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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 5 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSTURBOCHARGER VANE POSITION SENSOR REPLACEMENTTHERMAL REFLECTIVE SHIELD/TAPE INSTALLATION
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Thermal Reflective Shield/Tape Installation

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Thermal Reflective Shield/Tape Installation
WARNING: This page is about a different variant/trim than selected.
IMPORTANT:
  • Ensure outside surface of sensor body is clean and oil-free prior to beginning the installation procedure. If sensor body surface is oily, use a mild degreaser in order to remove the oil from the surface. Ensure degreased surface is dry prior to beginning the installation.
  • The thermal reflective shield and tie strap are to be installed over the vane position sensor AFTER the sensor is installed and torqued in the turbo centerhousing. Graphics below show the sensor prior to the installation process for clarity purposes only.
    Fig 1: Peeling Off The Protective Backing From The Back Side Of The Thermal Reflective Shield/Tape
    GM1488378Courtesy of GENERAL MOTORS CORP.
  1. Peel off the protective backing from the back side of the thermal reflective shield/tape.
    2. Fig 2: Aligning The Bottom Edge Of The Shield/Tape With The Bottom Edge Of The Sensor Hex
    GM1488379Courtesy of GENERAL MOTORS CORP.
  2. With the sticky side of the shield/tape applied against the sensor body, align the bottom edge of the shield/tape with the bottom edge of the hex, and begin wrapping the sensor.
    3. Fig 3: Completely Wrapping The Shield/Tape Around The Sensor
    GM1488381Courtesy of GENERAL MOTORS CORP.
  3. Completely wrap the shield/tape around the sensor.
    4. Fig 4: Tucking The Top Of The Shield/Tape Under The Head Of The Brass Cable Crimp Sleeve
    GM1488385Courtesy of GENERAL MOTORS CORP.
  4. Tuck the top of the shield/tape under the head of the brass cable crimp sleeve all around, allowing the shield/tape to fold over and overlap itself at the top.
    5. Fig 5: Sensor Wrapped In Shield/Tape
    GM1488387Courtesy of GENERAL MOTORS CORP.
  5. The top of the shield/tape is now shown tucked under the head of the brass cable crimp sleeve all around.
    6. Fig 6: Wrapping The Tie Strap Around The Necked Porting Of The Sensor Body
    GM1488391Courtesy of GENERAL MOTORS CORP.
  6. Wrap the tie strap around the necked porting of the sensor body just above the hex. Insert the end of the strap in the buckle and tighten by pulling the end with needlenose pliers.
    7. Fig 7: Bending the End Of The Tie Strap 180 Degrees Over The Top Of The Buckle
    GM1488393Courtesy of GENERAL MOTORS CORP.
  7. Bend the end of the tie strap 180 degrees over the top of the buckle.
    8. Fig 8: Cutting Off The Tie Strap Using Side Cutters
    GM1488398Courtesy of GENERAL MOTORS CORP.
  8. Cut off the tie strap using side cutters so that the cut end will lie approximately over the center of the buckle. Push down the end of the tie strap over the buckle in order to minimize protrusion of the cut end or any sharp edges.
    9. Fig 9: View Of Finished installation Of Sensor
    GM1488400Courtesy of GENERAL MOTORS CORP.
  9. Finished installation is shown.
  10. Install the engine cover. Refer to Engine Cover Replacement .
  11. Perform the turbocharger learn procedure. Refer to Turbocharger Learn .
RENDER: 1.0x

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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.