Installation Procedure
WARNING: This page is about a different variant/trim than selected.
- Install the J 41798 Engine Lift Bracket to the engine.
- Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
- Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).
- Position and install the engine hoist to the J 41798 Engine Lift Bracket.
- Remove the engine from the engine stand.
- Remove the J 21366 Converter Holding Strap from the transmission.
- Install the engine to the vehicle.
- Align and install the engine to the transmission. Raise or lower the transmission as required using the floor jack.
- Once aligned and mated together completely lower and remove the engine hoist.
- For 2500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to engine mount to frame bolts (1) and tighten to 65 (48 lb ft).
- For 1500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to frame bolts (1) and tighten to 65 (48 lb ft).
- For 1500 series vehicles with a 4.8L engine, install the left and right engine mount to frame bolts (1) tighten to 65 (48 lb ft).
- Remove the floor jack from under the transmission.
- Raise the vehicle.
- If equipped with the 6L80-E automatic transmission, install the transmission bolts/studs and tighten to 50 (37 lb ft).
- If equipped with the 4L80-E automatic transmission, install the transmission bolts/studs and tighten to 50 (37 lb ft).
- If equipped with the 4L60-E/4L70-E automatic transmission, install the transmission bolts/studs and tighten to 50 (37 lb ft).
- Position the transfer case vent hose bracket and hose and install the bracket to the stud, if equipped.
- For the 4L60-E/4L70-E/6L80-E automatic transmission, install the transfer case vent hose bracket (2) nut to the stud, if equipped and tighten to 20 (15 lb ft).
- For the 4L80-E automatic transmission, install the transfer case vent hose bracket (1) nut to the stud, if equipped and tighten to 20 N.m (15 lb ft).
- Position the fuel/EVAP pipe bracket and install the bracket to the stud. (typical installation shown).
- Install the fuel/EVAP pipe bracket nut to the transmission stud and tighten to 20 (15 lb ft).
- Align the torque converter bolt holes to the flywheel bolt holes.
- Install the flywheel to torque converter bolts.
- For the 4L60-E/4L70-E/6L80-E automatic transmission, tighten the bolts to 63 (47 lb ft).
- For the 4L80-E automatic transmission, tighten the bolts to 60 (44 lb ft).
- Install the catalytic converter. Refer to Catalytic Converter Replacement (with Exhaust Clamp) , or Three-Way Catalytic Converter Replacement .
- Lower the vehicle.
- Remove the J 41798 Engine Lift Bracket from the cylinder heads.
- Install the ignition coil(s) and spark plug wire(s), as required. Refer to Ignition Coil Replacement .
- Install the transmission oil level indicator tube.
- Install the transmission oil level indicator tube nut (1) and tighten to 18 (13 lb ft).
- Position the generator bracket (with power steering pump) to the engine.
- Install the generator bracket bolts and tighten to 50 (37 lb ft).
- Install the rear power steering pump-to-engine block bolt (1500 series shown, 2500 series similar) and tighten to 50 (37 lb ft).
- Raise the vehicle.
- Connect the coolant heater cord to the coolant heater, if equipped.
- Connect the engine harness electrical connector (1) to the CKP sensor.
- Connect the engine harness electrical connector (2) to the knock sensor.
- Connect the engine harness electrical connector (4) to the oil level sensor.
- Install the engine harness clip (3) to the transmission oil cooler line bracket.
- Install the starter motor. Refer to Starter Replacement .
- Connect the engine harness electrical connector (1) to the A/C refrigerant pressure sensor.
- Slide the channel pin (3) into the oil pan tab.
- Install the battery cable channel bolt (2) and tighten to 12 (106 lb in).
- Connect the engine harness electrical connector (1) to the CMP sensor wire harness.
- Position the transmission oil cooler line clip to the oil pan and install the bolt, if equipped and tighten to 9 (80 lb in).
- Connect the engine harness electrical connector (4) to the knock sensor.
- Position the engine harness grounds (3) to the engine block.
- Install the engine harness ground stud (2) to the engine block and tighten to 16 (12 lb ft).
- Install the engine harness clip (1) to the ground stud.
- Lower the vehicle.
- Position the negative battery cable terminal (2) and the engine harness ground (3) to the right cylinder head.
- Install the negative battery cable stud (1) to the right cylinder head and tighten to 25 (18 lb ft).
- Position the engine ground strap to the cylinder head and cowl.
- Install the engine ground strap bolt to the rear of the left cylinder head and cowl and tighten to 16 (12 lb ft).
- Connect the engine harness electrical connector (1) to the oil pressure sensor.
- Connect the engine harness electrical connector (2) to the lifter oil manifold.
- Install the heater hoses. Refer to Heater Inlet Hose Replacement (Non-HP2) and Heater Outlet Hose Replacement (Non-HP2) .
- Install the radiator outlet hose to the water pump.
- Position the radiator outlet hose clamp at the water pump.
- Install the radiator inlet hose to the water pump.
- Position the radiator inlet hose clamp (3) at the water pump.
- Position and install the radiator vent inlet hose (2) to the air bleed pipe.
- Position the radiator vent inlet hose clamp (1) at the air bleed pipe.
- Install the radiator vent inlet hose (2) to the radiator inlet hose clip (3).
- Position the generator battery jumper to the engine.
- Install the intake manifold. Refer to Intake Manifold Replacement (RPOs LC9, LMG, LY5, L76) , Intake Manifold Replacement (RPOs LY2, LY6) , Intake Manifold Replacement (Except RPOs LY2, LY6, LC9, LMG, LY5) .
- For 2500 series vehicles, install the oil pan skid plate and bolts, if equipped and tighten to 28 (21 lb ft).
- For 1500 series vehicles, install the oil pan skid plate and bolts, if equipped and tighten to 28 (21 lb ft).
- Install the engine shield and bolts and tighten to 20 (15 lb ft).
- Lower the vehicle.
- Install the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement .
- Install the hood latch. Refer to Hood Primary and Secondary Latch Replacement .
- Remove the hood from the service position. Refer to Hood Service Positioning .
- Prelube the engine. Refer to Engine Prelubing .
- Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn
.NOTE:
After an overhaul the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
- Disable the ignition system.
- Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
- Enable the ignition system.
- Start the engine and listen for unusual noises.
- Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
- Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
- Listen for sticking lifters or other unusual noises.
- Inspect for fuel, oil and/or coolant leaks while the engine is running.
- Perform a final inspection for the proper oil and coolant levels.
- Close the hood.
CAUTION:
Refer to Fastener Caution .
NOTE:
Start with the middle bolt then either side bolt.
NOTE:
Start with the middle bolt then either side bolt.
NOTE:
Start with the middle bolt then either side bolt.