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HOMESERVICE MANUALSCHEVROLET2001C3500 HD 8.1 G, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1756 (ENGINE CONTROLS - 6.6L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL JUNCTION BLOCK REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet C3500 HD 8.1 G, Automatic

Installation Procedure

2001 Chevrolet C3500 HD 8.1 G, AutomaticSECTION Installation Procedure
WARNING: This page is about a different car, the 2001 GMC Sierra, 2001 GMC Cab & Chassis Sierra, 2001 Chevrolet Silverado, and 2001 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Junction Block Nuts
    GM660442Courtesy of GENERAL MOTORS COMPANY
  1. Refer to FASTENER NOTICE in Cautions and Notices.

    Install the junction block and the 2 nuts holding the junction block.

    Tighten 

    Tighten the nuts to 25 N.m (18 Ib ft).

    2. Fig 2: Fuel Injection Block Banjo Bolt, Fuel Pipe & Nuts
    GM755766Courtesy of GENERAL MOTORS COMPANY
  2. Install the fuel system return line banjo bolt (1) to the junction block.

    Tighten 

    Tighten the fuel return line banjo bolt to 15 N.m (11 lb ft).

  3. Connect the 3 fuel pipes (3) to the junction block.

    Tighten 

    Tighten the high pressure fuel lines to 44 N.m (32 lb ft).

    4. Fig 3: Fuel Pipe Junction Block At Fuel Rail
    GM755759Courtesy of GENERAL MOTORS COMPANY
  4. Connect the other end of the pipe (1) to the left fuel rail.

    Tighten 

    Tighten the high pressure pipe from the junction block to the left fuel rail to 44 N.m (32 lb ft).

    5. Fig 4: Turbocharged Air Hose View
    GM664853Courtesy of GENERAL MOTORS COMPANY
  5. Install the charged air cooler inlet duct to turbocharger charged air cooler outlet. Align the marks on the hose and the intake manifold duct.

    Tighten 

    Tighten the charged air cooler clamp to 6 N.m (53 lb in).

    6. Fig 5: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS COMPANY
  6. Install the PCV hose to the upper valve rocker arm cover.
    7. Fig 6: View Of Water Outlet & Bolts
    GM699329Courtesy of GENERAL MOTORS COMPANY
  7. Install the water outlet tube using the following procedure:
    1. Install a new O-ring seal on the water outlet tube.
    2. Lightly lubricate the O-ring seal with coolant.
    3. Install the water outlet tube.
    4. Install the bolt retaining the water outlet tube to the thermostat housing.

      Tighten 

      Tighten the water outlet tube to thermostat housing bolt to 21 Y (16 lb ft).

    5. Install the 2 bolts retaining the water outlet tube to the valve rocker arm cover.

      Tighten 

      Tighten the water outlet tube to valve rocker arm cover bolts to 21 N.m (16 lb ft).

    8. Fig 7: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS COMPANY
  8. Install the turbocharger coolant hose and clamp from the turbocharger bypass valve.
  9. Connect the oil pressure sending unit harness connector.
    10. Fig 8: Left Front Injector Harness Electrical Connector
    GM759733Courtesy of GENERAL MOTORS COMPANY
  10. Connect the left front injector harness connector (1).
    11. Fig 9: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS COMPANY
  11. Install the A/C compressor using the following procedure:
    1. Install the A/C compressor mounting bolts.

      Tighten 

      Tighten the A/C compressor mounting bolts to 50 N.m (37 lb ft).

    2. Reconnect the A/C cut out switch electrical connector.
    3. Reconnect the A/C compressor clutch electrical connector.
  12. Replace the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
  13. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
    14. Fig 10: Upper Intake Manifold Sight Shield
    GM658266Courtesy of GENERAL MOTORS COMPANY
  14. Install the upper intake manifold sight shield.

    Tighten 

    Tighten the upper intake manifold sight shield bolt to 9 N.m (80 lb in).

  15. Install the fuel cap.
  16. Connect the negative batteries cables to both batteries. Refer to Battery Negative Cable Disconnection and Connection (Auxiliary Battery) , Battery Negative Cable Disconnection and Connection (Single Battery) in Engine Electrical.
    17. Fig 11: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS COMPANY
  17. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).

    Tighten 

    Tighten the bolts to 25 N.m (18 lb ft).

  18. Purge air from the fuel system. Refer to Fuel Feed and Return Pipe Purging .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.