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Home >> Pontiac >> 2001 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 944 (Engine Controls - 6.6L (LLY) (Introduction)) >> Repair Instructions >> Engine Wiring Harness Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Injector Control Module Harness
    GM1335560Courtesy of GENERAL MOTORS CORP.
  1. Install the engine wiring harness.
    2. Fig 2: View Of Glow Plug Controller Bolts
    GM1336490Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the glow plug electrical connector nuts.

    Tighten:  Tighten the nuts to 2 N.m (18 lb in).

  3. Install the glow plug controller.
  4. Install the glow plug controller bolts.

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

    5. Fig 3: View Of Oil Level Sensor Harness Bolt
    GM1335549Courtesy of GENERAL MOTORS CORP.
  5. Install the oil level sensor harness bolt.

    Tighten:  Tighten the bolt to 40 N.m (30 lb ft).

    6. Fig 4: View Of Oil Pressure Sensor Electrical Connector
    GM1335546Courtesy of GENERAL MOTORS CORP.
  6. Connect the oil pressure sensor electrical connector.
    7. Fig 5: View Of Fuel Rail Pressure Sensor And Electrical Connector
    GM1335543Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel rail pressure sensor electrical connector.
    8. Fig 6: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
    GM1335540Courtesy of GENERAL MOTORS CORP.
  8. Connect the turbocharger vane control solenoid valve.
    9. Fig 7: View Of Fuel Injector Electrical Connectors
    GM1335536Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel injector electrical connectors.
    10. Fig 8: View Of Turbocharger Vane Position Sensor And Electrical Connector
    GM1334926Courtesy of GENERAL MOTORS CORP.
  10. Install and connect the turbocharger vane position sensor.
    11. Fig 9: Glow Plug Controller Battery Feed Electrical Connector
    GM1409333Courtesy of GENERAL MOTORS CORP.
  11. Connect the glow plug controller battery feed electrical connector (1).
    12. Fig 10: View Of Glow Plug Controller Electrical Connectors
    GM1335531Courtesy of GENERAL MOTORS CORP.
  12. Connect the glow plug controller electrical connector.
    13. Fig 11: View Of Fuel Temperature Sensor Electrical Connector
    GM1335528Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel temperature sensor electrical connector.
    14. Fig 12: View Of Oil Level Sensor Electrical Harness Connector
    GM1335526Courtesy of GENERAL MOTORS CORP.
  14. Connect the oil level sensor electrical harness connector.
    15. Fig 13: View Of Turbocharger Boost Sensor Electrical Connector
    GM1335490Courtesy of GENERAL MOTORS CORP.
  15. Connect the turbocharger boost sensor electrical connector.
    16. Fig 14: View Of Fuel Pressure Control Valve Electrical Connector
    GM1335482Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel pressure control valve electrical connector.
    17. Fig 15: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  17. Install the main engine electrical harness connector screws.

    Tighten:  Tighten the screws to 10 N.m (89 lb in).

    18. Fig 16: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  18. Connect the barometric sensor electrical connector.
    19. Fig 17: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  19. Connect the main engine electrical harness connectors.
  20. Push down on the latches (1) in order to connect the connectors.
  21. Close the harness clip (2).
    22. Fig 18: View Of Electrical Harness Tie Strap
    GM1335476Courtesy of GENERAL MOTORS CORP.
  22. Install a NEW tie strap to the electrical harness.
    23. Fig 19: View Of Crankshaft Position Sensor Electrical Connector
    GM1335470Courtesy of GENERAL MOTORS CORP.
  23. Connect the CKP sensor electrical connector.
    24. Fig 20: View Of Ground Bolts
    GM1335467Courtesy of GENERAL MOTORS CORP.
  24. Install the 2 ground bolts.

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    25. Fig 21: View Of Camshaft Position Sensor Electrical Connector
    GM1334862Courtesy of GENERAL MOTORS CORP.
  25. Connect the CMP sensor electrical connector.
    26. Fig 22: View Of EGR Valve Electrical Connector
    GM1335463Courtesy of GENERAL MOTORS CORP.
  26. Connect the EGR valve electrical connector.
    27. Fig 23: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  27. Connect the ECT sensor electrical connector.
  28. Install the PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
    29. Fig 24: View Of Right Glow Plug Harness Bracket Bolts
    GM1335450Courtesy of GENERAL MOTORS CORP.
  29. Install the right glow plug harness bracket bolts.

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

  30. Install the right glow plug connectors to the glow plugs.

    Tighten:  Tighten the glow plug connector nuts to 2 N.m (18 lb in).

    31. Fig 25: View Of Left Glow Plug Harness Bracket Bolts
    GM1335443Courtesy of GENERAL MOTORS CORP.
  31. Install the left glow plug harness bracket bolts.

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

  32. Install the left glow plug connectors to the glow plugs.

    Tighten:  Tighten the glow plug connector nuts to 2 N.m (18 lb in).

    33. Fig 26: View Of Fuel Injection Control Module Electrical Connectors
    GM1334881Courtesy of GENERAL MOTORS CORP.
  33. Connect the fuel injection control module electrical connectors.
  34. Install a NEW tie strap attaching the harness to the bracket.
    35. Fig 27: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  35. Remove the tape from the turbocharger openings.
  36. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  37. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

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

    38. Fig 28: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  38. Install the charged air cooler outlet duct to the intake.
  39. Tighten the charged air cooler outlet duct to intake hose clamp.

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

  40. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  41. Install both front wheelhouse panels. Refer to Wheelhouse Panel Replacement in Body Front End.
  42. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  43. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
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