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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 380 (ENGINE CONTROLS - 6.6L (LB7) (INTRODUCTION))REPAIR INSTRUCTIONSGLOW PLUG RELAY REPLACEMENT (FEDERAL EMISSIONS)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal 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.
  1. Disconnect 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.
  2. Loosen the outlet duct clamp at the upper intake manifold cover.
  3. Remove the upper intake manifold cover from the outlet duct.
  4. Remove the upper intake manifold cover.
    5. Fig 1: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  5. Using a flat bladed screwdriver, disengage the glow plug controller cover clips.
    6. Fig 2: Disengaging Glow Plug Controller Cover Clips
    GM1177261Courtesy of GENERAL MOTORS CORP.
  6. Remove the glow plug controller cover.
    7. Fig 3: Glow Plug Controller Cover
    GM1177263Courtesy of GENERAL MOTORS CORP.
  7. Remove the glow plug relay terminal nuts and wires.
    8. Fig 4: Glow Plug Relay Terminal Nuts And Wires
    GM1177268Courtesy of GENERAL MOTORS CORP.
  8. Remove the glow plug controller nuts.
    9. Fig 5: Glow Plug Controller Nuts
    GM1177264Courtesy of GENERAL MOTORS CORP.
  9. Lift the glow plug controller off the studs.
    10. Fig 6: Glow Plug Controller & Studs
    GM1177266Courtesy of GENERAL MOTORS CORP.
  10. Separate the glow plug relay from the glow plug controller housing by inserting a small screwdriver between them while prying the relay assembly outward.
    11. Fig 7: Separating Glow Plug Relay From Glow Plug Controller Housing Using Screwdriver
    GM1177269Courtesy of GENERAL MOTORS CORP.
  11. Slide the glow plug relay outward to disengage it from the glow plug controller housing.
    12. Fig 8: Glow Plug Relay & Glow Plug Controller
    GM1177270Courtesy of GENERAL MOTORS CORP.
  12. Using a flat bladed screwdriver, disengage the glow plug relay clip.
    13. Fig 9: Disengaging Glow Plug Relay Clip Using Screwdriver
    GM1177271Courtesy of GENERAL MOTORS CORP.
  13. Remove the glow plug relay.
    14. Fig 10: Glow Plug Relay
    GM1177272Courtesy of GENERAL MOTORS CORP.
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.