Sierra, Silverado 2006-2007

Engine

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Removal & Installation



4.3L Engine
  1. Remove or disconnect the following:

    Battery negative cable
     
    Coolant
     
    A/C refrigerant, if equipped
     
    Oil pan skid plate
     
    Engine shield

    Click image to see an enlarged view

    Fig. Engine shield removal-4.3L engines

     



    Starter.
     
    Transmission cover
     
    Bolt holding the bracket for the starter cables and transmission cooler lines, if equipped
     
    Nuts at the catalytic converter pipe
     
    Exhaust pipes from the exhaust manifolds
     
    Bolts holding the brackets to the oil pan for both battery cables
     
    Crankshaft Position (CKP) sensor electrical connector and remove the harness from the retainer
     
    Low oil level sensor electrical connector and remove the wire harness from the retainer
     
    Bolt holding the battery negative cable and ground cable to the engine
     
    Torque converter-to-flywheel bolts, if equipped, through the starter opening
     
    Engine to transmission bolts

    Click image to see an enlarged view

    Fig. Hood in the service position

     

  2.  
  3. Move the hood hinge bolts to hold the hood in the service position.
  4.  
  5. Remove or disconnect 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.


    WARNING
    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.


    NOTE
    Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.



    Positive Crankcase Ventilation (PCV) hose from the air cleaner outlet duct
     
    Air cleaner outlet duct from the throttle body and the air cleaner assembly
     
    Fan shroud
     
    Drive belt
     
    Engine cooling fan
     
    Radiator inlet and outlet hoses from the engine
     



    Accelerator control cable
     
    Cruise control cable from the throttle body and the bracket on the throttle body and intake manifold, if equipped
     
    Engine wiring harness and clip from the accelerator control cable bracket
     
    Accelerator control cable bracket from the throttle body
     
    A/C hoses from the compressor and the accumulator, if equipped
     
    Secondary Air Injection (AIR) crossover pipe from the AIR pipe assemblies
     



    AIR pipe assemblies from the left exhaust manifold, if equipped
     
    AIR pipe assembly from the AIR pump
     
    AIR pipe assembly from the right exhaust manifold, if equipped.
     
    A/C pressure switch, if equipped
     
    A/C compressor clutch, if equipped
     
    Exhaust Gas Recirculation (EGR) valve
     
    Battery positive cable
     
    Fuel meter body
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    EVAP canister purge solenoid valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Ignition Control Module (ICM)
     
    Ignition coil
     
    Engine oil pressure gauge sensor
     
    Distributor
     
    Knock Sensor (KS)
     
    Nuts holding the bracket for the engine wiring harness to the intake manifold studs
     
    Bolt holding the engine wiring harness clip to the battery positive cable junction block bracket
     
    Bracket for the battery positive cable junction block from the power steering pump mounting bracket
     
    Battery positive and negative cables, if not done already
     
    Nut holding the ground wire to the stud at the rear of the right cylinder head
     
    Stud holding the engine wiring harness bracket to the rear of the right cylinder head
     
    Nut holding the engine wiring harness bracket to the stud for the EVAP canister purge solenoid valve
     
    Bolt holding the ground strap and the ground wire to the rear of the left cylinder head. Move the engine wiring harness aside.
     
    Both heater hoses from the engine and the cowl
     
    Distributor cap
     
    Fuel pipes at the rear of the engine
     
    Hose from the EVAP purge canister solenoid valve
     
    Power brake booster vacuum hose
     
    Nuts holding the power steering pump rear bracket to the side and front of the engine
     
    Three bolts and the nut holding the power steering pump mounting bracket to the engine
     

  6.  
  7. With the power steering pump and the A/C compressor still attached, slide the power steering pump mount bracket off the stud and set aside.

    Water outlet
     
    EGR valve inlet pipe from the intake and exhaust manifold
     

  8.  
  9. Attach the engine crane to the left front and right rear intake manifold mounting bolts.
  10.  
  11. Remove the engine motor mount to frame bracket bolts.
  12.  
  13. Support the transmission with a suitable jack.
  14.  
  15. Remove the engine.
  16.  

To install:

  1. Install or connect the following:

    Engine in the vehicle
     
    Engine mount to frame bracket bolts. Tighten the bolts to 48 ft. lbs. (65 Nm).
     

  2.  
  3. Remove the lifting device.
  4.  
  5. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts. Install the bolts and tighten as follows:
    1. First pass: 27 inch lbs. (3 Nm)
    2.  
    3. Second pass: 106 inch lbs. (12 Nm)
    4.  
    5. Final pass: 11 ft. lbs. (15 Nm)
    6.  

  6.  
  7. Loosely install one transmission to engine bolt. Remove the support jack from under the transmission.
  8.  
  9. Install the EGR valve inlet pipe to the intake and the exhaust manifold and tighten as follows:
    1. Tighten the EGR valve inlet pipe intake nut to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten the EGR valve inlet pipe exhaust nut to 22 ft. lbs. (30 Nm).
    4.  
    5. Tighten the EGR valve inlet pipe clamp bolt to 18 ft. lbs. (25 Nm).
    6.  

  10.  
  11. Install the water outlet.
  12.  
  13. Slide the power steering pump mounting bracket with the power steering pump and the A/C compressor on the stud.
  14.  
  15. Position the power steering pump rear bracket on the studs.
  16.  
  17. Install or connect the following:

    Power steering pump mounting bracket bolts and the nut
     
    Nut for the power steering pump rear bracket to the front of the engine. Tighten the power steering pump mounting bracket and the power steering pump rear bracket bolts and the nuts to 30 ft. lbs. (41 Nm).
     
    Fuel pipes
     
    Hose to the EVAP purge canister solenoid valve
     
    Vacuum brake booster hose to engine and the vacuum brake booster
     
    Distributor cap
     
    Both heater hoses to the engine and the cowl
     
    AIR pipe assembly with new gaskets to the right exhaust manifold, if equipped
     
    AIR pipe nuts and bracket bolt. Tighten the nuts to 18 ft. lbs. (25 Nm) and the bolt to 89 inch lbs. (10 Nm).
     
    AIR pipe assembly to the AIR pump
     
    AIR pipe assembly with new gaskets to the left exhaust manifold, if equipped. Install the AIR pipe nuts and bracket bolt. Tighten the to 18 ft. lbs. (25 Nm) and the bolt to 89 inch lbs. (10 Nm).
     
    AIR crossover pipe to the AIR pipe assemblies
     
    Engine wiring harness
     
    A/C pressure switch
     
    A/C compressor clutch
     
    EGR valve
     
    Alternator battery positive cable
     
    Fuel meter body assembly
     
    IAC motor
     
    TP sensor
     
    ECT sensor
     
    EVAP canister purge solenoid valve
     
    MAP sensor
     
    ICM
     
    Ignition coil
     
    Engine oil pressure gauge sensor
     
    Distributor
     
    Knock sensor
     

  18.  
  19. Install the bolt holding the ground strap and the ground wire to the rear of the left cylinder head. Tighten the ground strap and ground wire bolt to 12 ft. lbs. (16 Nm).
  20.  
  21. Position the engine wiring harness bracket on the EVAP purge canister solenoid valve stud and install the nut.
  22.  
  23. Install the stud holding the wire harness bracket to the rear of the right cylinder head. Tighten the nut on the EVAP solenoid to 80 inch lbs. (9 Nm). Tighten the stud at rear of the cylinder head to 18 ft. lbs. (25 Nm).
  24.  
  25. Install the nut holding the ground wire on the stud at the rear of the right cylinder head. Tighten the ground wire nut to 12 ft. lbs. (16 Nm).
  26.  
  27. Position the battery positive and negative cables. Do not connect the negative battery cable to the battery.
  28.  
  29. 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.



    Battery positive cable junction block bracket and bolt to the power steering pump mounting bracket. Tighten the bolt to 18 ft. lbs. (25 Nm).
     
    Bolt holding the engine wiring harness bracket to battery positive cable junction block bracket
     
    Engine wiring harness bracket on the intake manifold studs. Tighten the nuts to 106 inch lbs. (12 Nm) and the bolt to 80 inch lbs. (9 Nm).
     
    A/C hoses
     
    Accelerator control cable bracket. Tighten the nuts to 80 inch lbs. (9 Nm).
     
    Engine wire harness and clip to the accelerator control cable bracket
     



    NEW accelerator control cable
     
    Cruise control cable
     
    Radiator inlet and outlet hoses
     
    Engine cooling fan
     
    Drive belt
     
    Upper and lower radiator shroud
     
    Air cleaner outlet duct to the throttle body and the air cleaner assembly
     
    PCV hose to the air inlet duct
     

  30.  
  31. Move the hood hinge bolts from the service position to the normal operating position.
  32.  
  33. Raise the vehicle.
  34.  
  35. Install or connect the following:

    Remaining transmission to engine bolts except for the one where the transmission cover mounts
     
    Torque converter to flywheel
     
    Transmission cover and bolts. Tighten the transmission cover to oil pan bolt to 106 inch lbs. (12 Nm). Tighten the transmission cover to transmission bolt to 34 ft. lbs. (47 Nm).
     
    Bolt holding the bracket for the starter cables and the transmission cooler pipe and tighten to 80 inch lbs. (9 Nm)
     
    Positive and negative battery cable brackets-to-oil pan bolts and tighten to 106 inch lbs. (12 Nm).
     
    Bolt for the battery negative cable and ground wire to the front of the engine. Tighten the battery negative cable and ground wire bolt to 18 ft. lbs. (25 Nm).
     
    CKP sensor and install the harness in the retainer
     
    Low oil level sensor and install the wire harness in the retainer
     
    Exhaust pipe to the exhaust manifolds and tighten the nuts at the catalytic converter flange
     
    Starter motor
     
    Oil pan skid plate and tighten bolt to 15 ft. lbs. (20 Nm)
     
    Engine shield
     

  36.  
  37. Lower the vehicle.

    Battery negative cable
     
    Engine oil
     
    Coolant
     

  38.  
  39. Recharge the A/C system.
  40.  

4.8L, 5.3L, 6.0L & 6.2L Engines
2005-06 Models And 2007 Classic

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-4.8L, 5.3L, 6.0L and 6.2L engines

     



    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-4.8L, 5.3L, 6.0L and 6.2L engines

     

  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-4.8L, 5.3L, 6.0L and 6.2L engines

     



    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-4.8L, 5.3L, 6.0L and 6.2L engines

     

  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-4.8L, 5.3L, 6.0L and 6.2L engines

  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.  

Except Classic

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

NOTE
In order to remove the engine, the vehicle must be on a lift. the front tires also need to be removed. You will have to support the vehicle by its frame for tire removal.

  1. Drain the cooling system.
  2.  
  3. Discharge and recover the air conditioning system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  8.  
  9. Disconnect the battery cables.
  10.  
  11. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then left the shield off the rear bracket.
    4.  

  12.  
  13. Remove or disconnect the following:
    NOTE
    After you remove the duct, cover the turbocharger openings and ducts with tape to prevent foreign objects from entering.






    Air cleaner outlet duct from the air cleaner and turbocharger.
     
    Mass Air Flow (MAF) switch connector
     
    A/C pressure cycling switch connector
     
    Surge tank switch
     
    Engine wire harness clip from the accumulator
     
    Engine wire harness clips from the wheelhouse inner panel and engine bracket
     
    Air cleaner assembly and bracket
     
    Surge tank
     

  14.  
  15. Raise the vehicle.

    Front tires and wheels
     
    Both front fender wheelhouse inner panels
     

  16.  
  17. Lower the vehicle.

    Charged air cooler pipes and hoses from the engine and charged air cooler
     
    Radiator inlet hose form the radiator and engine
     
    Upper and lower fan shrouds
     
    Radiator outlet hose from the radiator
     
    Outlet heater hose from the outlet radiator hose
     
    Hose clips from the frame
     
    Radiator outlet hose from the engine
     
    Bolt securing the outlet heater hose pipe to the alternator mounting bracket
     
    Nut securing the outlet heater hose pipe to the fuel filter mounting bracket
     
    Secure the heater hose aside
     
    Upper radiator support
     
    Radiator
     
    Charged air cooler
     
    A/C condenser
     
    Alternator harness connector
     
    A/C refrigerant switch connector
     
    Dual alternator harness connector, if equipped
     
    A/C compressor clutch connector
     
    Harness clip from the A/C compressor bracket
     
    Battery cable from the alternator and auxiliary alternator, if equipped
     
    Battery cable harness clips from the bracket
     
    Bolt securing the battery cable junction block from the power steering pump
     
    Move and secure the battery cables aside
     
    Both fuel injection control module harness connectors, by flipping the latch up
     
    Engine wire harness from the retainer
     
    Fuel lines at the engine
     
    Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud
     
    Fuel lines aside
     
    Power supply cable from the glow plug relay
     
    Drive belt
     
    Suction hose from the accumulator. You can leave the compressor end on the compressor.
     
    A/C compressor bolts, then move the compressor, with the hoses attached, to the right side of the engine compartment
     
    Wiring harness to the left side of the engine and tie aside
     
    Bolts holding the power steering pump front bracket to the pump and A/C compressor mounting bracket
     
    A/C compressor and power steering pump bracket. Once the battery cables are removed from the engine, the power steering pump can be removed further out of the way
     
    Positive Crankcase Ventilation (PCV) oil separator from the bracket
     
    Bolts securing the PCV separator bracket and fuel bleed valve
     
    Right idler pulley (ribbed)
     
    Alternator mounting bracket and secure aside. You do not have to remove the alternator or the belt tensioner
     
    Inlet heater hose from the heater core inlet, using Quick Connect-Disconnect tool No. J 43181
     
    Bolt and ground wires from the rear of the left cylinder head
     

  18.  
  19. Raise the vehicle

    Oil pan skid plate
     
    Engine protection shield, if equipped
     
    Bolt for the negative battery cable and engine wiring harness ground wire from the left side of the engine
     
    Bolts holding the battery cable channel retainer to the lower crankcase
     
    Engine coolant heater cord
     
    Starter motor
     
    Nut securing the battery cable bracket to the right side of the lower crankcase
     
    Bolt holding the auxiliary negative battery cable and the engine wiring harness ground wires to the right side of the engine
     
    Position the battery cables aside
     
    Exhaust pipe-to-exhaust outlet clamp
     
    Lower oil pan, if 4WD
     

  20.  
  21. If equipped with an automatic transmission, matchmark the installed position of the flywheel and torque converter.

    Torque converter bolts through the starter opening
     
    Transmission oil line clip nut if equipped with A/T
     
    Nuts securing the transmission fluid fill tube bracket, if equipped with A/T
     
    Transmission-to-engine stud and bolts. Note the location of the studs and any brackets attached to the studs
     

  22.  
  23. Lower the vehicle to work through the wheel opening

    Engine mount-to-frame bracket bolts
     

  24.  
  25. Lower the vehicle.
  26.  
  27. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.
  28.  
  29. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  30.  
  31. Install a suitable lifting device. The engine will have to be angled to remove it. Use a load positioning sling to help in angling the engine.
  32.  
  33. Raise the vehicle off the engine mounts.
  34.  
  35. Remove the left and right engine mount frame brackets.
  36.  
  37. Remove the engine assembly from the vehicle.
  38.  
  39. Secure the engine on an engine stand by removing the following components:

    Flywheel/flexplate
     
    Rear main seal
     
    Exhaust outlet
     
    Oil pan
     
    Flywheel housing
     

  40.  

To install:

  1. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.

    Click image to see an enlarged view

    Fig. Install the engine lifting bracket to the rear of the left cylinder head-6.6L engines

  2.  
  3. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  4.  
  5. Install a suitable lifting device. The engine will have to be angled to install it. Use a load positioning sling to help in angling the engine.
  6.  
  7. Install or connect the following:

    Engine in the vehicle
     
    2 transmission-to-engine bolts, loosely
     
    Left and right side engine mount frame brackets and tighten to 55 ft. lbs. (75 Nm)
     
    Engine mount-to-frame bracket bolts and tighten to 50 ft. lbs. (65 Nm)
     

  8.  
  9. Remove the lifting brackets from the cylinder heads.

    Transmission-to-engine bolts/studs and tighten to 37 ft. lbs. (50 Nm)

    Click image to see an enlarged view

    Fig. Transmission-to-engine mounting-6.6L engines with A/T

     
    Torque converter bolts and tighten to 44 ft. lbs. (60 Nm)
     

  10.  
  11. Install the remaining components in the reverse of the removal procedure, noting the following important specifications and steps:

    Transmission fluid tube bracket nuts: 13 ft. lbs. (18 Nm)
     
    Transmission oil cooler line clip bolt: 80 inch lbs. (9 Nm)
     
    Exhaust pipe clamp: 30 ft. lbs. (40 Nm)
     
    Ground wire bolt: 25 ft. lbs. (34 Nm)
     
    Battery cable bracket bolts: 106 inch lbs. (12 Nm)
     
    Cable and ground wire bolts: 25 ft. lbs. (34 Nm)
     
    Oil pan skid plate bolts: 15 ft. lbs. (20 Nm)
     
    Engine protection shield bolts: 15 ft. lbs. (20 Nm)
     
    Alternator bracket bolt: 37 ft. lbs. (50 Nm)
     
    Idler pulley bolt: 32 ft. lbs. (43 Nm)
     
    A/C compressor bolts: 37 ft. lbs. (50 Nm)
     

  12.  
  13. Refill the crankcase and the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

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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