H3 2006

Engine 2

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Removal & Installation



3.5L & 3.7L Engines
  1. Remove the hood.

    Click image to see an enlarged view

    Fig. Remove the hood bolts (1) and the hood (2)

  2.  
  3. Remove the inspection plug from the transmission (A/T only).

    Click image to see an enlarged view

    Fig. Remove the inspection plug (3), and cap (2) from the transmission (1)

  4.  
  5. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment (A/T only).
  6.  
  7. Remove the service slot plug.

    Click image to see an enlarged view

    Fig. Remove the service slot plug (1)

  8.  
  9. Repeat the following steps for all 3 torque converter bolts (automatic only):
    1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt through the service slot.
    2.  
    3. Remove the torque converter bolts.
    4.  

  10.  
  11. Lower the transmission slightly.
  12.  
  13. Remove the 9 transmission bolts.

    Click image to see an enlarged view

    Fig. Remove the 9 transmission bolts

  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the left engine mount-to-frame bracket bolt.

    Click image to see an enlarged view

    Fig. Remove the left engine mount-to-frame bracket bolt

  18.  
  19. Place a jack under the transmission for support.
  20.  
  21. Remove the remaining transmission mounting bolts.

    Click image to see an enlarged view

    Fig. Remove the remaining transmission mounting bolts (2)

  22.  
  23. Install an engine lift chain to the engine lift brackets and attach to an engine lift device.

    Click image to see an enlarged view

    Fig. Install an engine lift chain to the engine lift brackets and attach to an engine lift device

  24.  
  25. Using the engine lift device, raise the engine only enough to remove the engine mounts.
  26.  
  27. Remove the bolts securing the following to the engine block:

    The left engine mount
     
    The right engine mount
     

  28.  
  29. Remove the engine mounts.
    NOTE
    Ensure clearance is maintained between the engine and the following:



    The A/C compressor
     
    The A/C hoses
     
    The engine mounts
     
    The engine wiring harness
     
    The fuel hose/pipes
     
    The heater outlet hose/pipe
     
    The power steering pump
     
    The transmission input shaft (manual only)
     
    The transmission oil cooler pipes (automatic only)
     

  30.  
  31. Carefully raise the engine from the engine compartment, ensuring the transmission stays supported.
  32.  
  33. Install the engine to an engine stand.
  34.  
  35. Remove the engine lift chain from the engine lift brackets.
  36.  

To install:

  1. Install an engine lift chain to the engine lift brackets and attach to an engine lift device.
  2.  
  3. Remove the engine from the engine stand.
  4.  
  5. Ensure the torque converter is fully engaged with the transmission oil pump (A/T only).
  6.  
  7. Position the engine mounts to the engine.
  8.  
  9. Install the engine mount bolts until snug, following the installation sequence.
    NOTE
    The engine lift device may have to be raised or lowered slightly to install these bolts.

  10.  
  11. Tighten the bolts using the installation sequence. Tighten the engine mount bolts to 37 ft. lbs. (50 Nm).
    NOTE
    Ensure clearance is maintained between the engine and the following:



    The A/C compressor
     
    The A/C hoses
     
    The engine mounts
     
    The engine wiring harness
     
    The fuel hose/pipes
     
    The heater outlet hose/pipe
     
    The power steering pump
     
    The transmission input shaft (manual only)
     
    The transmission oil cooler pipes (automatic only)
     

  12.  
  13. Carefully lower the engine into the engine compartment, aligning the engine dowels with the transmission.
    NOTE
    Ensure the torque converter turns freely while tightening the transmission mounting bolts (automatic only).

  14.  
  15. Align the engine dowels with the transmission.
  16.  
  17. Loosely install the 2 transmission mounting bolts.
    NOTE
    Ensure the dowels are fully engaged into the transmission.

  18.  
  19. Remove the jack from under the vehicle.
  20.  
  21. Lower the engine fully on to the engine mounts.
  22.  
  23. Remove the engine lift chain from the engine lift brackets.
  24.  
  25. Raise and support the vehicle.
  26.  
  27. Tighten the 2 transmission mounting bolts previously installed. Tighten the transmission mounting bolts to 37 ft. lbs. (50 Nm).
    NOTE
    Ensure the studded mounting bolts are located in the correct position. The heater pipe must be secured with the 2 upper mounting bolts.

  28.  
  29. Install the remaining transmission mounting bolts. Tighten the transmission mounting bolts to 37 ft. lbs. (50 Nm).
  30.  
  31. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure (automatic only).
  32.  
  33. Repeat the following steps for all 3 torque converter bolts (automatic only):
    1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt holes in the flexplate/flywheel through the service slot.
    2.  
    3. To aid in alignment of the torque converter to the flexplate/flywheel. Install all 3 torque converter bolts before fully tightening using one of the following:
    4.  

  34.  
  35. Tighten the torque converter bolts to 44 ft. lbs. (60 Nm).
  36.  
  37. Install the inspection plug to the transmission (automatic only).
  38.  
  39. Install the bolt securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (automatic only). Tighten the transmission oil cooler pipe bracket bolt to 15 ft. lbs. (20 Nm).
  40.  
  41. Install the exhaust seal.
  42.  
  43. Install the service slot plug.
  44.  
  45. Install the crossmember.
  46.  
  47. Position the differential carrier assembly to the frame.
  48.  
  49. Install the differential carrier assembly bushing to frame bolts. Tighten the differential carrier assembly bushing to frame bolts to 112 ft. lbs. (152 Nm).
  50.  
  51. Install the front propeller shaft.
  52.  
  53. Install the fuel line clips to the brackets on the transmission (automatic only). Tighten the fuel hose/pipe bracket nuts to 15 ft. lbs. (20 Nm).
  54.  
  55. Install the fuel line clips to the brackets on the transmission (manual only). Tighten the fuel hose/pipe bracket nuts to 15 ft. lbs. (20 Nm).
  56.  
  57. Connect the engine wiring harness retainer to the engine oil pan rail.
  58.  
  59. Install the 3 bolts securing the engine wiring ground leads to the engine block. Tighten the engine wiring ground lead bolts to 15 ft. lbs. (20 Nm).
  60.  
  61. Lower the vehicle to chest level in order to access the components through the wheelhouse.
  62.  
  63. Connect the engine wiring harness connector to the CKP sensor.
  64.  
  65. Install the A/C compressor and bolts, if equipped. Tighten the bolts to 37 ft. lbs. (50 Nm).
  66.  
  67. Install the A/C evaporator line to the compressor and install the bolt at the A/C compressor, if equipped. Tighten the bolt to 12 ft. lbs. (16 Nm).
  68.  
  69. Install the A/C condenser line to the compressor and install the bolt at the A/C compressor, if equipped. Tighten the bolts to 12 ft. lbs. (16 Nm).
  70.  
  71. Position the J 38185 to the clamp in order to connect the heater outlet hose to the heater outlet hose fitting.
  72.  
  73. Connect the engine wiring harness retainers to the A/C compressor and the engine oil pan rail.
  74.  
  75. Connect the engine wiring harness connector to the #2 KS.
  76.  
  77. Connect the coolant heater cord to the coolant heater, if equipped.
  78.  
  79. Connect the engine wiring harness connector to the EVAP canister purge solenoid valve.
  80.  
  81. Install the bolt securing the battery negative cable ground terminal to the engine block. Tighten the battery negative cable to engine block bolt to 26 ft. lbs. (35 Nm).
  82.  
  83. Connect the battery positive cable to the starter and install the starter terminal nut.
  84.  
  85. Connect the lead to the starter solenoid and install the starter solenoid "S" terminal nut.
  86.  
  87. Secure the following wiring harness retainers to the engine wiring harness bracket:

    The battery cable
     
    The engine
     
    The MAP sensor
     

  88.  
  89. Lower the vehicle.
  90.  
  91. Install the left engine mount-to-frame bracket bolt. Tighten the engine mount-to-frame bracket bolt to 63 ft. lbs. (85 Nm).
  92.  
  93. Connect the MAP sensor wiring harness retainer to the intake manifold.
  94.  
  95. Install the MAP sensor.
  96.  
  97. Install the oil level indicator and tube.
  98.  
  99. Connect the EVAP pipe at the purge solenoid.
  100.  
  101. Connect the fuel feed pipe to the fuel rail.
  102.  
  103. Connect the engine wiring harness retainer to the engine wiring harness bracket.
  104.  
  105. Install the right engine mount-to-frame bracket bolt. Tighten the engine mount-to-frame bracket bolt to 63 ft. lbs. (85 Nm).
  106.  
  107. Position the power steering pump to the power steering pump bracket.
  108.  
  109. Install the power steering pump mounting bolts. Tighten the power steering pump mounting bolts to 18 ft. lbs. (25 Nm).
  110.  
  111. Connect the inlet heater hose quick connect to the heater core.
  112.  
  113. Remove the J 44220 from the cylinder head.
  114.  
  115. Position the AIR pipe cover and NEW gasket to the cylinder head.
  116.  
  117. Install the AIR pipe cover studs. Tighten the AIR cover studs to 18 ft. lbs. (25 Nm).
  118.  
  119. Install the transmission filler tube, if equipped.
  120.  
  121. Position the A/C compressor evaporator hose bracket to the cylinder head and install the bolt.
  122.  
  123. Engage the engine wiring harness conduit to the camshaft cover.
  124.  
  125. Connect the engine wiring harness connector to the Intake CMP sensor.
  126.  
  127. Connect the engine wiring harness retainer to the camshaft cover.
  128.  
  129. Connect the engine wiring harness connector to the throttle body.
  130.  
  131. Connect the engine wiring harness connectors to the following components:

    The ECT sensor
     
    The fuel injector harness
     
    The ignition coils
     
    The HO2S
     

  132.  
  133. Connect the engine wiring harness retainer to the camshaft cover.
  134.  
  135. Connect the engine wiring harness connectors to the following components:

    The exhaust CMP sensor
     
    The exhaust camshaft actuator
     

  136.  
  137. Connect the engine wiring harness retainers to the power steering pump.
  138.  
  139. Connect the engine wiring harness connectors to the following components:

    The electric motor actuator connector (4WD only)
     
    The oil pressure switch
     

  140.  
  141. Connect the engine wiring harness retainers to the wheelhouse.
  142.  
  143. Connect the 2 engine wiring harness connectors to the PCM.
  144.  
  145. Install the washer solvent container/coolant recovery reservoir mounting bolts.
  146.  
  147. Install the radiator.
  148.  
  149. Position the J 38185 to the clamp in order to connect the radiator inlet hose to the water outlet housing.
  150.  
  151. Install the alternator.
  152.  
  153. Install the air cleaner resonator and outlet duct.
  154.  
  155. Install the air cleaner assembly.
  156.  
  157. Install the cooling fan.
  158.  
  159. Install the outlet radiator hose.
  160.  
  161. Fill the cooling system.
  162.  
  163. Install the battery box.
  164.  
  165. Install the hood.
  166.  
  167. Fill the engine oil, if previously drained.
  168.  
  169. Charge the A/C system.
  170.  

5.3L Engine

Specific to:

Hummer H3 2006-2010

  1. Remove the hood.

    Click image to see an enlarged view

    Fig. Remove the hood bolts (1) and the hood (2)

  2.  
  3. Place fender covers over both fenders.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Recover the refrigerant.
  8.  
  9. Remove the radiator.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Disconnect the oil pressure sensor and the oxygen sensors from the rear of the engine.
  14.  
  15. Disconnect the Engine Coolant Temperature (ECT) sensor.

    Click image to see an enlarged view

    Fig. Disconnect the Engine Coolant Temperature (ECT) sensor

  16.  
  17. Remove the ground terminal bolt.
  18.  
  19. Remove the retaining clips from the brackets.
  20.  
  21. Raise and suitably support the vehicle.
  22.  
  23. Remove the starter.
  24.  
  25. Disconnect the following connectors:

    Left and right side knock sensor electrical connector.
     
    A/C pressure switch electrical connector.
     
    Block heater electrical connector.

    Click image to see an enlarged view

    Fig. Disconnect right side knock sensor electrical connector (1) and A/C pressure switch electrical connector (2)

     

  26.  
  27. Remove the ground terminal bolt.

    Click image to see an enlarged view

    Fig. Remove the ground terminal bolt (1) and the engine harness bracket bolt (3); disconnect the left side knock sensor electrical connector (2)

  28.  
  29. Remove the engine harness bracket bolt.
  30.  
  31. Disconnect the engine wiring harness electrical connector from the Crankshaft Position (CKP) sensor.

    Click image to see an enlarged view

    Fig. Disconnect the engine wiring harness electrical connector (1) from the Crankshaft Position (CKP) sensor

  32.  
  33. Disconnect the engine wiring harness electrical connector from the Camshaft Position (CMP) sensor wire harness.
  34.  
  35. Remove the battery cable channel bolt.

    Click image to see an enlarged view

    Fig. Remove the battery cable channel bolt

  36.  
  37. Remove the battery cable channel from the oil pan.
  38.  
  39. Lower the vehicle.
  40.  
  41. Gather all branches of the engine wiring harness and reposition the harness off to the side.
  42.  
  43. Disconnect the engine wiring harness electrical connector from the alternator.
  44.  
  45. Reposition the engine wiring harness/positive battery cable boot.
  46.  
  47. Remove the engine wiring harness/positive battery cable nut from the alternator.
  48.  
  49. Remove the engine wiring harness/positive battery cable from the alternator.
  50.  
  51. Remove the inlet hose from the water outlet.

    Click image to see an enlarged view

    Fig. Remove the inlet hose from the water outlet

  52.  
  53. Remove the outlet hose from the water outlet.

    Click image to see an enlarged view

    Fig. Remove the outlet hose (1) from the water outlet

  54.  
  55. Remove the heater inlet and outlet hoses.
  56.  
  57. Raise the vehicle.
  58.  
  59. Remove the catalytic converters.
  60.  
  61. Remove the 3 bracket bolts from both the right and the left side engine mounts.

    Click image to see an enlarged view

    Fig. Remove the 3 bracket bolts (1) from the left side engine mount



    Click image to see an enlarged view

    Fig. Remove the 3 bracket bolts (1) from the right side engine mount

  62.  
  63. Remove the torque converter bolts.
  64.  
  65. Remove the transmission oil level indicator tube nut.
  66.  
  67. Remove the transmission oil level indicator tube.
  68.  
  69. Remove the transmission fluid cooler lines from the retainer located on the right side of the engine.
  70.  
  71. Remove the lower transmission bolts on the right and left side.

    Click image to see an enlarged view

    Fig. Remove the lower transmission bolts (1) on the right and left side

  72.  
  73. Remove the lower transmission bolt/studs.
  74.  
  75. Lower the vehicle.
  76.  
  77. Remove the 3 upper transmission bolts/studs.

    Click image to see an enlarged view

    Fig. Remove the 3 upper transmission bolts/studs (1)

  78.  
  79. Install an engine hoist to J 41798.
  80.  
  81. Install a floor jack under the transmission for support.
  82.  
  83. Separate the engine from the transmission.
  84.  
  85. Remove the engine.
  86.  
  87. Install the engine to an engine stand.
  88.  
  89. Install J 21366.
  90.  

To install:

  1. Remove J 21366.
  2.  
  3. Install an engine hoist to J 41798.
  4.  
  5. Remove the engine from the engine stand.
  6.  
  7. Install the engine.
  8.  
  9. Mate the engine to the transmission.
  10.  
  11. Remove the floor jack from under the transmission for support.
  12.  
  13. Install the 3 upper transmission bolts/studs. Tighten the bolts/studs to 37 ft. lbs. (50 Nm).
  14.  
  15. Raise the vehicle.
  16.  
  17. Install the lower transmission bolt/studs. Tighten the bolts/studs to 37 ft. lbs. (50 Nm).
  18.  
  19. Install the lower transmission bolts on the right and left side. Tighten the bolts/studs to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the transmission fluid cooler lines to the right side of the engine.
  22.  
  23. Install the transmission oil level indicator tube.
  24.  
  25. Install the transmission oil level indicator tube nut.
  26.  
  27. Install the torque converter bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
  28.  
  29. Install the 3 bracket bolts from both the right and the left side engine mounts.
  30.  
  31. Install the catalytic converters.
  32.  
  33. Lower the vehicle.
  34.  
  35. Install the heater inlet and outlet hoses.
  36.  
  37. Using J 38185, install the outlet hose to the water outlet.
  38.  
  39. Using J 38185, install the inlet hose to the water outlet.
  40.  
  41. Install the engine wiring harness/positive battery cable to the alternator.
  42.  
  43. Install the engine wiring harness/positive battery cable nut to the alternator.
  44.  
  45. Position the engine wiring harness/positive battery cable boot.
  46.  
  47. Connect the engine wiring harness electrical connector to the alternator.
  48.  
  49. Gather all branches of the engine wiring harness and position the harness over the engine.
  50.  
  51. Raise the vehicle.
  52.  
  53. Install the starter.
  54.  
  55. Connect the following connectors:

    Block heater electrical connector.
     
    A/C pressure switch electrical connector.
     
    Left and right side knock sensor electrical connector.
     

  56.  
  57. Connect the engine wiring harness electrical connector to the CMP sensor wire harness.
  58.  
  59. Connect the engine wiring harness electrical connector to the CKP sensor.
  60.  
  61. Install the battery cable channel to the oil pan.
  62.  
  63. Install the battery cable channel bolt.
  64.  
  65. Install the engine harness bracket bolt.
  66.  
  67. Install the ground terminal bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  68.  
  69. Install the retaining clips to the brackets.
  70.  
  71. Install the ground terminal bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  72.  
  73. Connect the ECT sensor.
  74.  
  75. Connect the oil pressure sensor and the oxygen sensors at the rear of the engine.
  76.  
  77. Lower the vehicle.
  78.  
  79. Install the intake manifold.
  80.  
  81. Install the radiator.
  82.  
  83. Recharge the refrigerant.
  84.  
  85. Connect the negative battery cable.
  86.  
  87. Remove the fender covers from both fenders.
  88.  
  89. Prelube the engine.
  90.  
  91. Perform the CKP system variation learn procedure.
  92.  
  93. Install the hood.
    NOTE
    After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

  94.  
  95. Test the vehicle using the following procedure:
    1. Disable the ignition system.
    2.  
    3. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    4.  
    5. Enable the ignition system.
    6.  
    7. Start the engine and listen for unusual noises.
    8.  
    9. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    10.  
    11. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
    12.  
    13. Listen for sticking lifter and other unusual noises.
    14.  
    15. Inspect for fuel, oil and/or coolant leaks while the engine is running.
    16.  
    17. Close the hood.
    18.  

  96.  

 
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