Avalanche, Express, Savana 2006-2007

Engine

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Removal & Installation



4.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Air cleaner
     
    Accessory drive belt
     
    Fan
     
    Water pump pulley
     
    Radiator and shroud
     
    Heater hoses at the engine
     
    Accelerator, cruise control and detent linkage if used
     
    Air conditioning compressor, if used, and lay aside
     
    Power steering pump, if used, and lay aside
     
    Wiring from the engine
     
    Fuel line
     
    Vacuum lines from the intake manifold
     
    Exhaust pipes from the manifold
     
    Strut rods at the engine mountings, if used
     
    Flywheel or torque converter cover
     
    Wiring along the oil pan rail
     
    Starter
     
    Wire for the fuel gauge
     
    Converter-to-flex plate bolts, if equipped with automatic transmission
     

  8.  
  9. Support the transmission

    Click image to see an enlarged view

    Fig. Transmission mounting bolts-4.3L engines



    Bell housing to engine bolts
     
    Rear engine mounting to frame bolts and the front through bolts and the engine
     

  10.  

To install:

  1. Lower the engine.
  2.  
  3. Install or connect the following:

    Engine mounting bolts. Torque the rear engine mounting to frame bolts or nuts to 45 ft. lbs. (54 Nm), the front through-bolts to 70 ft. lbs. (97 Nm) and the front nuts to 50 ft. lbs. (67 Nm).
     
    Bell housing to engine bolts and torque to 35 ft. lbs. (47 Nm)
     

  4.  
  5. Remove the transmission support.

    Converter-to-flex plate bolts and tighten to 35 ft. lbs. (47 Nm)
     
    Fuel gauge wiring
     
    Starter
     
    Flywheel or torque converter cover
     
    Strut rods at the engine mountings, if used
     
    Exhaust pipes at the manifold
     
    Vacuum lines to the intake manifold
     
    Fuel line
     
    Engine wiring harness
     
    Power steering pump, if used
     
    Air conditioning compressor, if used
     
    Accelerator, cruise control and detent linkage
     
    Heater hoses
     
    Radiator and shroud
     
    Accessory drive belts
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Refill coolant and engine oil.
  8.  

4.8L, 5.3L & 6.0L Engines

CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Recover the HVAC refrigerant.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the sheet metal to radiator support bolts and supports from the vehicle.
  12.  
  13. Remove the air cleaner assembly.
  14.  
  15. Remove the coolant reservoir.
  16.  
  17. Remove the right and left headlamp capsules.
  18.  
  19. Remove the front bumper.
  20.  
  21. Remove the radiator inlet hose from the water pump.
  22.  
  23. Remove the radiator outlet hose from the water pump.
  24.  
  25. Disconnect the transmission cooler lines from the radiator.
  26.  
  27. Disconnect the oil cooler line from the radiator, if equipped.
  28.  
  29. Disconnect and cap the HVAC lines from the condenser.
  30.  
  31. Disconnect the ground connection from the right hand inner fender and connector C4 at the underhood fuse block.
  32.  
  33. Disconnect the positive battery cable from the underhood fuse block and position aside.
  34.  
  35. Remove the core support retaining bolt .
  36.  
  37. With the aid of an assistant, remove the core support assembly with the radiator, condenser radiator hoses and fan shroud intact.
  38.  
  39. Remove the clutch fan.
  40.  
  41. Remove the accessory drive belt.
  42.  
  43. Remove the air bleed hose from the throttle body.
  44.  
  45. Remove the generator bracket from the engine. Leave the generator and power steering pump retained to the bracket. Use a suitable strap and position the bracket assembly aside.
  46.  
  47. Remove the radiator vent inlet hose from the throttle body.
  48.  
  49. Remove the ground straps from the frame and engine.
  50.  
  51. Remove the air conditioning compressor.
  52.  
  53. Disconnect the heater hoses from the water pump.
  54.  
  55. Remove the intake manifold.
  56.  
  57. Remove the ignition coils from the engine.
  58.  
  59. Remove the coolant air bleed pipe from the engine.
  60.  
  61. Raise and safely support the vehicle.
  62.  
  63. Remove the oil drain plug and drain the oil into a suitable container.
  64.  
  65. Remove the starter motor.
  66.  
  67. Disconnect the catalytic converter pipe from the exhaust manifolds.
  68.  
  69. Unplug the Crankshaft Position (CKP) sensor, engine oil level sensor, and the coolant heater, if equipped.
  70.  
  71. Remove the battery cable channel bolt.
  72.  
  73. Slide the channel pin out of the oil pan tab.
  74.  
  75. Gather all branches of the engine wiring harness and reposition off to the side.
  76.  
  77. Remove the lower 6 bell housing to engine studs and bolts. Leave the top 2 studs in place.
  78.  
  79. Remove the torque converter bolts.
  80.  
  81. Lower the vehicle.
  82.  
  83. Remove the left and right exhaust manifolds.
  84.  
  85. Install tool J42451-1 or similar lifting eye to the cylinder heads. Tighten the M10 engine lift bracket bolts to 37 ft. lbs. (50 Nm).
  86.  
  87. Remove the left and right engine mount-to-engine mount bracket bolts.
  88.  
  89. Remove the transmission oil level indicator tube nut.
  90.  
  91. Remove the transmission oil level indicator tube.
  92.  
  93. Remove the top 2 automatic transmission studs.
  94.  
  95. Position a floor jack under the transmission for support.
  96.  
  97. Install an engine hoist to the J 42451-1 lifting eyes.
  98.  
  99. Separate the engine from the automatic transmission, if equipped.
  100.  
  101. Install tool J 21366 to the transmission in order to hold the torque converter.

    Click image to see an enlarged view

    Fig. Transmission mounting bolts-4.8L, 5.3L and 6.0L engines



    Click image to see an enlarged view

    Fig. Engine mounting bolts-4.8L, 5.3L and 6.0L engines

  102.  
  103. Remove the engine.
  104.  

To install:

  1. Installation is the reverse of removal. Note the following and observe the following torque specifications:

    Engine mount-to-engine mount bracket bolts to 48 ft. lbs. (65 Nm)
     
    If equipped with the 4L60-E, tighten the torque converter bolts to 37 ft. lbs. (63 Nm). If equipped with the 4L80-E, tighten the torque converter bolts to 44 ft. lbs. (60 Nm)
     
    If equipped with the 4L80-E automatic transmission, tighten the transmission converter cover bolts to 24 ft. lbs. (33 Nm)
     
    Tighten the automatic transmission bolts/studs to 37 ft. lbs. (50 Nm)
     
    Tighten the core support bolts to 18 ft. lbs. (25 Nm). Tighten the support nuts to 42 ft. lbs. (57 Nm)
     

  2.  
  3. Fill the engine to the proper level with oil and coolant.
  4.  
  5. Perform the CKP system variation learn procedure using a scan tool.
  6.  
  7. Check for and correct any leaks. Recharge the A/C system if equipped.
  8.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    A/C refrigerant
     

  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Upper and the lower radiator hoses from the engine
     
    Air cleaner duct from the engine
     
    A/C condenser mounting bolts
     
    Radiator support from the vehicle
     
    A/C compressor
     
    Coolant hose from the throttle body
     
    Heater hoses from the engine and the cowl
     
    Engine sight shield from the intake manifold
     
    Accelerator control cable mounting bracket from the intake manifold
     



    Accelerator control cable and the cruise control cable, if equipped, from the throttle shaft
     

  4.  
  5. Open the large electrical harness retainer. Remove one 10 mm nut in order to release the engine harness from the intake manifold.
  6.  
  7. Disconnect the electrical connectors from the following:

    Eight injectors
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Evaporative Emissions (EVAP) canister purge solenoid
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft Position (CMP) sensor

    Click image to see an enlarged view

    Fig. Ignition coil removal-2005-06 Avalanche 5.3L

     



    Ground splice at the rear of the right side of the block
     
    Ground splice and the ground strap at the rear of the left side of the block
     
    Coolant Temperature (CTS) sensor
     
    Oil pressure sensor/switch
     
    Electrical connector from intake and disconnect from harness
     
    Junction block bracket from alternator bracket

    Click image to see an enlarged view

    Fig. Power steering pump removal-2005-06 Avalanche 5.3L

     

  8.  
  9. Set the electrical harness aside.
  10.  
  11. Remove or disconnect the following:

    EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid
     
    Battery negative cable from the engine block
     
    Drive belt
     
    Bolts holding the alternator mounting bracket to the cylinder head and block
     
    Bolt behind the power steering pump to engine block

    Click image to see an enlarged view

    Fig. Power steering mount bracket removal-2005-06 Avalanche 5.3L

     



    Alternator mounting bracket. Position the bracket aside.
     
    Fuel pipes from the engine
     

  12.  
  13. Raise the vehicle.

    Steering linkage under body shield, if equipped
     
    Engine oil pan under body shield, if equipped
     
    Engine oil
     
    Starter motor

    Click image to see an enlarged view

    Fig. Bell housing bolt removal-2005-06 Avalanche 5.3L

     

  14.  
  15. Disconnect the engine wiring harness from the following components:

    Crankshaft Position (CKP) sensor
     
    Engine oil level sensor
     
    Block heater, if equipped
     
    Oil pan wiring harness
     

  16.  
  17. Reposition wiring from the lower engine area.

    Exhaust pipes from the exhaust manifolds
     
    Transmission cooler pipe retainer from the right side of the engine block, if equipped
     
    Torque converter shield from the engine
     
    Torque converter bolts
     
    Nut and the transmission oil level indicator tube from the bell housing stud
     
    Lower bell housing studs from the engine
     

  18.  
  19. Lower the vehicle.

    Remaining bell housing bolts
     
    Engine electrical harness aside
     
    Ignition coil(s)
     

  20.  
  21. Install an engine crane.
  22.  
  23. Install a floor jack or stands to transmission for support.
  24.  
  25. Remove the engine mount bolts.
    NOTE
    Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

  26.  
  27. Remove the engine from the vehicle.

    Click image to see an enlarged view

    Fig. Engine mount disconnect-2005-06 Avalanche 5.3L

  28.  

To install:

  1. Install or connect the following:

    Engine to the vehicle
     
    Engine mount bolts
     
    Upper bell housing bolts
     

  2.  
  3. Remove transmission support apparatus.
  4.  
  5. Remove the lifting device.
  6.  
  7. Remove the lift brackets from both cylinder heads.
  8.  
  9. Install the ignition coil(s) and the spark plug wire(s).
  10.  
  11. Route the engine wiring harness to the lower right hand side of the engine.
  12.  
  13. Raise the vehicle.
  14.  
  15. Install or connect the following:

    Remaining bell housing bolts
     
    Torque converter bolts
     
    Torque converter shield
     
    Transmission oil level indicator tube and nut to bell housing stud
     
    A/C compressor
     
    Transmission cooler pipe retainer to right side of engine block
     
    Engine exhaust pipes to the exhaust manifolds
     

  16.  
  17. Reroute wiring to lower engine area and install bolt to oil pan.
  18.  
  19. Connect electrical connectors to the CKP sensor, the engine oil level sensor and the block heater, if equipped.
  20.  
  21. Install or connect the following:

    Starter motor
     
    Engine oil pan under body shield, if equipped
     
    Steering linkage under body shield
     

  22.  
  23. Lower the vehicle.

    Fuel pipes to the engine
     
    Alternator mounting bracket to the cylinder head using the nuts and the bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump to the engine block and tighten to 37 ft. lbs. (50 Nm)
     
    Alternator
     
    Drive belt
     
    Battery negative cable to the engine block
     
    EVAP canister purge solenoid to the intake manifold
     

  24.  
  25. Route the engine harness over the top of the engine. Attach the connectors for following components:

    Eight injectors
     
    IAC motor
     
    TP sensor
     
    EVAP canister purge solenoid.
     
    MAP sensor
     
    CMP sensor
     
    Ground splice at the rear of the right side of engine block
     
    Ground splice and the ground strap at the rear of the left side of engine block
     
    CTS sensor
     

  26.  
  27. Install or connect the following:
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Nut to the engine wiring harness bracket and tighten to 89 inch lbs. (10 Nm)
     



    NEW accelerator control cable
     
    Cruise control cable, if equipped, to the throttle shaft
     
    Bolts for the accelerator control cable mounting bracket and tighten to 89 inch lbs. (10 Nm)
     
    Engine sight shield to the intake manifold
     
    Heater hoses to the cowl and the engine
     
    Coolant hose to the throttle body
     
    Radiator support in the vehicle
     
    A/C condenser mounting bolts
     
    Air cleaner duct
     
    Lower radiator hoses to the engine
     

  28.  
  29. Lower the hood.
  30.  
  31. Fill the engine with oil.
  32.  
  33. Fill the engine with coolant.
  34.  
  35. Connect the negative battery cable.
  36.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Engine oil
     
    A/C refrigerant
     

  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.

    Hood latch and radiator support
     
    Intake manifold
     
    Upper and the lower radiator hoses from the engine
     
    Heater hoses from the engine and the cowl
     
    Harness connectors from the oil pressure sensor and lifter oil manifold
     
    Ground strap from the left cylinder head
     
    Negative battery cable and harness ground from the right cylinder head
     

  4.  
  5. Raise and safely support the vehicle.

    Harness grounds and clips from the engine block
     
    Transmission oil cooler line clip bolt form the oil pan
     
    Starter
     
    Harness connectors for the knock sensors, CMP sensor, A/C pressure sensor, CKP sensor and oil level sensor
     
    Block heater connector, if equipped
     

  6.  
  7. Lower the vehicle.

    Power steering pump engine block bolt
     
    Alternator bracket assembly and set aside with the power steering pump
     
    Ignition coils to allow attachment of the engine lift brackets
     
    Transmission dipstick tube nut and tube
     

  8.  
  9. Install engine lift brackets J41798 or equivalent. Tighten the M8 bolts to 18 ft. lbs. (25 Nm) and the M10 bolts to 37 ft. lbs. (50 Nm).

    Engine mount bolts
     

  10.  
  11. Raise and safely support the vehicle.

    Engine shield or skid plate
     
    Exhaust pipes from the exhaust manifolds and catalytic converters
     
    Torque converter bolts
     
    Transmission mounting bolts
     

  12.  
  13. Lower the vehicle.
  14.  
  15. Install an engine crane.
  16.  
  17. Install a floor jack or stands to transmission for support.
  18.  
  19. Remove the engine from the vehicle.
  20.  

To install:

  1. Position the engine in the vehicle. Make sure the engine is properly aligned and mated with the transmission, then remove the crane.
  2.  
  3. Install the engine mount bolts; start with the middle bolt then the outer bolts. Tighten to 48 ft. lbs. (65 Nm).
  4.  
  5. Install the transmission bolts. Tighten to 37 ft. lbs. (50 Nm).
  6.  
  7. Align the torque converter bolt holes and install the bolts. Tighten to 47 ft. lbs. (63 Nm) except on 4L80E transmissions. On the 4L80E, tighten the bolts to 44 ft. lbs. (60 Nm).
  8.  
  9. The remaining installation is the reverse of removal.
  10.  

6.6L Engine

CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Recover the HVAC refrigerant.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the cooling fan and accessory drive belt.
  12.  
  13. Unplug the generator electrical connector. Unbolt and reposition the generator to access the output wire nut. Remove the generator.
  14.  
  15. Disconnect the RH engine wiring harness connector. Remove the 2 RH engine wiring harness bracket bolts and position aside. Remove the 2 wiring harness routing bolts.
  16.  
  17. Remove the transmission tube bolt and reposition the transmission tube. Remove the oil indicator tube bracket bolt.
  18.  
  19. Remove the drive belt tensioner bolt and tensioner.
  20.  
  21. Remove the bolts and the generator mounting bracket.
  22.  
  23. If equipped, remove the auxiliary generator. Remove the auxiliary generator bracket bolt and bracket.
  24.  
  25. If equipped with a dual generator system, remove the bolt from the left side idler pulley and remove the idler pulley.
  26.  
  27. Unplug the A/C compressor clutch electrical connector and the A/C cut out switch electrical connector.
  28.  
  29. Disconnect the A/C suction and discharge lines at the compressor. Remove the A/C compressor.
  30.  
  31. Remove the power steering pump and bracket bolts. Position the power steering pump aside and secure.
  32.  
  33. Remove the A/C and power steering bracket mounting nuts/bolts and bracket.
  34.  
  35. Remove the fuel line bolt and position the fuel line aside.
  36.  
  37. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.
  38.  
  39. Remove the oil fill tube bolts and the oil fill tube.
  40.  
  41. Remove the Exhaust Gas Recirculation (EGR) valve coolant pipe to thermostat housing bolt.
  42.  
  43. Unplug the coolant temperature sensor electrical connector.
  44.  
  45. Remove the fuel pipe bracket bolt.
  46.  
  47. Remove the thermostat housing crossover bolts/nuts and the thermostat housing crossover. Remove the thermostat pipe.
  48.  
  49. Unplug the intake air heater electrical connector.
  50.  
  51. Disconnect the engine harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  52.  
  53. Disconnect the positive cable from the IAH.
  54.  
  55. Remove the intake manifold tube with the stud.
  56.  
  57. Remove and discard the 2 metal EGR gaskets from the EGR valve.
  58.  
  59. Remove and discard the O-ring seal from the center intake manifold.
  60.  
  61. Remove the air intake pipe.
  62.  
  63. Remove the right and left exhaust pipes.
  64.  
  65. Remove the EGR coolant hose.
  66.  
  67. Compress the clamp and disconnect the EGR heater inlet hose/pipe from the EGR cooler tube. Remove the EGR cooler tube bracket bolts.
  68.  
  69. Remove the crankcase ventilation hose/pipe.
  70.  
  71. Unplug the EGR solenoid electrical connector. Remove the EGR valve and EGR cooler tube as an assembly. Remove the 2 bolts and the EGR cooler tube bracket.
  72.  
  73. Unplug the engine wiring harness electrical connector from the turbocharger vane position sensor and solenoid valve.
  74.  
  75. Remove the turbocharger upper heat shield.
  76.  
  77. Reposition the turbocharger coolant outlet pipe clamp and remove the hose from the turbocharger pipe. Disconnect the fuel feed and return pipes.
  78.  
  79. Disconnect the positive battery cable from the glow plug control module. Remove the glow plug control module.
  80.  
  81. Remove the glow plug control module bracket bolts. Remove the fuel line bracket bolt.
  82.  
  83. Remove the turbocharger coolant inlet pipe bolt and remove the hose from the turbocharger.
  84.  
  85. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer. Reposition and secure the turbocharger oil fed pipe out of the way.
  86.  
  87. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
  88.  
  89. Remove the turbocharger (with the oil return pipe).
  90.  
  91. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing. Remove the turbocharger lower heat shield, oil feed pipe, washer, and pipe.
  92.  
  93. Unplug the LH main engine wiring harness connector and remove the bracket bolts.
  94.  
  95. Remove the LH glow plug nuts and the routing bolts.
  96.  
  97. Unplug the fuel injector electrical connectors, the Intake Air Temperature (IAT) sensor and fuel rail temperature sensor electrical connectors.
  98.  
  99. Unplug the Engine Coolant Temperature (ECT) wiring harness electrical connector and the oil pressure sensor electrical wiring harness electrical connector. Position the engine wiring harness over the RH side of engine.
  100.  
  101. Remove the fuel feed/return pipe bracket bolt. Disconnect the fuel hoses from the fuel pipe.
  102.  
  103. Remove the fuel line bracket bolt. Disconnect the fuel pump hose from the fuel pipe.
  104.  
  105. Disconnect the fuel injector return hoses from the return pipe assembly. Remove the fuel pipe. Remove the fuel pipe clamp bolt and turbocharger coolant inlet pipe bracket bolt.
  106.  
  107. Remove the center intake manifold.
  108.  
  109. Remove the fuel pump to LH fuel rail pipe. Compress the clamp and remove the fuel pressure relief hose. Remove the fuel pipe bracket bolt, disconnect the hose at the fuel pump and remove the fuel pipe/hose assembly.
  110.  
  111. Remove the LH to RH fuel rail pipe. Remove the LH fuel injector feed pipes. Remove the 2 bolts and the LH fuel rail.
  112.  
  113. Unplug the Fuel Rail Pressure (FRP) sensor electrical connector. Remove the RH fuel injector feed pipes. Remove the 2 bolts and the RH fuel rail.
  114.  
  115. Remove the 2 bolts and the turbocharger cooling outlet pipe.
  116.  
  117. Remove the intake manifolds.
  118.  
  119. Unplug the fuel pump electrical connector. Remove the 4 bolts and fuel injection pump.
  120.  
  121. Remove the transmission fill tube. Remove the engine oil indicator tube.
  122.  
  123. Remove the transmission.
  124.  
  125. Remove the engine flywheel.
  126.  
  127. Remove the upper oil pan.
  128.  
  129. Remove the engine flywheel housing.
  130.  
  131. Remove the oil pump pickup tube. Remove the oil filter adapter and the oil cooler assembly.
  132.  
  133. Remove the exhaust manifolds.
  134.  
  135. Disconnect any remaining ground straps from the engine.
  136.  
  137. Using tool J 36857 or similar engine lift hooks, install a suitable lifting device.
    NOTE
    The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.

  138.  
  139. Raise the engine off the engine mounts.
  140.  
  141. Remove the left engine mount to engine mount frame bracket bolts. Remove the left engine mount to engine bolts. Remove the left engine mount bracket to frame bolts.
  142.  
  143. Remove the right engine mount to engine mount frame bracket bolts. Remove the right engine mount to engine bolts. Remove the right engine mount bracket to frame bolts.

    Click image to see an enlarged view

    Fig. Engine mount to frame mounting bolts-6.6L engines



    Click image to see an enlarged view

    Fig. Engine mount to engine mounting bolts-6.6L engines

  144.  
  145. Remove the engine from the vehicle.
  146.  

To install:

  1. Installation is the reverse of removal. Note the following and observe the following torque specifications:

    Engine mount bracket to frame bolts to 48 ft. lbs. (65 Nm)
     
    Engine mount to engine bolts to 43 ft. lbs. (58 Nm)
     
    Engine mount to engine mount bracket bolts to 48 ft. lbs. (65 Nm)
     

  2.  
  3. Fill the engine to the proper level with oil and coolant. Prime the fuel system.
  4.  
  5. Check for and correct any leaks. Recharge the A/C system if equipped.
  6.  

8.1L Engine
  1. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     
    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     




  6.  
  7. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  8.  
  9. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  10.  
  11. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand.
     
    A/C compressor/power steering pump bracket from the cylinder head
     
    Lift brackets from the cylinder head
     

  14.  

To install:

  1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed.
     
    Alternator
     
    Ground cable bolt to engine block and tighten to 12 ft. lbs. (16 Nm)
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Slowly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

 
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