2007 Chevrolet Silverado 1500 HD Service & Repair Manual

2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Specification Metric English A/C Compressor Bolt 50 N.m 37 lb ft Air Cleaner Outlet Duct Clamp 8 N.m 71 lb in Air Conditioning Compressor/Power Steering Pump Bracket Bolt 46 N.m 34 lb ft Air Inlet Tube Nut 25 N.m 18 lb ft Battery Cable Bracket Bolt 12 N.m 106 lb in Battery Cable Bracket Nut 8 N.m 71 lb in Bypass Pipe Bolt 25 N.m 18 lb ft Camshaft Gear Bolt 234 N.m 173 lb ft Camshaft Position Sensor Bolt 10 N.m 89 lb in Camshaft Position Sensor Exciter Ring Bolt 9 N.m 80 lb in Camshaft Thrust Plate Bolt 22 N.m 16 lb ft Charged Air Cooler Bolt 21 N.m 15 lb ft Charged Air Cooler Clamp 8 N.m 71 lb in Connecting Rod Cap Bolt - Angular Tightening Method 1st Step 64 N.m 1st Step 47 lb ft 2nd Step 30 degrees 2nd Step 30 degrees 3rd Step 30 degrees 3rd Step 30 degrees Coolant Pipe Bolt and Nut 25 N.m 18 lb ft Coolant Tube to Water Pump Nut 25 N.m 18 lb ft Cooling Fan Pulley 41 N.m 30 lb ft Crankshaft Balancer Bolt 1st Step 100 N.m 1st Step 74 lb ft 2nd Step 105 degrees 2nd Step 105 degrees 1st Step 98 N.m 1st Step 72 lb ft 2nd Step 132 N.m 2nd Step 97 lb ft 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

Crankshaft Bearing Cap Bolt 3rd Step 30 degrees 3rd Step 30 degrees Crankshaft Bearing Cap Bolt - Angular Tightening Method 1st Step 100 N.m 1st Step 74 lb ft 2nd Step 90 degrees 2nd Step 90 degrees Crankshaft Bearing Cap Side Bolt 70 N.m 52 lb ft Crankshaft Position Sensor Bolt 10 N.m 89 lb in Crankshaft Position Sensor Spacer Bolt 10 N.m 89 lb in Crossmember Bolt 100 N.m 74 lb ft Cylinder Head M12 Bolt - Angular Tightening Method 1st Step 50 N.m 1st Step 37 lb ft 2nd Step 80 N.m 2nd Step 59 lb ft 3rd Step 60 degrees 4th Step 60 degrees Cylinder Head M8 Bolt 25 N.m 18 lb ft Drive Belt Tensioner Pulley Bolt 50 N.m 37 lb ft EGR to EGR Cooler Bolt 25 N.m 18 lb ft EGR Bracket 25 N.m 18 lb ft EGR Bracket Bolt 25 N.m 18 lb ft EGR Bracket to Cooler Bolt 25 N.m 18 lb ft Electrical Harness Bracket Bolt 10 N.m 89 lb in Engine Block Coolant Plug 18 N.m 13 lb ft Engine Block Ground Bolt 34 N.m 25 lb ft Engine Mount Through Bolt to Frame 75 N.m 55 lb ft Engine Mount to Block Bolts 58 N.m 43 lb ft Engine Mount to Frame Bolt 65 N.m 48 lb ft Engine Shield Bolt 20 N.m 15 lb ft Exhaust Heat Shield Nut 10 N.m 89 lb in Exhaust Manifold Bolt/Nut 57 N.m 42 lb ft Exhaust Manifold Heat Shield Bolts 10 N.m 89 lb in Exhaust Outlet Clamp 15 N.m 11 lb ft Exhaust Outlet Heat Shield Bolts 10 N.m 89 lb in Exhaust Pipe Bracket Nut 53 N.m 39 lb ft Exhaust Pipe Clamp 53 N.m 39 lb ft Exhaust Pipe Heat Shield Bolts 10 N.m 89 lb in Exhaust Pipe to EGR Cooler Nuts 26 N.m 19 lb ft 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

Fan Pulley Bracket Bolt 50 N.m 37 lb ft Flywheel Bolt - Angular Tightening Method 1st Step 79 N.m 1st Step 58 lb ft 2nd Step 60 degrees 2nd Step 60 degrees 3rd Step 60 degrees 3rd Step 60 degrees Flywheel Housing Bolt 80 N.m 60 lb ft Flywheel Housing to Upper Oil Pan Bolt 50 N.m 37 lb ft Front Engine Cover Bolt 25 N.m 18 lb ft Fuel Filter Bracket Bolt 30 N.m 22 lb ft Fuel Injection Pipe Nut 41 N.m 30 lb ft Fuel Injector Bracket Bolt 30 N.m 22 lb ft Fuel Inlet Pipe Bracket Bolt 21 N.m 15 lb ft Fuel Injection Pump Assembly to Cylinder Block Bolt 25 N.m 18 lb ft Fuel Injection Pump to Bracket Bolt 28 N.m 20 lb ft Fuel Injection Pump Drive Gear Nut 70 N.m 52 lb ft Fuel Line Bracket Nut 21 N.m 15 lb ft Fuel Temperature Sensor 22 N.m 16 lb ft Fuel Pipes Bracket Bolt 25 N.m 18 lb ft Fuel Pressure Relief Valve 100 N.m 74 lb ft Fuel Rail Assembly Bolt 25 N.m 18 lb ft Fuel Rail Balance Pipe Bolt 21 N.m 15 lb ft Generator Bracket Bolt and Nut 50 N.m 37 lb ft Generator Positive Cable Nut 9 N.m 80 lb in Glow Plug 18 N.m 13 lb ft Glow Plug Controller Bolt 10 N.m 89 lb in Glow Plug Harness Bracket Bolt 10 N.m 89 lb in Glow Plug Nut 2 N.m 18 lb in Glow Plug Power Feed Nut 15 N.m 11 lb ft Glow Plug Relay Assembly Bolt 10 N.m 89 lb in Heater Outlet Pipe Bolt 25 N.m 18 lb ft Heater Pipe Bolt 25 N.m 18 lb ft Hood Hinge Bolt 25 N.m 18 lb ft Idle Pulley Bolt 50 N.m 37 lb ft 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

Injector Bracket Bolt 23 N.m 16 lb ft Intake Manifold Bolts/Nuts 25 N.m 18 lb ft Oil Cooler Adapter Bolts 25 N.m 18 lb ft Oil Cooler Adapter Nuts 25 N.m 18 lb ft Oil Cooler Assembly Bolts 25 N.m 18 lb ft Oil Cooler Adapter Stud 10 N.m 89 lb in Oil Drain Plug 84 N.m 62 lb ft Oil Fill Tube Bolt 25 N.m 18 lb ft Oil Filter 24 N.m 18 lb ft Oil Gallery Plugs 53 N.m 39 lb ft Oil Level Indicator Tube Bolt 21 N.m 15 lb ft Oil Level Sensor Bolt 10 N.m 89 lb in Oil Level Sensor Harness Bolt 40 N.m 29 lb ft Oil Pan Bolts/Nuts - Lower 10 N.m 89 lb in Oil Pan Bolt - Upper 20 N.m 15 lb ft Oil Pan Skid Plate Bolt 20 N.m 15 lb ft Oil Pressure Sensor Unit 49 N.m 36 lb ft Oil Pressure Relief Valve 39 N.m 29 lb ft Oil Pump Bolt 21 N.m 15 lb ft Oil Pump Driven Gear Nut 100 N.m 74 lb ft Oil Pump Gear Cover Bolt 21 N.m 15 lb ft Oil Pump Pipe and Screen Assembly Bolts and Nuts 25 N.m 18 lb ft Piston Cooling Nozzle Eye Bolt 21 N.m 15 lb ft Positive Cable Junction Block Bracket to Power Steering Pump Bolt 9 N.m 80 lb in Positive Crankcase Ventilation Cover Screws 4 N.m 35 lb in Positive Crankcase Ventilation Oil Separator Bracket Nut 25 N.m 18 lb ft Power Steering Pump Bracket Bolt 50 N.m 37 lb ft Power Steering Pump Bolt 50 N.m 37 lb ft Rocker Arm Shaft Bracket Bolt 41 N.m 30 lb ft Starter Motor Bolt 78 N.m 58 lb ft Transmission Fill Tube Nut 18 N.m 13 lb ft Thermostat Housing Bolts/Nuts 25 N.m 18 lb ft Thermostat Cover Bolt 25 N.m 18 lb ft 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

ENGINE MECHANICAL SPECIFICATIONS Torque Converter Bolt 60 N.m 44 lb ft Transmission Oil Cooler Clip Nut 9 N.m 80 lb in Turbocharger Bolt 108 N.m 80 lb ft Turbocharger Coolant Outlet Pipe Bracket Nut 10 N.m 89 lb in Turbocharger Heat Shield Bolts 10 N.m 89 lb in Turbocharger Oil Return Pipe Stud 10 N.m 89 lb in Turbocharger Oil Supply Hose Eye Bolt 26 N.m 19 lb ft Turbocharger Oil Return Pipe Bolts/Nuts 25 N.m 18 lb ft Upper Oil Pan to Flywheel Housing Bolts 20 N.m 15 lb ft Valve Adjusting Nut 22 N.m 16 lb ft Valve Lifter Holdown Bracket Bolt 11 N.m 97 lb in Valve Rocker Arm Cover Bolt - Lower 10 N.m 89 lb in Valve Rocker Arm Cover Bolt - Upper 8 N.m (Two Times) 71 lb in (Two Times) Water Outlet Bolts 25 N.m 18 lb ft Water Pump Bolt 25 N.m 18 lb ft Water Pump Inlet Pipe Bolts 25 N.m 18 lb ft Application Specification Metric English General  Engine Type 90 degree V-8  Displacement 6.6 Liter 402 cu in  RPO LMM  Bore 103 mm 4.0551 in  Stroke 99 mm 3.8976 in  Compression Ratio 16.8:1  Engine Compression Test - Minimum 2069 KPa 300 psi  Idle Speed 680 RPM  Firing Order 1-2-7-8-4-5-6-3 Block 103.11 mm 4.0594 in 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

 Cylinder Bore Diameter - Service Limits  Cylinder Bore Diameter - Production Value 103.0-103.014 mm 4.0551-4.0557 in  Cylinder Bore Out-of-Round - Production Value 0.015 mm 0.0006 in  Cylinder Bore Taper - Production Value 0.015 mm 0.0006 in Camshaft  Camshaft Bearing Inside Diameter - Service Limit 61.07 mm 2.4043 in  Camshaft Bearing Inside Diameter - Production Value 61.00-61.03 mm 2.4016-2.4028 in  Camshaft End Play - Service Limit 0.2 mm 0.0079 in  Camshaft Journal Diameter - Service Limit 60.92 mm 2.3984 in  Camshaft Journal Diameter - Production Value 60.932-60.962 mm 2.3990-2.4001 in  Camshaft Lobe Lift - Exhuast - Production Value 5.907 mm 0.2326 in  Camshaft Lobe Lift - Intake - Production Value 7.273 mm 0.2863 in  Camshaft Runout - Service Limit 0.05 mm 0.0020 in Cooling System  Capacity @ Engine RPM 270 L/min @ 3172 RPM  Thermostat Full Open Temperature 110 degrees C 230 degrees F  Turbocharger Coolant Bypass Valve 60 degrees C 140 degrees F Connecting Rod  Connecting Rod Bearing Clearance - Service Limit 0.10 mm 0.0039 in  Connecting Rod Bearing Clearance - Production Value 0.036-0.077 mm 0.0014-0.0030 in  Connecting Rod Bore Diameter - Bearing End - Production Value 62.958-62.979 mm 2.4789-2.4795 in  Connecting Rod Bore Diameter - Pin End - Service Limit 34.53 mm 1.3594 in  Connecting Rod Bore Diameter - Pin End - 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

Production Value 34.512-34.522 mm 1.3587-1.3591 in  Connecting Rod Length 163.0 mm 6.42 in  Connecting Rod Side Clearance - Service Limit 0.54 mm 0.0213 in  Connecting Rod Side Clearance - Production Value 0.31-0.49 mm 0.0122-0.0193 in Crankshaft  Connecting Rod Journal Diameter - Service Limit 62.88 mm 2.4756 in  Connecting Rod Journal Diameter - Production Value 62.902-62.922 mm 2.4764-2.4772 in  Crankshaft End Play - Service Limit 0.54 mm 0.0213 in  Crankshaft End Play - Production Value 0.04-0.205 mm 0.0016-0.0081 in  Crankshaft Main Bearing Clearance - Service Limit 0.14 mm 0.0055 in  Crankshaft Main Bearing Clearance - Production Value 0.039-0.070 mm 0.0015-0.0028 in  Crankshaft Main Journal Diameter - Service Limit 79.89 mm 3.1453 in  Crankshaft Main Journal Diameter - Production Value 79.905-79.925 mm 3.1459-3.1466 in  Crankshaft Runout - Service Limit 0.44 mm 0.0173 in  Crankshaft Runout - Production Value 0.05 mm 0.0020 in Cylinder Head  Surface Flatness - Block Deck - Service Limit 0.2 mm 0.0079 in  Surface Flatness - Block Deck - Production Value 0.075 mm 0.0030 in  Surface Flatness - Exhaust Manifold Deck - Production Value 0.1 mm 0.0039 in  Surface Flatness - Intake Manifold Deck - Production Value 0.1 mm 0.0039 in Exhaust Manifold 0.3 mm 0.0118 in 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

 Surface Flatness- Production Value Intake Manifold  Surface Flatness - Production Value 0.3 mm 0.0118 in Lubrication System  Oil Capacity - with Filter 10 qt 9.5 L  Oil Capacity - without Filter 9.2 qt 8.7 L  Oil Pressure - Minimum- Hot - at idle 98 KPa 14 psi  Oil Pressure - Minimum - 1800 RPM 294 KPa 42 psi  Oil Relief Valve Opening Pressure 441 KPa 64 psi  Piston Cooling Jet Valve Opening Pressure 196 KPa 29 psi Oil Pump  Gear Shaft Outside Diameter - Drive - Service Limit 19.86 mm 0.7819 in  Gear Shaft Outside Diameter - Drive - Production Value 19.947-19.960 mm 0.7853-0.7858 in  Gear Shaft Outside Diameter - Driven - Service Limit 19.86 mm 0.7819 in  Gear Shaft Outside Diameter - Driven - Production Value 19.947-19.960 mm 0.7853-0.7858 in  Gear Shaft-to-Bushing - Service Limit Clearance 0.14 mm 0.0055 in  Gear-to-Cover Clearance - Drive/Driven - Service Limit 0.109 mm 0.0043 in  Gear-to-Cover Clearance - Drive/Driven - Production Value 0.064-0.109 mm 0.0025-0.0043 in  Gear-to-Housing Clearance - Drive/Driven - Service Limit 0.22 mm 0.0087 in  Gear-to-Housing Clearance - Drive/Driven - Production Value 0.125-0.221 mm 0.0049-0.0087 in Piston Rings  Piston Ring End Gap-First Compression Ring - Service Limit 1.37 mm 0.0539 in 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

 Piston Ring End Gap-First Compression Ring - Production Value 0.3-0.45 mm 0.0118-0.0177 in  Piston Ring End Gap-Second Compression Ring - Service Limit 1.35 mm 0.0531 in  Piston Ring End Gap-Second Compression Ring - Production Value 0.50-0.65 mm 0.0197-0.0256 in  Piston Ring End Gap-Oil Control Ring - Service Limit 1.20 mm 0.0472 in  Piston Ring End Gap-Oil Control Ring - Production Value 0.15-0.35 mm 0.0059-0.0138 in  Piston Ring to Groove Clearance-First Compression Ring - Service Limit 0.26 mm 0.0102 in  Piston Ring to Groove Clearance-First Compression Ring - Production Value 0.08-0.17 mm 0.0030-0.0067 in  Piston Ring to Groove Clearance-Second Compression Ring - Service Limit 0.10 mm 0.0039 in  Piston Ring to Groove Clearance-Second Compression Ring - Production Value 0.01-0.03 mm 0.0004-0.0012 in  Piston Ring to Groove Clearance-Oil Control Ring - Service Limit 0.12 mm 0.0047 in  Piston Ring to Groove Clearance-Oil Control Ring - Production Value 0.01-0.03 mm 0.0004-0.0012 in Pistons and Pins  Piston-Piston Diameter 102.948-102.960 mm 4.0531-4.0535 in  Piston-Piston Pin Bore Diameter 34.504-34.512 mm 1.3584-1.3587 in  Pin-Piston Pin Clearance to Piston Pin Bore - Service Limit 0.017 mm 0.0007 in  Pin-Piston Pin Clearance to Piston Pin Bore - Production Value 0.004-0.017 mm 0.0002-0.0007 in  Pin-Piston Pin Diameter - Service Limit 34.45 mm 1.3563 in  Pin-Piston Pin Diameter - Production Value 34.495-34.5 mm 1.3581-1.3583 in Starter 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

 Rated Output 3.5 KW Valve System  Valves-Valve Face Angle - Production Value 45 degrees  Valves-Valve Face Width - Service Limit 2.5 mm 0.0984 in  Valves-Valve Face Width - Production Value 2.1 mm 0.0827 in  Valves-Valve Head Diameter - Exhaust 31.0 mm 1.22 in  Valves-Valve Head Diameter - Intake 33.0 mm 1.30 in  Valves-Valve Seat Angle 45 degrees  Valves-Valve Stem Diameter 7.0 mm 0.28 in  Valves-Valve Stem Oil Seal Installed Height 6.05 mm 0.2382 in  Valves-Valve Stem-to-Guide Clearance - Service Limit 0.20 mm 0.0079 in  Valves-Valve Stem-to-Guide Clearance - Exhaust - Production Value 0.038-0.071 mm 0.0015-0.0028 in  Valves-Valve Stem-to-Guide Clearance - Intake - Production Value 0.030-0.063 mm 0.0012-0.0025 in  Valves-Valve Stem-to-Guide Clearance 0.20 mm 0.0079 in  Valve Lifters/Push Rods- Push Rod Straightness 0.8 mm 0.0315 in  Rocker Arms-Valve Rocker Arm Bore Diameter 22.010-22.035 mm 0.8665-0.8675 in  Rocker Arms-Valve Rocker Arm Bore-to- Shaft Clearance - Service Limit 0.20 mm 0.0079 in  Rocker Arms-Valve Rocker Arm Bore-to- Shaft Clearance - Production Value 0.010-0.056 mm 0.0004-0.0022 in  Rocker Arms-Valve Rocker Arm Ratio - Exhaust 1.69:1  Rocker Arms-Valve Rocker Arm Ratio - Intake 1.36:1  Rocker Arms-Valve Rocker Arm Shaft Diameter - Service Limit 21.85 mm 0.8602 in  Rocker Arms-Valve Rocker Arm Shaft Diameter - Production Value 21.979-22.000 mm 0.8653-0.8661 in 2008 Chevrolet Silverado 1500 2008 ENGINE Engine Mechanical - 6.6L - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

2007 Chevrolet Silverado 1500 HD Service & Repair Manual

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