12) Hose Bracket-To-Steering Knuckle 80 (9) Hose Bracket-To-Upper Control Arm Bolt 80 (9) Intermediate Cable Threaded Rod Nut 31 (3.5) Park Brake Cable Guide-To-Frame Bolt 106 (12) Park Brake Equalizer 31 (3.5) Park Brake Warning Light Switch Bolt 25 (3)
CHARGING SYSTEM
GENERATOR
Generator Service Specifications
GENERATOR SERVICE SPECIFICATIONSStandard Specification Delphi AD230 Rated Output 102 Amps Load Test Output 71 Amps Optional (Dual) Delphi AD244 Rated Output 130 Amps Load Test Output 91 Amps Optional Bosch® 15755900 Rated Output 130 Amps Load Test Output 91 Amps
Generator Torque Specifications
GENERATOR TORQUE SPECIFICATIONSApplication Ft. Lbs. (N.m) Auxiliary Battery Tray Nut 18 (25) Auxiliary Generator Bolt (6.6L) 37 (50) Auxiliary Generator Bracket Bolt (6.6L) 37 (50) Auxiliary Negative Battery Cable Bolt (6.6L) 25 (34) Auxiliary Negative Battery Cable Bolt (Except 6.6L) 13 (17) Auxiliary Positive Battery Cable Bolt 13 (17) Battery Cable Bracket Bolt 18 (25) Battery Hold Down Retainer Bolt 18 (25) Crossbar Bolt 74 (100) Drive Belt Tensioner Bolt (6.6L) 30 (41) EGR Vacuum Pump Bolt (6.6L) 16 (22) Engine Wiring Harness Auxiliary Negative Battery Cable Bolt 12 (16) Ground Bolt 12 (16) Ground/Negative Cable Bolt Except 6.6L 18 (25) 6.6L 25 (34) Retainer Bolt (6.6L) 15 (21) Fuel Bleed Valve & PCV Oil Separator Bracket Nut (6.6L) 18 (25) Generator Bracket Bolt (4.8L, 5.3L, 6.0L, 6.6L & 8.1L) 37 (50) Generator Bolt (4.3L, 4.8L, 5.3L, 6.0L, 6.6L & 8.1L) 37 (50) Generator Bracket Bolt/Nut (4.3L) 30 (41) Generator Bracket Stud (8.1L) 15 (20) Heater Hose Bracket Bolt (4.3L) 18 (25) Heater Outlet Pipe Bolt (6.6L) 18 (25) Idler Pulley Bolt (6.6L) 32 (43) Negative Battery Cable Bolt 13 (17) Positive Battery Cable Bolt 13 (17) Wiring Harness Bracket Bolt (4.3L) 18 (25) In. Lbs. (N.m) Auxiliary Battery Cable Clip Bolt 89 (10) Auxiliary Battery Relay Nut 80 (9) Auxiliary Positive Battery Cable Nut 71 (8) Auxiliary Positive Cable to Relay Nut 80 (9) Battery Cable Channel Bolt Except 6.6L 106 (12) 6.6L 71 (8) Battery Cable Junction Block Bracket Bolt (4.8L, 5.3L, 6.0L & 8.1L) 80 (9) Battery Cable Retainer Nut (6.6L) 106 (12) Battery Tray Bolt 80 (9) Fender-To-Cowl Support Brace Bolt 80 (9) Forward Lamp Wiring Harness Ground/Negative Cable Bolt 80 (9) Front End Diagonal Brace Bolt 80 (9) Generator Cable Nut 80 (9) Ground Strap Nut 80 (9) Harness Clip-To-Junction Block Bracket Bolt 80 (9) Positive Battery Cable Nut (6.6L) 80 (9) Positive Cable Clip Nut (8.1L) 71 (8) Positive Cable At Underhood Bussed Electrical Center (UBEC) Bolt 80 (9) Transmission Cover Bolt (4.8L, 5.3L & 6.0L) 80 (9)
DRIVE BELTS
ADJUSTMENT
Drive Belt Specifications & Procedures
Accessory belt adjustment is not required. Automatic tensioner is used.
DRIVE BELT ROUTING
Routing Illustrations
Fig. 1: Belt Routing (4.3L)
Courtesy of GENERAL MOTORS CORP.
Fig. 2: Belt Routing (4.8L, 5.3L & 6.0L)
Courtesy of GENERAL MOTORS CORP.
Fig. 3: Belt Routing (6.6L)
Courtesy of GENERAL MOTORS CORP.
Fig. 4: Belt Routing (8.1L)
Courtesy of GENERAL MOTORS CORP.
ENGINE COOLING
SERVICE
Engine Cooling System Specifications
ENGINE COOLING SYSTEM SPECIFICATIONSApplication Specification Coolant Capacity 4.3L (1) 12.6 Qts. (11.9L) 4.8L & 5.3L (2) (1) 13.4 Qts. (12.7L) 6.0L (1)(3) 14.8 Qts. (14.0L) 6.6L (1) 20.3 Qts. (19.2L) 8.1L (1) 20.7 Qts. (19.6L) Coolant Replacement Intervals (4) 150,000 Miles Thermostat Opening Temperatures Thermostat Starts To Open 188°F (87°C) Thermostat Fully Open 206°F (97°C) (1) Add about 0.4 Qts. (0.3L) if equipped with manual transmission. (2) Add about 1.5 Qts. (1.4L) if equipped with 5.3L and optional Air Conditioning. (3) Subtract about 0.4 Qts. (0.3L) if equipped with optional engine oil cooler. (4) Or every 60 months, whichever comes first. Use GM Goodwrench DEX-COOL®.
Engine Cooling System Torque Specifications
ENGINE COOLING SYSTEM TORQUE SPECIFICATIONSApplication Ft. Lbs. (N.m) Air Conditioning (A/C) Compressor Mounting Bolt (6.6L) 37 (50) Air Inlet Tube Nut (6.6L) 18 (25) Bypass Pipe-To-Water Pump Bolt (6.6L) 16 (21) Coolant Crossover Bolt (8.1L) 37 (50) Coolant Heater (4.8L, 5.3L & 6.0L) 37 (50) Coolant Heater (8.1L) 47 (60) EGR Coolant Pipe Bolt (6.6L) 16 (21) Engine Block Coolant Drain Plug 44 (60) Engine Coolant Temperature (ECT) Sensor (6.6L) 24 (33) Engine Shield Bolt 15 (20) Exhaust Manifold Pipe Nut (4.8L, 5.3L & 6.0L) 37 (50) Fan Clutch Bolt 17 (23) Fan Clutch Nut 41 (56) Fan Pulley Bolt/Nut (6.6L) 34 (46) Fan and Water Pump Pulley Bolt (4.3L) 18 (25) Fuel Line Bracket Bolt (6.6L) 15 (21) Fuel Line-To-Fuel Injection Control Module Bolt (6.6L) 26 (35) Generator Bracket Bolt (6.6L & 8.1L) 37 (50) Generator Bracket Stud (8.1L) 15 (20) Heater Inlet Pipe-To-Fuel Filter Bolt (6.6L) 16 (21) Heater Inlet Pipe-To-Thermostat Bolt (6.6L) 16 (21) Heater Outlet Hose Bracket Bolt (6.6L) 16 (21) Hood Hinge Bolts 18 (25) Idler Pulley Bolt (6.6L) 32 (43) Main Electrical Harness Bracket Bolt (6.6L) 15 (21) Oil Cooler Hose Bracket Bolt (6.0L) 18 (25) Oil Cooler Hose Bracket Bolt (8.1L) 37 (50) PCV Oil Separator Bracket Nut (6.6L) 16 (21) Power Steering Pump Bracket Bolt (6.6L) 34 (46) Radiator Bolt 18 (25) Thermostat Housing Bolt (4.8L, 5.3L & 6.0L) 11 (15) Thermostat Housing Bolt (8.1L) 27 (37) Thermostat Housing Cover Bolt (6.6L) 16 (21) Thermostat Housing Crossover Bolt/Nut (6.6L) 16 (21) Turbocharger Coolant Bypass Valve (6.6L) 44 (60) Turbocharger Coolant Feed Pipe Bracket Bolt (6.6L) 16 (21) Turbocharger Coolant Inlet Banjo Bolt (6.6L) 18 (25) Water Crossover Bolt (8.1L) 37 (50) Water Outlet Bolt (8.1L) 22 (30) Water Outlet Stud (4.3L) 18 (25) Water Outlet Tube Bolt (6.6L) 16 (21) Water Outlet Tube-To-Valve Rocker Arm Cover Bolt (6.6L) 16 (21) Water Pump Bolt (4.3L) 33 (45) Water Pump Bolt (First Pass) (4.8L, 5.3L & 6.0L) 11 (15) Water Pump Bolt (Final Pass) (4.8L, 5.3L & 6.0L) 22 (30) Water Pump Bolt (6.6L) 16 (21) Water Pump Bolt (8.1L) 37 (50) Water Pump Inlet Pipe Bolt (6.6L) 16 (21) Water Pump Pulley Bolt (4.3L) 18 (25) Water Pump-To-Oil Cooler Inlet Pipe Nut (6.6L) 16 (21) INCH Lbs. (N.m) Air Cleaner Outlet Duct Clamp (4.8L, 5.3L & 6.0L) 62 (7) Air Cleaner Outlet Duct Clamp (6.6L) 53 (6) Auxiliary Water Pump Bracket Nut 80 (9) Charged Air Cooler Duct Clamp (6.6L) 53 (6) Coolant Air Bleed Pipe Stud/Bolt (4.8L, 5.3L & 6.0L) 106 (12) Coolant Heater Bolt (4.3L & 6.6L) 18 (2) Coolant Heater Cord Bolt 71 (8) Coolant Outlet Pipe Clip Bolt (6.6L) 80 (9) Fan Shroud Bolt 80 (9) Generator Positive Cable Nut (6.6L) 80 (9) Intake Manifold Cover Clamp (6.6L) 53 (6) Junction Block Bracket Bolt (6.6L) 80 (9) Main Engine Electrical Harness Connector Bolt (6.6L) 89 (10) Oil Cooler Hose Adapter Bolt (6.0L) 106 (12) Surge Tank Bolt/Nut 80 (9) Transmission Control Module (TCM) Cover Bolt 80 (9) Transmission Control Module (TCM) Electrical Connector Bolt 71 (8) Turbocharger Coolant Feed Pipe Nut (6.6L) 80 (9) Turbocharger Coolant Outlet Pipe Bolt/Nut (6.6L) 80 (9) Wiring Harness Bracket-To-Thermostat Housing Bolt (6.6L) 71 (8)
RADIATOR CAP PRESSURE
The pressure cap seals the cooling system. It contains a blow off or pressure relief valve and a vacuum or atmospheric valve. The pressure valve is held against its seat by a spring, which protects the radiator from excessive cooling system pressure. The vacuum valve is held against its seat by a spring, which permits opening of the valve to relieve vacuum created in the cooling system as it cools off. The vacuum, if not relieved, might cause the radiator and/or coolant hoses to collapse.
The pressure cap allows cooling system pressure to build up as the temperature increases. As the pressure builds, the boiling point of the coolant increases. Engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant is, the faster the heat transfers from the radiator to the cooler, passing air.
The pressure in the cooling system can get too high. When the cooling system pressure exceeds the rating of the pressure cap, it raises the pressure valve, venting the excess pressure.
As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open, allowing outside air into the surge tank. This equalizes the pressure in the cooling system with atmospheric pressure, preventing the radiator and coolant hoses from collapsing.
THERMOSTAT REMOVAL & INSTALLATION
THERMOSTAT REPLACEMENT (4.3L ENGINE)THERMOSTAT REPLACEMENT (6.6L (LB7) ENGINE)THERMOSTAT REPLACEMENT (6.6L (LLY) ENGINE)THERMOSTAT REPLACEMENT (8.1L ENGINE)
WATER PUMP REMOVAL & INSTALLATION
WATER PUMP REPLACEMENT (4.8L, 5.3L, AND 6.0L ENGINES)WATER PUMP REPLACEMENT (4.8L, 5.3L, AND 6.0L ENGINES)WATER PUMP REPLACEMENT (6.6L (LB7) ENGINE)WATER PUMP REPLACEMENT (6.6L (LLY))WATER PUMP REPLACEMENT (8.1L)
ENGINE MECHANICAL
COMPRESSION
ENGINE COMPRESSION TEST (4.3L)ENGINE COMPRESSION TEST (4.8L, 5.3L & 6.0L)ENGINE COMPRESSION TEST (6.6L)ENGINE COMPRESSION TEST (8.1L)
OIL PRESSURE
OIL PRESSURE SPECIFICATIONS (4.3, 4.8, 5.3 & 6.0L)Application Specifications Metric English Oil Pressure - @ 1,000 rpm 42 kPa 6 psi Oil Pressure - @ 2,000 rpm 125 kPa 18 psi Oil Pressure - @ 4,000 rpm 166 kPa 24 psi
OIL PRESSURE SPECIFICATIONS (6.6L)Application Specifications Metric English Oil Pressure - Minimum - At Idle 98 kPa 14 psi Oil Pressure - Minimum - @ 1,800 rpm 294 kPa 42 psi
OIL PRESSURE SPECIFICATIONS (8.1L)Application Specifications Metric English Oil Pressure - Minimum @ 1,000 rpm 34 kPa 5 psi Oil Pressure - Minimum @ 2,000 rpm 69 kPa 10 psi
OVERHAUL
ENGINE MECHANICAL SPECIFICATIONS (4.3L)ENGINE MECHANICAL SPECIFICATIONS (LR4 VIN V)ENGINE MECHANICAL SPECIFICATIONS (LM7 VIN T)ENGINE MECHANICAL SPECIFICATIONS (L59 VIN Z)ENGINE MECHANICAL SPECIFICATIONS (LQ4 VIN U)ENGINE MECHANICAL SPECIFICATIONS (LQ9 VIN N)ENGINE MECHANICAL SPECIFICATIONS (6.6L LB7)ENGINE MECHANICAL SPECIFICATIONS (6.6L LLY)ENGINE MECHANICAL SPECIFICATIONS (8.1L)
TORQUE
FASTENER TIGHTENING SPECIFICATIONS (4.3L)FASTENER TIGHTENING SPECIFICATIONS (4.8, 5.3 & 6.0L)FASTENER TIGHTENING SPECIFICATIONS (6.6L LB7)FASTENER TIGHTENING SPECIFICATIONS (6.6L LLY)FASTENER TIGHTENING SPECIFICATIONS (8.1L)
FLUID SPECIFICATIONS
See FLUIDS under MAINTENANCE tab. From within Manager or Service Writer, click the "30/60/90 Interval" or "Maint." button.
FLYWHEEL/FLEX PLATE TORQUE
FLYWHEEL/FLEX PLATE TORQUE SPECIFICATIONSApplication Specifications Metric English Engine Flywheel Bolt (4.3L) 100 N.m 74 lb ft. Engine Flywheel Bolt (4.8, 5.3 & 6.0L) First Pass 20 N.m 15 lb ft Second Pass 50 N.m 37 lb ft Final Pass 100 N.m 74 lb ft Engine Flywheel Bolt (6.6L) First Pass 79 N.m 58 lb ft Second Pass 60° 60° Final Pass 60° 60° Engine Flywheel Bolt (8.1L) First Pass 40 N.m 30 lb ft Second Pass 80 N.m 59 lb ft Final Pass 100 N.m 74 lb ft
FUEL SYSTEM
NOTE: Refer to graphic for 6.6L Diesel engine firing order. See Fig.7.
FUEL PRESSURE SPECIFICATIONS
FUEL PRESSURE SPECIFICATIONSApplication Psi (kPa) Except Flex-Fuel 55-62 (379-428) Flex-Fuel (VIN Z) 48-54 (335-375)
FUEL PRESSURE TEST PROCEDURE
FUEL PRESSURE RELIEF PROCEDURE (4.3L)FUEL PRESSURE RELIEF PROCEDURE (4.8, 5.3, 6.0L)FUEL PRESSURE RELIEF PROCEDURE (6.0L)FUEL PRESSURE RELIEF PROCEDURE (8.1L)
FUEL FILTER
FUEL FILTER REPLACEMENT (4.3L)FUEL FILTER REPLACEMENT (5.3L (L59) ENGINE)FUEL FILTER REPLACEMENT (6.0L)FUEL FILTER REPLACEMENT (6.6L)
IGNITION SYSTEM
FIRING ORDER & CYLINDER IDENTIFICATION
NOTE: The 4.8L, 5.3L, 6.0L & 8.1L engines are equipped with a coil for each spark plug and is connected to spark plug with a short high tension wire.
See FIRING ORDER & CYLINDER IDENTIFICATION.
Fig. 5: Firing Order (4.3L) & Cylinder Identification
Courtesy of GENERAL MOTORS CORP.
Fig. 6: Firing Order (4.8L, 5.3L, 6.0L & 8.1L) & Cylinder Identification
Courtesy of GENERAL MOTORS CORP.
Fig. 7: Injector Firing Order (6.6L Diesel) & Cylinder Identification
Courtesy of GENERAL MOTORS CORP.
HIGH TENSION WIRES
High Tension Wire Resistance Specifications
HIGH TENSION WIRE RESISTANCEApplication Ohms All Gasoline Engines 1000 Per Foot
IGNITION TIMING
NOTE: Ignition timing is not adjustable.
SPARK PLUGS
Spark Plug Specifications
SPARK PLUG SPECIFICATIONSApplication Specification Glow Plugs Type - 6.6L Diesel (VIN No.) LB6 ("1") GM 97226202 LLY ("2") GM 97326305 Spark Plug Type (VIN No.) 4.3L ( "X") AC R41-932 4.8L ("V"), 5.3L ("Z"& "T") , 6.0L ("U" & "N") & 8.1L ("G") AC R41-985 Gap Iridium .040 in. (1.04 mm)
Platinum .060 in. (1.52 mm)Tightening Torque Glow Plugs 13 Ft. Lbs. (18 N.m) Spark Plugs Tighten to 15 ft. lbs. (20 N.m) when using NEW cylinder head. Tighten to 11 ft. lbs. (15 N.m) for all subsequent installations. Firing Order 4.3L 1-6-5-4-3-2 4.8L, 5.3L, 6.0L & 8.1L 1-8-7-2-6-5-4-3 6.6L Diesel 1-2-7-8-4-5-6-3
STARTING SYSTEM
STARTER
Starter Service Specifications
STARTER SERVICE SPECIFICATIONSApplication Specification 4.3L, 4.8L & 5.3L PG-260G 6.0L & 8.1L PG-260L 6.6L Diesel Hitachi S14-100B
Starter Torque Specifications
STARTER TORQUE SPECIFICATIONSApplication Ft. Lbs. (N.m) Auxiliary Battery Tray Nut 18 (25) Auxiliary Negative Battery Cable Bolt 13 (17) Auxiliary Positive Battery Cable Bolt 13 (17) Battery Cable Bracket Bolt 18 (25) Battery Hold Down Retainer Bolt 18 (25) Drive Belt Tensioner Bolt (6.6L) 30 (41) Engine Wiring Harness Auxiliary Negative Battery Cable Bolt 12 (16) Engine Wiring Harness Ground Bolt 12 (16) Engine Wiring Harness Ground/Negative Cable Bolt Except 6.6L 18 (25) 6.6L 25 (34) Engine Wiring Harness Retainer Bolt (6.6L) 15 (21) Fuel Bleed Valve & PCV Oil Separator Bracket Nut (6.6L) 18 (25) Heater Hose Bracket Bolt (4.3L) 18 (25) Heater Outlet Pipe Bolt (6.6L) 18 (25) Idler Pulley Bolt (6.6L) 32 (43) Negative Battery Cable Bolt 13 (17) Positive Battery Cable Bolt 13 (17) Starter Bolt 4.3L 32 (43) 4.8L, 5.3L, 6.0L & 8.1L 37 (50) 6.6L 58 (79) INCH Lbs. (N.m) Auxiliary Battery Cable Clip Bolt 89 (10) Auxiliary Battery Relay Nut 80 (9) Auxiliary Positive Battery Cable Nut 71 (8) Auxiliary Positive Cable to Relay Nut 80 (9) Battery Cable Channel Bolt Except 6.6L 106 (12) 6.6L 71 (8) Battery Cable Junction Block Bracket Bolt (4.8L, 5.3L & 6.0L) 80 (9) Battery Cable Retainer Nut (6.6L) 106 (12) Battery Tray Bolt 80 (9) Forward Lamp Wiring Harness Ground/Negative Cable Bolt 80 (9) Front End Diagonal Brace Bolt 80 (9) Ground Strap Nut 80 (9) Positive Battery Cable Nut (6.6L) 80 (9) Positive Cable Clip Nut (8.1L) 71 (8) Positive Cable at Underhood Bussed Electrical Center (UBEC) Bolt 80 (9) Starter Heat Shield Bolt (8.1L) 35 (4) Starter Heat Shield Nut (8.1L) 44 (5) Starter Lead Nut 80 (9) Starter Solenoid Nut 40 (3.4) Surge Tank Bolt/Nut 80 (9) Transmission Cover Bolt (4.8L, 5.3L & 6.0L) 80 (9) Wiring Harness Bracket Bolt (4.3L) 18 (2)
WHEEL ALIGNMENT
ADJUSTMENT SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
TORQUE
FASTENER TIGHTENING SPECIFICATIONS
WHEEL & TIRE
WHEEL LUG NUT TORQUE
WHEEL LUG NUT TORQUE SPECIFICATIONSApplication Specifications Metric English Wheel Nut 190 N.m 140 lb ft
