TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)

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2004 SPECIFICATIONSSierra, Silverado, Cab & ChassisTORQUE SPECIFICATIONSApplicationA/C Compressor BoltBypass Pipe BoltCamshaft Gear BoltCamshaft Thrust Plate BoltConnecting Rod Cap Bolt (Angular Tightening Method)1st Step2nd Step3rd StepCoolant Pipe-To-Water Pump NutCooling Fan PulleyCrankshaft Balancer BoltCylinder Head M12 Bolt (Angular Tightening Method) (1)1st Step2nd Step3rd Step4th StepCylinder Head M8 Bolt (1)Drive Belt Tensioner Pulley BoltEGR Bolt (California Emissions)EGR Bracket Bolt (California Emissions)EGR Valve Nut (California Emissions)Engine Block Coolant PlugEngine Block Ground BoltEngine Mount-To-Block BoltExhaust Manifold Bolt/Nut (2)Exhaust Outlet Pipe BoltExhaust Pipe BoltExhaust Pipe Bracket BoltFan Pulley Bracket BoltFlywheel Bolt (Angular Tightening Method) (3)1st Step2nd Step3rd StepFlywheel Housing Bolt (Black Circle Mark)Flywheel Housing-To-Upper Oil Pan Bolts (Black Triangle Mark)Front Engine Cover BoltFuel Block BoltFt. Lbs. (N.m)37 (50)15 (21)173 (234)16 (22)47 (64)Tighten Additional 30 Tighten Additional 30 18 (25)30 (41)260 (353)37 (50)59 (80)Tighten Additional 90 Tighten Additional 75 18 (25)30 (41)15 (20)15 (20)14 (19)13 (18)25 (34)43 (58)28 (38)39 (53)39 (53)25 (34)34 (46)58 (79)Tighten Additional 60 Tighten Additional 60 67 (90)37 (50)15 (21)18 (25)

ApplicationFuel Filter Bracket BoltFuel Injection Control Module BoltFuel Injection Control Module Bracket BoltFuel Injection Control Module Connector Bracket BoltFuel Injection Control Module Cooler Eye BoltFuel Injection Pipe NutFuel Inlet Pipe Bracket BoltFuel Pipes Bracket BoltFuel Rail Assembly BoltFuel Rail ConnectorFuel Return Eye Bolt (Cylinder Head Side)Fuel Return Eye Bolt (Injector Side)Fuel Return Pipe Sleeve NutFuel Return Sleeve UnitFuel Injection Pump Assembly-To-Cylinder Block BoltFuel Injection Pump-To-Bracket BoltFuel Injection Pump Drive Gear NutFuel Temperature Sensor Eye BoltFunction Block NutFunction Block-To-Injection Pipe NutGenerator Bracket BoltGlow PlugGlow Plug Power Feed NutGlow Plug Relay Assembly BoltHeater Pipe BoltIdle Pulley Bolt/ScrewInjector Bracket BoltIntake Air HeaterIntake Manifold Bolt/NutOil Cooler Adapter BoltOil Cooler Adapter NutOil Cooler Assembly BoltOil Drain PlugOil Fill Tube BoltOil filterOil Gallery PlugOil Level Indicator Tube BoltOil Pan Bolt (Upper)Oil Pressure Sensor Adapter Eye BoltOil Pressure Sensor UnitOil Pressure Relief ValveOil Pump BoltFt. Lbs. (N.m)15 (21)15 (20)15 (21)15 (21)20 (27)30 (41)15 (21)15 (21)18 (25)33 (45)12 (17)12 (16)30 (41)30 (41)15 (21)15 (21)52 (70)11 (15)18 (25)30 (41)37 (50)13 (18)11 (15)18 (25)15 (21)27 (37)37 (50)37 (50)15 (21)15 (21)18 (25)18 (25)62 (84)15 (21)18 (24)39 (53)15 (21)15 (20)28 (38)22 (30)29 (39)15 (21)

ApplicationOil Pump Driven Gear NutOil Pump Gear Cover BoltOil Strainer Bolts/NutPiston Cooling Nozzle Eye BoltPower Steering Pump BoltPower Steering Pump Bracket BoltRocker Arm Shaft Bracket BoltStarter Motor BoltThermostat Housing Bolt/NutThermostat Cover BoltTurbocharger BoltTurbocharger Coolant Outlet Pipe Bracket BoltTurbocharger Oil Supply Hose Eye BoltTurbocharger Oil Return Pipe Bolts/NutTurbocharger Thermostatic Coolant ValveUpper Oil Pan-To-Flywheel Housing ScrewVacuum Pump Nut (California Emissions)Valve Adjusting Screw NutWater Outlet BoltWater Pump BoltCamshaft Position Sensor BoltCamshaft Position Sensor Exciter Ring BoltCrankshaft Position Sensor BoltCrankshaft Position Sensor Spacer BoltExhaust Manifold Heat Shield BoltExhaust Outlet Heat Shield BoltExhaust Pipe Heat Shield BoltFuel Injection Control Module Connector BoltGlow Plug Connector NutInjector Harness Bracket BoltInjector Terminal NutInjector Pipe Lock Plate ScrewIntake Manifold Tube Bolt/NutOil Cooler Adapter StudOil Level Sensor BoltOil Pan Bolt/Nut (Lower) (4)Positive Crankcase Ventilation Cover ScrewTurbocharger Boost Sensor BoltTurbocharger Heat Shield BoltTurbocharger Inlet Duct-To-Turbocharger BoltTurbocharger Oil Return Pipe StudFt. Lbs. (N.m)74 (100)15 (21)18 (25)15 (21)37 (50)34 (46)30 (41)58 (78)18 (25)15 (21)80 (108)15 (21)25 (34)15 (21)44 (60)15 (20)16 (22)16 (22)18 (25)15 (21)INCH Lbs. (N.m)89 (10)80 (9)89 (10)89 (10)71 (8)71 (8)71 (8)89 (10)18 (2)80 (9)18 (2)35 (4)80 (9)89 (10)89 (10)89 (10)35 (4)89 (10)80 (9)80 (9)89 (10)

ApplicationValve Lifter Hold-Down Bracket BoltValve Rocker Arm Cover Bolt (Lower) (5)Valve Rocker Arm Cover Bolt (Upper)1st Step2nd Step(1)Tighten in sequence. See Fig. 25 .(2)Tighten in sequence. See Fig. 26 .(3)Tighten in sequence. See Fig. 27 .(4)Tighten in sequence. See Fig. 29 .(5)Tighten in sequence. See Fig. 28 .Ft. Lbs. (N.m)97 (11)89 (10)71 (8)71 (8)HVAC SYSTEM SERVICE SPECIFICATIONSApplicationAccumulator ReplacementCompressor Replacement (3)Condenser ReplacementEvaporator Replacement (Front Or Rear)Total System PAG Oil CapacityR-134a Refrigerant ChargeSpecification(1)2 ozs.(2)2 ozs.(2)1 ozs.(2)3 ozs.8 ozs.1.6 lbs.(1)Add PAG oil equal to amount of oil drained from component plus the specified additional amount.PAG Oil GM P/N 12378526 for U.S. & GM P/N 88900060 for Canada.(2)Add amount specified or amount drained, which ever is greater.(3)The Denso service compressor is precharged with 8.0 ozs. (237 ml) of PAG oil.HVAC System Torque SpecificationsHVAC SYSTEM TORQUE SPECIFICATIONSApplicationA/C Refrigerant Filter Retaining NutsCompressor Bracket Mounting BoltsCompressor Clutch Plate Retaining BoltCompressor Discharge Hose Nut At ConnectorCompressor Hose Bolt At Compressor - Harrison (4.3L, 6.6L & 8.1L)Compressor Mounting Bolts - Denso (4.8L, 5.3L, 6.0L & 6.6L)Compressor Mounting Bolts - Harrison (4.3L, 6.6L & 8.1L)Compressor Suction/Discharge Hose BoltCompressor Suction Hose Nut At AccumulatorFt. Lbs. (N.m)11 (15)37 (50)13 (18)12 (16)25 (34)37 (50)37 (50)25 (34)12 (16)

ApplicationCompressor Suction Hose-To-AccumulatorDischarge Hose Mounting Bolt - Denso (4.8L, 5.3L, 6.0L & 6.6L)Evaporator Tube Fitting At OrificeEvaporator Tube Nut At CondenserEvaporator Tube Nut At EvaporatorHeater Hose Mounting Bolt (4.3L)Heater Hose Outlet Mounting Nut/BoltSuction Hose Mounting Bolt - Denso (4.8L, 5.3L, 6.0L & 6.6L)A/C High Pressure Recirculation SwitchA/C Low Pressure SwitchAccumulator Bracket NutAccumulator Clamp BoltAir Distribution Duct ScrewAir Outlet Mounting ScrewAir Temperature Actuator Mounting ScrewBlower Motor Control Processor ScrewBlower Motor Insulating Cover ScrewBlower Motor Relay/Resistor ScrewCompressor Clutch Coil Connector Retaining Bracket ScrewCondenser Upper Insulator Retainer BoltsFilter Access Door ScrewFloor Air Outlet Duct ScrewHeater Core Cover ScrewsHeater Ventilation Module ScrewsHeater/Ventilation Module Mounting NutsHeater/Ventilation Module Mounting ScrewsHVAC Control Module ScrewInsulator Retainers & BoltsMode Actuator Mounting ScrewPressure Relief ValveRecirculation Actuator Mounting ScrewFt. Lbs. (N.m)30 (41)12 (16)18 (25)12 (16)12 (16)18 (25)18 (25)12 (16)In. Lbs. (N.m)53 (6)53 (6)80 (9)88 (10)14 (1.6)14 (1.6)14 (1.6)14 (1.6)14 (1.6)14 (1.6)80 (9)21 (2.4)14 (1.6)14 (1.6)14 (1.6)14 (1.6)80 (9)35 (4)17 (1.9)21 (2.4)14 (1.6)80 (9)14 (1.6)BATTERYBattery Service SpecificationsBATTERY SERVICE SPECIFICATIONSStandardGM Part NumberReplacement Battery Number1900181078-6YR

Cold Cranking Amperage (CCA)Reserve Capacity RatingOptional (Dual)GM Part NumberReplacement Battery NumberCold Cranking Amperage (CCA)Reserve Capacity Rating600 Amps115 Minutes1900181478-7YR770 Amps115 MinutesBRAKESBLEEDING SEQUENCEBRAKE BLEEDING SEQUENCEApplicationAll ModelsSequenceFront Master Cylinder Port, Rear Master Cylinder Port, RR, LR, RF & LFDISC BRAKESDisc Brakes Service SpecificationsDISC BRAKES SERVICE SPECIFICATIONSApplicationFront Brakes (1) or (2) (6400 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationFront Brakes (1) (7200 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationFront Brakes (2) (9900 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutIn. (mm)1.082 (27.50)1.10 (28.0)1.14 (29.0)0.005 (0.13)0.059 (1.50)0.001 (0.025)1.082 (27.50)1.10 (28.0)1.14 (29.0)0.005 (0.13)0.059 (1.50)0.001 (0.025)1.437 (36.50)1.46 (37.0)1.50 (38.0)0.005 (0.13)

ApplicationRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationFront Brakes (2) (12,300 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationRear Brakes (1) or (2) (6400 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationRear Brakes (1) (7200 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationRear Brakes (2) (9900 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationRear Brakes (2) (12,400 Lbs. GVWR)Rotor Discard Thickness (3)Rotor Minimum Allowable Thickness After RefinishRotor Thickness (New)Rotor Maximum Allowable Lateral RunoutRotor Maximum Allowable ScoringRotor Maximum Allowable Thickness VariationIn. (mm)0.059 (1.50)0.001 (0.025)1.437 (36.50)1.46 (37.0)1.50 (38.0)0.005 (0.13)0.059 (1.50)0.001 (0.025)0.728 (18.50)0.748 (19.0)0.787 (20.0)0.005 (0.13)0.059 (1.50)0.001 (0.025)1.122 (28.50)1.142 (29.0)1.181 (30.0)0.005 (0.13)0.059 (1.50)0.001 (0.025)1.082 (27.50)1.102 (28.0)1.141 (29.0)0.005 (0.13)0.059 (1.5)0.001 (0.025)1.122 (28.5)1.142 (29.0)1.181 (30.0)0.005 (0.13)0.059 (1.50)0.001 (0.025)(1)With vacuum assisted power brakes.(2)With hydraulic assisted power brakes.(3)All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet thisspecification. After refinishing rotor, replace any rotor that does not meet the minimum thickness

ApplicationIn. (mm)specifications.Disc Brakes Torque SpecificationsDISC BRAKES TORQUE SPECIFICATIONSApplicationBacking Plate BoltsBrake Caliper Mounting BoltFrontRear15-Series25/35-SeriesBrake Hose-To-Caliper BoltFrontRearBrake Pedal BoltBrake Pipe FittingsCable Support Bracket BoltsCaliper Mounting Bracket Bolt - Rear6400 & 7200 Lbs. GVWR9900 Lbs. GVWR12,300 Lbs. GVWR4-Wheel SteeringCaliper Mounting Bracket-To-Knuckle - Front15-Series25/35-SeriesEHCU Bracket Mounting BoltsFront Brake Pipe Fitting-To-BPMVFront Wheel Speed Sensor Mounting BoltHose Bracket-To-Anchor Plate BoltHose Bracket-To-Rear Axle BoltMaster Cylinder Brake Lines-To-BPMVMaster Cylinder Mounting NutsNegative Battery Cable BoltPark Brake Cable Bracket-To-Knuckle Bolt (4-Wheel Steering)Park Brake Cable-To-Rear Axle Clip BoltPark Brake Cable-To-Shock Absorber Bracket BoltPark Brake Lever Mounting BoltsPower Brake Booster Nuts (Hydraulic)Power Brake Booster Nuts (Vacuum)Ft. Lbs. (N.m)100 (135)80 (108)31 (42)80 (108)30 (40)30 (40)35 (47)18 (25)64 (85)148 (200)122 (165)221 (300)148 (200)129 (175)221 (300)18 (25)18 (25)13 (18)18 (25)16 (22)18 (25)27 (36)13 (17)45 (61)18 (25)18 (25)18 (25)24 (33)24 (33)

ApplicationQuarter Shaft ShieldRear Brake Pipe Fitting-To-BPMVBrake Caliper Bleeder ValveFrontRearBrake Pressure Modulator Bleeder ValvesEBCM-To-BPMV Torx BoltsEHCU-To-Bracket BoltsHose Bracket-To-Frame BoltHose Bracket-To-Knuckle BoltHose Bracket-To-Steering KnuckleHose Bracket-To-Upper Control Arm BoltIntermediate Cable Threaded Rod NutPark Brake Cable Guide-To-Frame BoltPark Brake EqualizerPark Brake Warning Light Switch BoltFt. Lbs. (N.m)18 (25)18 (25)In. Lbs. (N.m)115 (13)97 (11)80 (9)44 (5)80 (9)106 (12)106 (12)80 (9)80 (9)31 (3.5)106 (12)31 (3.5)25 (3)CHARGING SYSTEMGENERATORGenerator Service SpecificationsGENERATOR SERVICE SPECIFICATIONSStandardDelphiRated OutputLoad Test OutputOptional (Dual)DelphiRated OutputLoad Test OutputOptionalBosch(R)Rated OutputLoad Test OutputGenerator Torque SpecificationsGENERATOR TORQUE SPECIFICATIONSSpecificationAD230102 Amps71 AmpsAD244130 Amps91 Amps15755900130 Amps91 Amps

ApplicationAuxiliary Battery Tray NutAuxiliary Generator Bolt (6.6L)Auxiliary Generator Bracket Bolt (6.6L)Auxiliary Negative Battery Cable Bolt (6.6L)Auxiliary Negative Battery Cable Bolt (Except 6.6L)Auxiliary Positive Battery Cable BoltBattery Cable Bracket BoltBattery Hold Down Retainer BoltCrossbar BoltDrive Belt Tensioner Bolt (6.6L)EGR Vacuum Pump Bolt (6.6L)Engine Wiring HarnessAuxiliary Negative Battery Cable BoltGround BoltGround/Negative Cable BoltExcept 6.6L6.6LRetainer Bolt (6.6L)Fuel Bleed Valve & PCV Oil Separator Bracket Nut (6.6L)Generator Bracket Bolt (4.8L, 5.3L, 6.0L, 6.6L & 8.1L)Generator Bolt (4.3L, 4.8L, 5.3L, 6.0L, 6.6L & 8.1L)Generator Bracket Bolt/Nut (4.3L)Generator Bracket Stud (8.1L)Heater Hose Bracket Bolt (4.3L)Heater Outlet Pipe Bolt (6.6L)Idler Pulley Bolt (6.6L)Negative Battery Cable BoltPositive Battery Cable BoltWiring Harness Bracket Bolt (4.3L)Auxiliary Battery Cable Clip BoltAuxiliary Battery Relay NutAuxiliary Positive Battery Cable NutAuxiliary Positive Cable to Relay NutBattery Cable Channel BoltExcept 6.6L6.6LBattery Cable Junction Block Bracket Bolt (4.8L, 5.3L, 6.0L & 8.1L)Battery Cable Retainer Nut (6.6L)Battery Tray BoltFender-To-Cowl Support Brace BoltForward Lamp Wiring Harness Ground/Negative Cable BoltFt. Lbs. (N.m)18 (25)37 (50)37 (50)25 (34)13 (17)13 (17)18 (25)18 (25)74 (100)30 (41)16

Compressor Clutch Coil Connector Retaining Bracket Screw 80 (9) Condenser Upper Insulator Retainer Bolts 21 (2.4) Filter Access Door Screw 14 (1.6) Floor Air Outlet Duct Screw 14 (1.6) Heater Core Cover Screws 14 (1.6) Heater Ventilation Module Screws 14 (1.6) Heater/Ventilation Module Mounting Nuts 80 (9)

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STEP 1-Torque all bolts in sequence to 60 Nm (44 ft. lbs.) torque. STEP 2-Torque all bolts in sequence to 119 Nm (88 ft. lbs.) torque. STEP 3-Torque all bolts in sequence to 176 Nm (129 ft. lbs.) torque. 14. Turn the crankshaft to determine that it will rotate freely all 360 . Check the main