Installation 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.

Attach J 36857 to the rear of the right cylinder head and to the front of the left cylinder head.
NOTE: Refer to Fastener Notice in Cautions and Notices.

Fig 1: View Of J 36857 At Right Cylinder Head

GM66457

Courtesy of GENERAL MOTORS CORP.

Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963.
Tighten: Tighten the lift bracket bolts to 40 N.m (30 lb ft).
Install the air compressor/power steering mounting bracket to the engine block.
Tighten: Tighten the power steering pump bracket bolts and nut to 50 N.m (37 lb ft).

Fig 2: View Of A/C Compressor/Power Steering Pump Bracket

GM746257

Courtesy of GENERAL MOTORS CORP.

Install the generator bracket. Refer to Generator Bracket Replacement (8.1L Engine) in Engine Electrical.
Remove the engine using a suitable lifting devise.
Install the engine into the vehicle.
Install the engine mount to engine mount bracket bolts.

Fig 3: View Of Engine Mount-To-Engine Mount Bracket

GM750192

Courtesy of GENERAL MOTORS CORP.

Install the engine mount heat shield and bolts.

Fig 4: View Of Engine Mount Heat Shield

GM750194

Courtesy of GENERAL MOTORS CORP.

Remove the engine lift hooks from the cylinder heads.
Raise the vehicle and support with safety stands.
Install the engine oil cooler lines to the engine block. Refer to Engine Oil Cooler Hose/Pipe Replacement (2WD) or Engine Oil Cooler Hose/Pipe Replacement (4WD) in Engine Cooling.
Install the bolts from the transmission to the engine.
- For the automatic transmission, refer to Transmission Replacement (With 8.1L (L18) Engine) in Automatic Transmission - Allison.
- For the manual transmission, refer to Transmission Replacement in Manual Transmission - NV 4500 or Transmission Replacement in Manual Transmission - ZF S6-650.

Fig 5: Identifying Six Studs & One Bolt Securing Transmission To Engine

GM394446

Courtesy of GENERAL MOTORS CORP.

Install the clutch pressure plate bolts, if equipped.
Install the torque converter bolts, if equipped.
Install the catalytic converter. Refer to Catalytic Converter Replacement (6.0L and 8.1L Engines) in Engine Exhaust.
Install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines) in Engine Exhaust.
Install the hoses to the power steering pump. Refer to Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) or Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) or Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) or Power Steering Cooler Pipe/Hose Replacement (Parellel Hybrid Truck) in Power Steering System.
Install the starter motor. Refer to Starter Motor Replacement (8.1L Engine) in Engine Electrical.
Lower the vehicle.
Route the engine electrical harness.
Install the generator. Refer to Generator Replacement (8.1L Engine) in Engine Electrical.
Install the ground cable bolt at the engine block.
Tighten: Tighten the engine wiring harness bolt to 16 N.m (12 lb ft).

Fig 6: View Of Ground Cable Bolt At Engine Block

GM663475

Courtesy of GENERAL MOTORS CORP.

Install the vacuum lines to the engine.
Connect the TAC module electrical connector (1).

Fig 7: View Of TAC Module Electrical Connector

GM871922

Courtesy of GENERAL MOTORS CORP.

Install the radiator. Refer to Radiator Replacement (8.1L) in Engine Cooling.
Install the A/C compressor. Refer to Compressor Replacement (L18) in Heating, Ventilation and Air Conditioning.
Connect the fuel feed pipe (1) to the fuel rail.

Fig 8: View Of Fuel Feed Pipe & EVAP Canister Purge Pipe

GM1238587

Courtesy of GENERAL MOTORS CORP.

Install the ignition coils. Refer to Ignition Coil(s) Replacement in Engine Controls - 8.1 L.
Connect the positive battery cable.
Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
Install the air cleaner outlet duct.

Fig 9: View Of Air Cleaner Outlet Duct

GM700979

Courtesy of GENERAL MOTORS CORP.

Tighten the clamps at the throttle body and air cleaner.
Tighten: Tighten the clamps to 4 N.m (35 lb in).
Remove fender covers from both fenders.
Remove the hood hinge bolts from the service position (2).

Fig 10: Identifying Hood Hinge Normal And Service Position Bolt Holes

GM310799

Courtesy of GENERAL MOTORS CORP.

Lower the hood to the normal position.
Install the hood hinge bolts.
Tighten: Tighten the hood hinge bolts to 25 N.m (18 lb ft).
Before starting a new engine or one that has been repaired, complete the following procedure.
1. Prelube the engine. Refer to Engine Prelubing .
2. Remove the fuel pump fuse and disconnect the coil harness connectors, then crank the engine until oil pressure is present.
3. Crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
4. Install the fuel pump fuse and connect the coil harness connectors and start the engine and listen for unusual noises.
5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure. If necessary install an oil pressure gauge and measure the oil pressure.
6. Run the engine at about 1000 RPM until the engine has reached normal operating temperature.
7. Inspect for oil and or coolant leaks while the engine is running.
8. Stop the engine and perform a final inspection for the proper engine oil and coolant levels.
9. The final step is to perform the crankshaft position (CKP) sensor variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 8.1 L.