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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1020 (Engine Mechanical - 6.6L (LLY)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: In order to remove the engine the vehicle needs to be on a hoist. The front wheels and tires will also require removal. The vehicle will have to be supported by the frame when the tires are removed.
  1. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  2. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  3. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
    4. Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  4. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  5. Disconnect the following engine wire harness connectors:
    • Mass air flow switch (1)
    • A/C pressure cycling switch (2)
    • Surge tank switch (6)
  6. Remove the engine wire harness clip from the accumulator (3).
  7. Remove the engine wire harness clips from the wheelhouse inner panel (4).
  8. Remove the engine wire harness clip from the engine bracket (5).
    9. Fig 2: View Of Engine Wire Harness Connectors & Clips
    GM674588Courtesy of GENERAL MOTORS CORP.
  9. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6L (LLY).
  10. Remove the surge tank. Refer to Surge Tank Replacement in Engine Cooling.
  11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  12. Remove both front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  13. Remove both fender wheelhouse inner panels. Refer to Wheelhouse Panel Replacement in Body Front End.
  14. Lower the vehicle.
  15. Remove the charged air cooler pipes. Refer to Charged Air Cooler Hoses/Pipes Replacement (Left)  or Charged Air Cooler Hoses/Pipes Replacement (Right) .
  16. Loosen the hose clamps and remove the radiator inlet hose from the radiator and the engine.
    17. Fig 3: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  17. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74) or Fan Shroud Replacement - Upper (W/M74) in Engine Cooling.
  18. Remove the lower fan shroud. Refer to Fan Shroud Replacement - Lower in Engine Cooling.
  19. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
  20. Disconnect the outlet heater hose from the outlet radiator hose.
    21. Fig 4: View Of Outlet Heater Hose & Outlet Radiator Hose
    GM674543Courtesy of GENERAL MOTORS CORP.
  21. Remove the hose clips from the frame.
  22. Loosen the hose clamp and remove the radiator outlet hose from the engine.
  23. Remove the outlet heater hose pipe bolt from the bracket.
  24. Remove the outlet heater hose pipe nut (1).
    25. Fig 5: View Of Outlet Heater Hose Pipe & Nut
    GM674559Courtesy of GENERAL MOTORS CORP.
  25. Move the heater hose and secure aside.
  26. Remove the upper radiator support. Refer to Radiator Support Replacement in Body Front End.
  27. Remove the radiator. Refer to Radiator Replacement (EXC 8.1L) or Radiator Replacement (8.1L) in Engine Cooling.
  28. Remove the charged air cooler. Refer to Charged Air Cooler Replacement .
  29. Remove the A/C condenser. Refer to Condenser Replacement in Heating, Ventilation and Air Conditioning.
  30. Disconnect the following electrical connectors:
    • Generator connector (1)
    • A/C refrigerant switch (2)
    • Dual generator harness connector (3), if equipped
    • A/C compressor clutch (4)
    31. Fig 6: View Of A/C & Generator Electrical Connectors
    GM1369550Courtesy of GENERAL MOTORS CORP.
  31. Remove the harness clip from the A/C compressor bracket.
  32. Remove the battery cable to the generator.
  33. If equipped, remove the battery cable to the auxiliary generator.
  34. Remove the battery cable harness clip from the bracket.
  35. Remove the battery cable junction block bolt (1) from the power steering pump.
    36. Fig 7: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  36. Move and secure the battery cables out of the way.
  37. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  38. Open the harness clip (2).
    39. Fig 8: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  39. Remove the main engine electrical harness connectors.
  40. Disconnect the fuel lines at the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 6.6L (LLY).
  41. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
    42. Fig 9: View Of Fuel Lines At Engine
    GM1378747Courtesy of GENERAL MOTORS CORP.
  42. Secure the fuel lines out of the way.
  43. Remove the drive belt. Refer to Drive Belt Replacement .
  44. Disconnect the suction hose from the accumulator. The compressor end can remain on the compressor.
  45. Remove the A/C compressor bolts.
  46. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
    47. Fig 10: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  47. Move the wiring harness to the left side of the vehicle and secure out to the way.
  48. Remove the bolts retaining the power steering pump front bracket to the power steering pump and the air conditioner compressor mounting bracket.
  49. Remove the air conditioning and power steering pump mounting bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement .

    When the battery cables are removed from the engine the power steering pump can be removed further out of the way.

    50. Fig 11: View Of Power Steering Pump Front Bracket
    GM698146Courtesy of GENERAL MOTORS CORP.
  50. Remove the right idler pulley bolt (1) and pulley.
    51. Fig 12: View Of Right Side Idler & Center Idler Pulley Bolts
    GM1409331Courtesy of GENERAL MOTORS CORP.
  51. Remove the generator mounting bracket and secure to the side.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
    52. Fig 13: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  52. Use the J 43181  in order to disconnect the inlet heater hose from the heater core inlet.
    53. Fig 14: Identifying Heater Hose To Heater Core Fittings
    GM362171Courtesy of GENERAL MOTORS CORP.
  53. Remove the bolt and the ground wires at the rear of the left cylinder head.
  54. Raise the vehicle.
  55. Remove the oil pan skid plate.
    56. Fig 15: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  56. Remove the engine shield from the vehicle, if equipped.
    57. Fig 16: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  57. Remove the bolt for the battery negative cable and the engine wiring harness ground wire from the left side of the engine.
    58. Fig 17: View Of Battery Negative Cable & Engine Wiring Harness Ground Wire
    GM674628Courtesy of GENERAL MOTORS CORP.
  58. Remove the bolts holding the battery cable channel retainer to the lower crankcase.
    59. Fig 18: View Of Battery Cable Bracket & Bolts
    GM673564Courtesy of GENERAL MOTORS CORP.
  59. Disconnect the cord for the engine coolant heater.
    60. Fig 19: View Of Engine Coolant Heater
    GM674570Courtesy of GENERAL MOTORS CORP.
  60. Remove the starter. Refer to Starter Motor Replacement (6.6L (LLY) Engine) in Engine Electrical.
  61. Remove the nut holding the battery cable bracket to the right side of the lower crankcase.
    62. Fig 20: View Of Battery Cable Bracket Nut
    GM673568Courtesy of GENERAL MOTORS CORP.
  62. Remove the bolt holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.
    63. Fig 21: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness Ground Wires
    GM674624Courtesy of GENERAL MOTORS CORP.
  63. Move and secure the battery cables out of the way.
  64. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  65. Drain the engine oil.
  66. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
    67. Fig 22: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  67. If vehicle is 4WD remove the lower oil pan. Refer to Oil Pan Replacement - Lower .
  68. If equipped with an automatic transmission, mark the flywheel and torque converter relationship for assembly purposes.
  69. Remove the torque convertor bolts through the starter opening.
    70. Fig 23: View Of Torque Convertor Bolts Through Starter Opening
    GM702519Courtesy of GENERAL MOTORS CORP.
  70. If equipped with an automatic transmission, remove the transmission oil line clip nut.
    71. Fig 24: View Of Transmission Oil Cooler Lines, Bracket & Bolt
    GM686706Courtesy of GENERAL MOTORS CORP.
  71. If equipped with an automatic transmission, remove the nuts retaining transmission fluid fill tube bracket.
    72. Fig 25: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  72. Remove the transmission to engine stud and bolts (automatic transmission shown). Note the location of the studs and any brackets attached to the studs.
    73. Fig 26: View Of Transmission To Engine Stud & Bolts
    GM686685Courtesy of GENERAL MOTORS CORP.
  73. Lower the vehicle to work through the wheelhouse opening.
  74. Remove the engine mount to frame bracket bolts (left side shown).
    75. Fig 27: View Of Engine Mount To Engine Mount Frame Bracket
    GM657625Courtesy of GENERAL MOTORS CORP.
  75. Lower the vehicle.
  76. Install the J 36857  (1) to the rear of the left cylinder head with a suitable bolt.
    Fig 28: View Of J 36857 At Rear Of Left Cylinder Head
    GM674699Courtesy of GENERAL MOTORS CORP.
  77. Install the J 36857  (1) to the front of the right cylinder head with a suitable bolt.
    78. Fig 29: View Of J 36857 At Front Of Right Cylinder Head
    GM674703Courtesy of GENERAL MOTORS CORP.
  78. Install a suitable lifting device. The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.
  79. Raise the vehicle off of the engine mounts.
  80. Remove the left and right engine mount frame brackets.
    81. Fig 30: View Of Engine Mount, Frame Bracket & Bolts
    GM657623Courtesy of GENERAL MOTORS CORP.
  81. Remove the engine from the vehicle.
  82. In order to secure the engine to an engine stand remove the following and follow the special procedures:
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