2004 SPECIFICATIONS
Sierra, Silverado, Cab & Chassis
TORQUE SPECIFICATIONS
Application
A/C Compressor Bolt
Bypass Pipe Bolt
Camshaft Gear Bolt
Camshaft Thrust Plate Bolt
Connecting Rod Cap Bolt (Angular Tightening Method)
1st Step
2nd Step
3rd Step
Coolant Pipe-To-Water Pump Nut
Cooling Fan Pulley
Crankshaft Balancer Bolt
Cylinder Head M12 Bolt (Angular Tightening Method) (1)
1st Step
2nd Step
3rd Step
4th Step
Cylinder Head M8 Bolt (1)
Drive Belt Tensioner Pulley Bolt
EGR Bolt (California Emissions)
EGR Bracket Bolt (California Emissions)
EGR Valve Nut (California Emissions)
Engine Block Coolant Plug
Engine Block Ground Bolt
Engine Mount-To-Block Bolt
Exhaust Manifold Bolt/Nut (2)
Exhaust Outlet Pipe Bolt
Exhaust Pipe Bolt
Exhaust Pipe Bracket Bolt
Fan Pulley Bracket Bolt
Flywheel Bolt (Angular Tightening Method) (3)
1st Step
2nd Step
3rd Step
Flywheel Housing Bolt (Black Circle Mark)
Flywheel Housing-To-Upper Oil Pan Bolts (Black Triangle Mark)
Front Engine Cover Bolt
Fuel Block Bolt
Ft. Lbs. (N.m)
37 (50)
15 (21)
173 (234)
16 (22)
47 (64)
Tighten Additional 30°
Tighten Additional 30°
18 (25)
30 (41)
260 (353)
37 (50)
59 (80)
Tighten Additional 90°
Tighten Additional 75°
18 (25)
30 (41)
15 (20)
15 (20)
14 (19)
13 (18)
25 (34)
43 (58)
28 (38)
39 (53)
39 (53)
25 (34)
34 (46)
58 (79)
Tighten Additional 60°
Tighten Additional 60°
67 (90)
37 (50)
15 (21)
18 (25)
Application
Fuel Filter Bracket Bolt
Fuel Injection Control Module Bolt
Fuel Injection Control Module Bracket Bolt
Fuel Injection Control Module Connector Bracket Bolt
Fuel Injection Control Module Cooler Eye Bolt
Fuel Injection Pipe Nut
Fuel Inlet Pipe Bracket Bolt
Fuel Pipes Bracket Bolt
Fuel Rail Assembly Bolt
Fuel Rail Connector
Fuel Return Eye Bolt (Cylinder Head Side)
Fuel Return Eye Bolt (Injector Side)
Fuel Return Pipe Sleeve Nut
Fuel Return Sleeve Unit
Fuel Injection Pump Assembly-To-Cylinder Block Bolt
Fuel Injection Pump-To-Bracket Bolt
Fuel Injection Pump Drive Gear Nut
Fuel Temperature Sensor Eye Bolt
Function Block Nut
Function Block-To-Injection Pipe Nut
Generator Bracket Bolt
Glow Plug
Glow Plug Power Feed Nut
Glow Plug Relay Assembly Bolt
Heater Pipe Bolt
Idle Pulley Bolt/Screw
Injector Bracket Bolt
Intake Air Heater
Intake Manifold Bolt/Nut
Oil Cooler Adapter Bolt
Oil Cooler Adapter Nut
Oil Cooler Assembly Bolt
Oil Drain Plug
Oil Fill Tube Bolt
Oil filter
Oil Gallery Plug
Oil Level Indicator Tube Bolt
Oil Pan Bolt (Upper)
Oil Pressure Sensor Adapter Eye Bolt
Oil Pressure Sensor Unit
Oil Pressure Relief Valve
Oil Pump Bolt
Ft. Lbs. (N.m)
15 (21)
15 (20)
15 (21)
15 (21)
20 (27)
30 (41)
15 (21)
15 (21)
18 (25)
33 (45)
12 (17)
12 (16)
30 (41)
30 (41)
15 (21)
15 (21)
52 (70)
11 (15)
18 (25)
30 (41)
37 (50)
13 (18)
11 (15)
18 (25)
15 (21)
27 (37)
37 (50)
37 (50)
15 (21)
15 (21)
18 (25)
18 (25)
62 (84)
15 (21)
18 (24)
39 (53)
15 (21)
15 (20)
28 (38)
22 (30)
29 (39)
15 (21)
Application
Oil Pump Driven Gear Nut
Oil Pump Gear Cover Bolt
Oil Strainer Bolts/Nut
Piston Cooling Nozzle Eye Bolt
Power Steering Pump Bolt
Power Steering Pump Bracket Bolt
Rocker Arm Shaft Bracket Bolt
Starter Motor Bolt
Thermostat Housing Bolt/Nut
Thermostat Cover Bolt
Turbocharger Bolt
Turbocharger Coolant Outlet Pipe Bracket Bolt
Turbocharger Oil Supply Hose Eye Bolt
Turbocharger Oil Return Pipe Bolts/Nut
Turbocharger Thermostatic Coolant Valve
Upper Oil Pan-To-Flywheel Housing Screw
Vacuum Pump Nut (California Emissions)
Valve Adjusting Screw Nut
Water Outlet Bolt
Water Pump Bolt
Camshaft Position Sensor Bolt
Camshaft Position Sensor Exciter Ring Bolt
Crankshaft Position Sensor Bolt
Crankshaft Position Sensor Spacer Bolt
Exhaust Manifold Heat Shield Bolt
Exhaust Outlet Heat Shield Bolt
Exhaust Pipe Heat Shield Bolt
Fuel Injection Control Module Connector Bolt
Glow Plug Connector Nut
Injector Harness Bracket Bolt
Injector Terminal Nut
Injector Pipe Lock Plate Screw
Intake Manifold Tube Bolt/Nut
Oil Cooler Adapter Stud
Oil Level Sensor Bolt
Oil Pan Bolt/Nut (Lower) (4)
Positive Crankcase Ventilation Cover Screw
Turbocharger Boost Sensor Bolt
Turbocharger Heat Shield Bolt
Turbocharger Inlet Duct-To-Turbocharger Bolt
Turbocharger Oil Return Pipe Stud
Ft. Lbs. (N.m)
74 (100)
15 (21)
18 (25)
15 (21)
37 (50)
34 (46)
30 (41)
58 (78)
18 (25)
15 (21)
80 (108)
15 (21)
25 (34)
15 (21)
44 (60)
15 (20)
16 (22)
16 (22)
18 (25)
15 (21)
INCH Lbs. (N.m)
89 (10)
80 (9)
89 (10)
89 (10)
71 (8)
71 (8)
71 (8)
89 (10)
18 (2)
80 (9)
18 (2)
35 (4)
80 (9)
89 (10)
89 (10)
89 (10)
35 (4)
89 (10)
80 (9)
80 (9)
89 (10)
Application
Valve Lifter Hold-Down Bracket Bolt
Valve Rocker Arm Cover Bolt (Lower) (5)
Valve Rocker Arm Cover Bolt (Upper)
1st Step
2nd Step
(1)
Tighten in sequence. See Fig. 25 .
(2)
Tighten in sequence. See Fig. 26 .
(3)
Tighten in sequence. See Fig. 27 .
(4)
Tighten in sequence. See Fig. 29 .
(5)
Tighten in sequence. See Fig. 28 .
Ft. Lbs. (N.m)
97 (11)
89 (10)
71 (8)
71 (8)
HVAC SYSTEM SERVICE SPECIFICATIONS
Application
Accumulator Replacement
Compressor Replacement (3)
Condenser Replacement
Evaporator Replacement (Front Or Rear)
Total System PAG Oil Capacity
R-134a Refrigerant Charge
Specification
(1)
2 ozs.
(2)
2 ozs.
(2)
1 ozs.
(2)
3 ozs.
8 ozs.
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 SPECIFICATIONS
Application
A/C Refrigerant Filter Retaining Nuts
Compressor Bracket Mounting Bolts
Compressor Clutch Plate Retaining Bolt
Compressor Discharge Hose Nut At Connector
Compressor Hose Bolt At Compressor - Harrison (4.3L, 6.6L & 8.1L)
Compressor Mounting Bolts - Denso (4.8L, 5.3L, 6.0L & 6.6L)
Compressor Mounting Bolts - Harrison (4.3L, 6.6L & 8.1L)
Compressor Suction/Discharge Hose Bolt
Compressor Suction Hose Nut At Accumulator
Ft. Lbs. (N.m)
11 (15)
37 (50)
13 (18)
12 (16)
25 (34)
37 (50)
37 (50)
25 (34)
12 (16)
Application
Compressor Suction Hose-To-Accumulator
Discharge Hose Mounting Bolt - Denso (4.8L, 5.3L, 6.0L & 6.6L)
Evaporator Tube Fitting At Orifice
Evaporator Tube Nut At Condenser
Evaporator Tube Nut At Evaporator
Heater Hose Mounting Bolt (4.3L)
Heater Hose Outlet Mounting Nut/Bolt
Suction Hose Mounting Bolt - Denso (4.8L, 5.3L, 6.0L & 6.6L)
A/C High Pressure Recirculation Switch
A/C Low Pressure Switch
Accumulator Bracket Nut
Accumulator Clamp Bolt
Air Distribution Duct Screw
Air Outlet Mounting Screw
Air Temperature Actuator Mounting Screw
Blower Motor Control Processor Screw
Blower Motor Insulating Cover Screw
Blower Motor Relay/Resistor Screw
Compressor Clutch Coil Connector Retaining Bracket Screw
Condenser Upper Insulator Retainer Bolts
Filter Access Door Screw
Floor Air Outlet Duct Screw
Heater Core Cover Screws
Heater Ventilation Module Screws
Heater/Ventilation Module Mounting Nuts
Heater/Ventilation Module Mounting Screws
HVAC Control Module Screw
Insulator Retainers & Bolts
Mode Actuator Mounting Screw
Pressure Relief Valve
Recirculation Actuator Mounting Screw
Ft. Lbs. (N.m)
30 (41)
12 (16)
18 (25)
12 (16)
12 (16)
18 (25)
18 (25)
12 (16)
In. Lbs. (N.m)
53 (6)
53 (6)
80 (9)
88 (10)
14 (1.6)
14 (1.6)
14 (1.6)
14 (1.6)
14 (1.6)
14 (1.6)
80 (9)
21 (2.4)
14 (1.6)
14 (1.6)
14 (1.6)
14 (1.6)
80 (9)
35 (4)
17 (1.9)
21 (2.4)
14 (1.6)
80 (9)
14 (1.6)
BATTERY
Battery Service Specifications
BATTERY SERVICE SPECIFICATIONS
Standard
GM Part Number
Replacement Battery Number
19001810
78-6YR
Cold Cranking Amperage (CCA)
Reserve Capacity Rating
Optional (Dual)
GM Part Number
Replacement Battery Number
Cold Cranking Amperage (CCA)
Reserve Capacity Rating
600 Amps
115 Minutes
19001814
78-7YR
770 Amps
115 Minutes
BRAKES
BLEEDING SEQUENCE
BRAKE BLEEDING SEQUENCE
Application
All Models
Sequence
Front Master Cylinder Port, Rear Master Cylinder Port, RR, LR, RF & LF
DISC BRAKES
Disc Brakes Service Specifications
DISC BRAKES SERVICE SPECIFICATIONS
Application
Front Brakes (1) or (2) (6400 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Front Brakes (1) (7200 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Front Brakes (2) (9900 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
In. (mm)
1.082 (27.50)
1.10 (28.0)
1.14 (29.0)
0.005 (0.13)
0.059 (1.50)
0.001 (0.025)
1.082 (27.50)
1.10 (28.0)
1.14 (29.0)
0.005 (0.13)
0.059 (1.50)
0.001 (0.025)
1.437 (36.50)
1.46 (37.0)
1.50 (38.0)
0.005 (0.13)
Application
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Front Brakes (2) (12,300 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Rear Brakes (1) or (2) (6400 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Rear Brakes (1) (7200 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Rear Brakes (2) (9900 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
Rear Brakes (2) (12,400 Lbs. GVWR)
Rotor Discard Thickness (3)
Rotor Minimum Allowable Thickness After Refinish
Rotor Thickness (New)
Rotor Maximum Allowable Lateral Runout
Rotor Maximum Allowable Scoring
Rotor Maximum Allowable Thickness Variation
In. (mm)
0.059 (1.50)
0.001 (0.025)
1.437 (36.50)
1.46 (37.0)
1.50 (38.0)
0.005 (0.13)
0.059 (1.50)
0.001 (0.025)
0.728 (18.50)
0.748 (19.0)
0.787 (20.0)
0.005 (0.13)
0.059 (1.50)
0.001 (0.025)
1.122 (28.50)
1.142 (29.0)
1.181 (30.0)
0.005 (0.13)
0.059 (1.50)
0.001 (0.025)
1.082 (27.50)
1.102 (28.0)
1.141 (29.0)
0.005 (0.13)
0.059 (1.5)
0.001 (0.025)
1.122 (28.5)
1.142 (29.0)
1.181 (30.0)
0.005 (0.13)
0.059 (1.50)
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
Application
In. (mm)
specifications.
Disc Brakes Torque Specifications
DISC BRAKES TORQUE SPECIFICATIONS
Application
Backing Plate Bolts
Brake Caliper Mounting Bolt
Front
Rear
15-Series
25/35-Series
Brake Hose-To-Caliper Bolt
Front
Rear
Brake Pedal Bolt
Brake Pipe Fittings
Cable Support Bracket Bolts
Caliper Mounting Bracket Bolt - Rear
6400 & 7200 Lbs. GVWR
9900 Lbs. GVWR
12,300 Lbs. GVWR
4-Wheel Steering
Caliper Mounting Bracket-To-Knuckle - Front
15-Series
25/35-Series
EHCU Bracket Mounting Bolts
Front Brake Pipe Fitting-To-BPMV
Front Wheel Speed Sensor Mounting Bolt
Hose Bracket-To-Anchor Plate Bolt
Hose Bracket-To-Rear Axle Bolt
Master Cylinder Brake Lines-To-BPMV
Master Cylinder Mounting Nuts
Negative Battery Cable Bolt
Park Brake Cable Bracket-To-Knuckle Bolt (4-Wheel Steering)
Park Brake Cable-To-Rear Axle Clip Bolt
Park Brake Cable-To-Shock Absorber Bracket Bolt
Park Brake Lever Mounting Bolts
Power Brake Booster Nuts (Hydraulic)
Power Brake Booster Nuts (Vacuum)
Ft. Lbs. (N.m)
100 (135)
80 (108)
31 (42)
80 (108)
30 (40)
30 (40)
35 (47)
18 (25)
64 (85)
148 (200)
122 (165)
221 (300)
148 (200)
129 (175)
221 (300)
18 (25)
18 (25)
13 (18)
18 (25)
16 (22)
18 (25)
27 (36)
13 (17)
45 (61)
18 (25)
18 (25)
18 (25)
24 (33)
24 (33)
Application
Quarter Shaft Shield
Rear Brake Pipe Fitting-To-BPMV
Brake Caliper Bleeder Valve
Front
Rear
Brake Pressure Modulator Bleeder Valves
EBCM-To-BPMV Torx Bolts
EHCU-To-Bracket Bolts
Hose Bracket-To-Frame Bolt
Hose Bracket-To-Knuckle Bolt
Hose Bracket-To-Steering Knuckle
Hose Bracket-To-Upper Control Arm Bolt
Intermediate Cable Threaded Rod Nut
Park Brake Cable Guide-To-Frame Bolt
Park Brake Equalizer
Park Brake Warning Light Switch Bolt
Ft. Lbs. (N.m)
18 (25)
18 (25)
In. Lbs. (N.m)
115 (13)
97 (11)
80 (9)
44 (5)
80 (9)
106 (12)
106 (12)
80 (9)
80 (9)
31 (3.5)
106 (12)
31 (3.5)
25 (3)
CHARGING SYSTEM
GENERATOR
Generator Service Specifications
GENERATOR SERVICE SPECIFICATIONS
Standard
Delphi
Rated Output
Load Test Output
Optional (Dual)
Delphi
Rated Output
Load Test Output
Optional
Bosch(R)
Rated Output
Load Test Output
Generator Torque Specifications
GENERATOR TORQUE SPECIFICATIONS
Specification
AD230
102 Amps
71 Amps
AD244
130 Amps
91 Amps
15755900
130 Amps
91 Amps
Application
Auxiliary Battery Tray Nut
Auxiliary Generator Bolt (6.6L)
Auxiliary Generator Bracket Bolt (6.6L)
Auxiliary Negative Battery Cable Bolt (6.6L)
Auxiliary Negative Battery Cable Bolt (Except 6.6L)
Auxiliary Positive Battery Cable Bolt
Battery Cable Bracket Bolt
Battery Hold Down Retainer Bolt
Crossbar Bolt
Drive Belt Tensioner Bolt (6.6L)
EGR Vacuum Pump Bolt (6.6L)
Engine Wiring Harness
Auxiliary Negative Battery Cable Bolt
Ground Bolt
Ground/Negative Cable Bolt
Except 6.6L
6.6L
Retainer Bolt (6.6L)
Fuel Bleed Valve & PCV Oil Separator Bracket Nut (6.6L)
Generator Bracket Bolt (4.8L, 5.3L, 6.0L, 6.6L & 8.1L)
Generator Bolt (4.3L, 4.8L, 5.3L, 6.0L, 6.6L & 8.1L)
Generator Bracket Bolt/Nut (4.3L)
Generator Bracket Stud (8.1L)
Heater Hose Bracket Bolt (4.3L)
Heater Outlet Pipe Bolt (6.6L)
Idler Pulley Bolt (6.6L)
Negative Battery Cable Bolt
Positive Battery Cable Bolt
Wiring Harness Bracket Bolt (4.3L)
Auxiliary Battery Cable Clip Bolt
Auxiliary Battery Relay Nut
Auxiliary Positive Battery Cable Nut
Auxiliary Positive Cable to Relay Nut
Battery Cable Channel Bolt
Except 6.6L
6.6L
Battery Cable Junction Block Bracket Bolt (4.8L, 5.3L, 6.0L & 8.1L)
Battery Cable Retainer Nut (6.6L)
Battery Tray Bolt
Fender-To-Cowl Support Brace Bolt
Forward Lamp Wiring Harness Ground/Negative Cable Bolt
Ft. Lbs. (N.m)
18 (25)
37 (50)
37 (50)
25 (34)
13 (17)
13 (17)
18 (25)
18 (25)
74 (100)
30 (41)
16 (22)
12 (16)
12 (16)
18 (25)
25 (34)
15 (21)
18 (25)
37 (50)
37 (50)
30 (41)
15 (20)
18 (25)
18 (25)
32 (43)
13 (17)
13 (17)
18 (25)
In. Lbs. (N.m)
89 (10)
80 (9)
71 (8)
80 (9)
106 (12)
71 (8)
80 (9)
106 (12)
80 (9)
80 (9)
80 (9)
Application
Front End Diagonal Brace Bolt
Generator Cable Nut
Ground Strap Nut
Harness Clip-To-Junction Block Bracket Bolt
Positive Battery Cable Nut (6.6L)
Positive Cable Clip Nut (8.1L)
Positive Cable At Underhood Bussed Electrical Center (UBEC) Bolt
Transmission Cover Bolt (4.8L, 5.3L & 6.0L)
Ft. Lbs. (N.m)
80 (9)
80 (9)
80 (9)
80 (9)
80 (9)
71 (8)
80 (9)
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 SPECIFICATIONS
Application
Coolant Capacity
Specification
Application
4.3L
4.8L & 5.3L (2)
6.0L
6.6L
8.1L
Coolant Replacement Intervals
Thermostat Opening Temperatures
Thermostat Starts To Open
Thermostat Fully Open
Specification
12.6 Qts. (11.9L)
(1)
13.4 Qts. (12.7L)
(1) (3)
14.8 Qts. (14.0L)
(1)
20.3 Qts. (19.2L)
(1)
20.7 Qts. (19.6L)
(4)
150,000 Miles
(1)
(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(R).
188°F (87°C)
206°F (97°C)
Engine Cooling System Torque Specifications
ENGINE COOLING SYSTEM TORQUE SPECIFICATIONS
Application
Air Conditioning (A/C) Compressor Mounting Bolt (6.6L)
Air Inlet Tube Nut (6.6L)
Bypass Pipe-To-Water Pump Bolt (6.6L)
Coolant Crossover Bolt (8.1L)
Coolant Heater (4.8L, 5.3L & 6.0L)
Coolant Heater (8.1L)
EGR Coolant Pipe Bolt (6.6L)
Engine Block Coolant Drain Plug
Engine Coolant Temperature (ECT) Sensor (6.6L)
Engine Shield Bolt
Exhaust Manifold Pipe Nut (4.8L, 5.3L & 6.0L)
Fan Clutch Bolt
Fan Clutch Nut
Fan Pulley Bolt/Nut (6.6L)
Fan and Water Pump Pulley Bolt (4.3L)
Fuel Line Bracket Bolt (6.6L)
Fuel Line-To-Fuel Injection Control Module Bolt (6.6L)
Generator Bracket Bolt (6.6L & 8.1L)
Generator Bracket Stud (8.1L)
Heater Inlet Pipe-To-Fuel Filter Bolt (6.6L)
Heater Inlet Pipe-To-Thermostat Bolt (6.6L)
Heater Outlet Hose Bracket Bolt (6.6L)
Ft. Lbs. (N.m)
37 (50)
18 (25)
16 (21)
37 (50)
37 (50)
47 (60)
16 (21)
44 (60)
24 (33)
15 (20)
37 (50)
17 (23)
41 (56)
34 (46)
18 (25)
15 (21)
26 (35)
37 (50)
15 (20)
16 (21)
16 (21)
16 (21)
Application
Hood Hinge Bolts
Idler Pulley Bolt (6.6L)
Main Electrical Harness Bracket Bolt (6.6L)
Oil Cooler Hose Bracket Bolt (6.0L)
Oil Cooler Hose Bracket Bolt (8.1L)
PCV Oil Separator Bracket Nut (6.6L)
Power Steering Pump Bracket Bolt (6.6L)
Radiator Bolt
Thermostat Housing Bolt (4.8L, 5.3L & 6.0L)
Thermostat Housing Bolt (8.1L)
Thermostat Housing Cover Bolt (6.6L)
Thermostat Housing Crossover Bolt/Nut (6.6L)
Turbocharger Coolant Bypass Valve (6.6L)
Turbocharger Coolant Feed Pipe Bracket Bolt (6.6L)
Turbocharger Coolant Inlet Banjo Bolt (6.6L)
Water Crossover Bolt (8.1L)
Water Outlet Bolt (8.1L)
Water Outlet Stud (4.3L)
Water Outlet Tube Bolt (6.6L)
Water Outlet Tube-To-Valve Rocker Arm Cover Bolt (6.6L)
Water Pump Bolt (4.3L)
Water Pump Bolt (First Pass) (4.8L, 5.3L & 6.0L)
Water Pump Bolt (Final Pass) (4.8L, 5.3L & 6.0L)
Water Pump Bolt (6.6L)
Water Pump Bolt (8.1L)
Water Pump Inlet Pipe Bolt (6.6L)
Water Pump Pulley Bolt (4.3L)
Water Pump-To-Oil Cooler Inlet Pipe Nut (6.6L)
Air Cleaner Outlet Duct Clamp (4.8L, 5.3L & 6.0L)
Air Cleaner Outlet Duct Clamp (6.6L)
Auxiliary Water Pump Bracket Nut
Charged Air Cooler Duct Clamp (6.6L)
Coolant Air Bleed Pipe Stud/Bolt (4.8L, 5.3L & 6.0L)
Coolant Heater Bolt (4.3L & 6.6L)
Coolant Heater Cord Bolt
Coolant Outlet Pipe Clip Bolt (6.6L)
Fan Shroud Bolt
Generator Positive Cable Nut (6.6L)
Intake Manifold Cover Clamp (6.6L)
Junction Block Bracket Bolt (6.6L)
Main Engine Electrical Harness Connector Bolt (6.6L)
Ft. Lbs. (N.m)
18 (25)
32 (43)
15 (21)
18 (25)
37 (50)
16 (21)
34 (46)
18 (25)
11 (15)
27 (37)
16 (21)
16 (21)
44 (60)
16 (21)
18 (25)
37 (50)
22 (30)
18 (25)
16 (21)
16 (21)
33 (45)
11 (15)
22 (30)
16 (21)
37 (50)
16 (21)
18 (25)
16 (21)
INCH Lbs. (N.m)
62 (7)
53 (6)
80 (9)
53 (6)
106 (12)
18 (2)
71 (8)
80 (9)
80 (9)
80 (9)
53 (6)
80 (9)
89 (10)
Application
Oil Cooler Hose Adapter Bolt (6.0L)
Surge Tank Bolt/Nut
Transmission Control Module (TCM) Cover Bolt
Transmission Control Module (TCM) Electrical Connector Bolt
Turbocharger Coolant Feed Pipe Nut (6.6L)
Turbocharger Coolant Outlet Pipe Bolt/Nut (6.6L)
Wiring Harness Bracket-To-Thermostat Housing Bolt (6.6L)
Ft. Lbs. (N.m)
106 (12)
80 (9)
80 (9)
71 (8)
80 (9)
80 (9)
71 (8)
FUEL SYSTEM
NOTE:
Refer to graphic for 6.6L Diesel engine firing order. See Fig. 7 .
FUEL PRESSURE SPECIFICATIONS
FUEL PRESSURE SPECIFICATIONS
Application
Except Flex-Fuel
Flex-Fuel (VIN Z)
Psi (kPa)
55-62 (379-428)
48-54 (335-375)
IGNITION SYSTEM
FIRING ORDER
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.
Fig. 5: Firing Order (4.3L)
Courtesy of GENERAL MOTORS CORP.
Fig. 6: Firing Order (4.8L, 5.3L, 6.0L & 8.1L)
Courtesy of GENERAL MOTORS CORP.
Fig. 7: Injector Firing Order (6.6L Diesel)
Courtesy of GENERAL MOTORS CORP.
HIGH TENSION WIRES
High Tension Wire Resistance Specifications
HIGH TENSION WIRE RESISTANCE
Application
Ohms
Application
All Gasoline Engines
Ohms
1000 Per Foot
IGNITION TIMING
NOTE:
Ignition timing is not adjustable.
SPARK PLUGS
Spark Plug Specifications
SPARK PLUG SPECIFICATIONS
Application
Glow Plugs Type - 6.6L Diesel (VIN No.)
LB6 ("1")
LLY ("2")
Spark Plug Type (VIN No.)
4.3L ( "X")
4.8L ("V"), 5.3L ("Z"& "T") , 6.0L ("U" & "N") & 8.1L ("G")
Gap
Tightening Torque
Glow Plugs
Spark Plugs
Firing Order
4.3L
4.8L, 5.3L, 6.0L & 8.1L
6.6L Diesel
Specification
GM 97226202
GM 97326305
AC R41-932
AC R41-985
0.060" (1.52 mm)
13 Ft. Lbs. (18 N.m)
11 Ft. Lbs. (15 N.m)
1-6-5-4-3-2
1-8-7-2-6-5-4-3
1-2-7-8-4-5-6-3
STARTING SYSTEM
STARTER
Starter Service Specifications
STARTER SERVICE SPECIFICATIONS
Application
4.3L, 4.8L & 5.3L
6.0L & 8.1L
6.6L Diesel
Specification
PG-260G
PG-260L
Hitachi S14-100B
Starter Torque Specifications
STARTER TORQUE SPECIFICATIONS
Application
Auxiliary Battery Tray Nut
Auxiliary Negative Battery Cable Bolt
Auxiliary Positive Battery Cable Bolt
Battery Cable Bracket Bolt
Battery Hold Down Retainer Bolt
Drive Belt Tensioner Bolt (6.6L)
Engine Wiring Harness Auxiliary Negative Battery Cable Bolt
Engine Wiring Harness Ground Bolt
Engine Wiring Harness Ground/Negative Cable Bolt
Except 6.6L
6.6L
Engine Wiring Harness Retainer Bolt (6.6L)
Fuel Bleed Valve & PCV Oil Separator Bracket Nut (6.6L)
Heater Hose Bracket Bolt (4.3L)
Heater Outlet Pipe Bolt (6.6L)
Idler Pulley Bolt (6.6L)
Negative Battery Cable Bolt
Positive Battery Cable Bolt
Starter Bolt
4.3L
4.8L, 5.3L, 6.0L & 8.1L
6.6L
Auxiliary Battery Cable Clip Bolt
Auxiliary Battery Relay Nut
Auxiliary Positive Battery Cable Nut
Auxiliary Positive Cable to Relay Nut
Battery Cable Channel Bolt
Except 6.6L
6.6L
Battery Cable Junction Block Bracket Bolt (4.8L, 5.3L & 6.0L)
Battery Cable Retainer Nut (6.6L)
Battery Tray Bolt
Forward Lamp Wiring Harness Ground/Negative Cable Bolt
Front End Diagonal Brace Bolt
Ground Strap Nut
Positive Battery Cable Nut (6.6L)
Positive Cable Clip Nut (8.1L)
Ft. Lbs. (N.m)
18 (25)
13 (17)
13 (17)
18 (25)
18 (25)
30 (41)
12 (16)
12 (16)
18 (25)
25 (34)
15 (21)
18 (25)
18 (25)
18 (25)
32 (43)
13 (17)
13 (17)
32 (43)
37 (50)
58 (79)
INCH Lbs. (N.m)
89 (10)
80 (9)
71 (8)
80 (9)
106 (12)
71 (8)
80 (9)
106 (12)
80 (9)
80 (9)
80 (9)
80 (9)
80 (9)
71 (8)
Application
Positive Cable at Underhood Bussed Electrical Center (UBEC) Bolt
Starter Heat Shield Bolt (8.1L)
Starter Heat Shield Nut (8.1L)
Starter Lead Nut
Starter Solenoid Nut
Surge Tank Bolt/Nut
Transmission Cover Bolt (4.8L, 5.3L & 6.0L)
Wiring Harness Bracket Bolt (4.3L)
Ft. Lbs. (N.m)
80 (9)
35 (4)
44 (5)
80 (9)
40 (3.4)
80 (9)
80 (9)
18 (2)