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Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Engine Mechanical (Repair Instructions -- 1 Of 3) -- 4.8L, 5.3L & 6.0L) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. Install the J 41798  to the engine.

    Tighten: 

    • 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).

  2. Install an engine hoist to the J 41798  .
    3. Fig 1: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
  6. Install the left and right engine mount-to-engine mount bracket bolts.

    Tighten:  Tighten the engine mount-to-engine mount bracket bolts to 65 N.m (48 lb ft).

    7. Fig 2: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  7. Install the upper transmission bolts until snug.
  8. Remove the floor jack from under the transmission.
  9. Remove the engine hoist.
  10. Remove the J 41798  from the engine.
    11. Fig 3: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  11. Install the ignition coils and the spark plug wires. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
    12. Fig 4: View Of Ignition Coils & Spark Plug Wires
    GM339300Courtesy of GENERAL MOTORS CORP.
  12. Raise the vehicle.
  13. Remove the J 21366  from the transmission.
  14. Install the automatic transmission bolt/studs.
    15. Fig 5: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  15. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.
    16. Fig 6: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  16. If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side.

    Tighten:  Tighten the automatic transmission bolts/studs to 50 N.m (37 lb ft).

    17. Fig 7: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  17. Install the automatic transmission oil level indicator tube.
    18. Fig 8: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  18. Install the automatic transmission oil level indicator tube nut.

    Tighten:  Tighten the nut to 18 N.m (13 lb ft).

    19. Fig 9: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  19. Install the flywheel to torque converter bolts.

    Tighten: 

    • If equipped with a 4L60E transmission, tighten the bolts to 63 N.m (47 lb ft).
    • If equipped with a 4L80E transmission, tighten the bolts to 60 N.m (44 lb ft).

    20. Fig 10: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  20. Install the positive battery cable clip and bolt.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    21. Fig 11: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  21. Install the catalytic converter. Refer to Catalytic Converter Replacement (4.8L and 5.3L Engines) or Catalytic Converter Replacement (6.0L and 8.1L Engines) in Engine Exhaust.
  22. Install the starter motor. Refer to Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines) in Engine Electrical.
  23. Install the oil pan skid plate and bolts, if equipped.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    24. Fig 12: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  24. Install the engine shield and bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    25. Fig 13: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  25. Lower the vehicle.
  26. Install the vacuum brake booster hose.
    27. Fig 14: View Of Vacuum Brake Booster Hose To Intake Manifold Rear (5.3L Engine w/RPO HP2)
    GM1236362Courtesy of GENERAL MOTORS CORP.
  27. Position the generator bracket to the front of the engine.
  28. Install the generator bracket bolts until snug.
    29. Fig 15: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  29. Install the rear power steering pump-to-engine block bolt until snug.

    Tighten: 

    • Tighten the rear power steering pump bolt to 50 N.m (37 lb ft).
    • Tighten the generator bracket bolts to 50 N.m (37 lb ft).

  30. Route the engine wiring harness to the lower engine area.
  31. Raise the vehicle.
  32. Slide the channel pin into the oil pan tab.
  33. Install the battery cable channel bolt.

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

    34. Fig 16: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  34. Connect the following electrical connectors:
    • The CKP sensor (1)
    • The engine oil level sensor (3)
    • The coolant heater, if equipped
    35. Fig 17: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  35. Lower the vehicle.
  36. Connect the fuel pipes.
  37. Install the EVAP purge solenoid vent tube to the solenoid (1).
  38. Install the EVAP tube end to the vapor pipe (2).
    39. Fig 18: View Of EVAP Tube To Solenoid & Vapor Pipe
    GM1285743Courtesy of GENERAL MOTORS CORP.
  39. Install the battery cable junction block to the junction block bracket.
  40. Clip all of the engine wiring harness clips to their correct location.
    41. Fig 19: View Of Battery Cable Junction Block To Bracket
    GM662505Courtesy of GENERAL MOTORS CORP.
  41. Connect the following electrical connectors:
    • The oil pressure sensor (1)
    • The CMP sensor (3)
  42. Position the harness ground and the engine ground strap to the block.
  43. Install the harness ground bolt at the left rear of the engine block.
  44. Position the harness ground, and auxiliary negative battery cable, if equipped to the block.
  45. Install the harness ground bolt at the right rear of the engine block.

    Tighten:  Tighten the bolts to 16 N.m (12 lb ft).

    46. Fig 20: View Of Oil Pressure Sensor, Harness Ground & CMP Sensor Electrical Connector
    GM1236366Courtesy of GENERAL MOTORS CORP.
  46. Connect the following electrical connectors:
    • The coolant temperature sensor (5)
    • The electronic variable orifice switch
  47. Position the harness ground and negative battery cable to the block.
  48. Install the harness ground bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    49. Fig 21: View Of Engine Wiring Harness Ground Bolt, ECT Sensor Electrical Connector, Negative Battery Cable & Harness Ground (4.8L, 5.3L, and 6.0L Engines)
    GM1235684Courtesy of GENERAL MOTORS CORP.
  49. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    50. Fig 22: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  50. Connect the following electrical connectors:
    • The main coil harness (4)
    • The fuel injectors (3)
    • The ETC (2)
  51. Install the CPA retainer (5).
    52. Fig 23: View Of CPA Retainer, Harness Clips, ETC, Coil Harness & Fuel Injectors Electrical Connectors
    GM1235686Courtesy of GENERAL MOTORS CORP.
  52. Connect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    53. Fig 24: View Of Main Coil Harness & Fuel Injector Electrical Connectors (Left Side)
    GM679597Courtesy of GENERAL MOTORS CORP.
  53. Install the generator cable to the generator, perform the following:
    1. Install the generator cable.
    2. Install the generator cable nut to the terminal stud.

      Tighten:  Tighten the nut to 9 N.m (80 lb in).

    3. Slide the boot over the terminal stud.
    54. Fig 25: View Of Generator Cable & Nut
    GM395686Courtesy of GENERAL MOTORS CORP.
  54. Install the radiator vent inlet hose to the throttle body.
  55. Position the vent inlet hose clamp at the throttle body.
    56. Fig 26: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  56. Install the engine wiring harness bracket and nut (2).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  57. Connect the following electrical connectors:
    • The EVAP canister purge solenoid (1)
    • The Generator (3)
    58. Fig 27: View Of EVAP Canister Purge Solenoid & Generator Electrical Connectors & Bracket Nut
    GM1235683Courtesy of GENERAL MOTORS CORP.
  58. If equipped with the 6.0L with RPO LQ9, perform the following:
    1. Install the right fuel rail cover.
    2. Tighten the right fuel rail cover bolts.

      Tighten:  Tighten the bolts to 9 N.m (80 lb in).

    3. Install the left fuel rail cover.
    4. Tighten the left fuel rail cover bolts.

      Tighten:  Tighten the bolts to 9 N.m (80 lb in).

    5. Install the sight shield to the retainer.
    6. Tighten the intake manifold sight shield bolt.

      Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    59. Fig 28: View Of Engine Sight Shield (6.0L - RPO LQ9)
    GM832097Courtesy of GENERAL MOTORS CORP.
  59. If equipped with the 4.8L, 5.3L, or 6.0L with RPO LQ4, install the engine sight shield to the retainer.
  60. Tighten the engine sight shield bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    61. Fig 29: View Of Engine Sight Shield (4.8L, 5.3L & 6.0L - RPO LQ4)
    GM832094Courtesy of GENERAL MOTORS CORP.
  61. Install the heater hoses. Refer to Heater Hose Replacement - Inlet (Utility LR4, LM7, LQ4) or Heater Hose Replacement - Inlet (Avalanche/Xlt LR4, LM7, LQ4) and Heater Hose Replacement - Outlet (Utility LR4, LM7, LQ4) or Heater Hose Replacement - Outlet (Avalanche/Xlt LR4, LM7, LQ4) in Heating, Ventilation and Air Conditioning.
  62. Install the radiator outlet hose to the water pump.
  63. Position the radiator outlet hose clamp at the water pump.
    64. Fig 30: View Of Radiator Outlet Hose
    GM308983Courtesy of GENERAL MOTORS CORP.
  64. Install the radiator inlet hose to the water pump.
  65. Position the radiator inlet hose clamp at the water pump.
    66. Fig 31: View Of Inlet Hose & Water Pump
    GM659418Courtesy of GENERAL MOTORS CORP.
  66. Install the radiator supports. Refer to Radiator Support Replacement in Body Front End.
  67. Install the A/C compressor. Refer to Compressor Replacement (LR4, LM7, and LQ4) in HVAC System - Manual.
  68. Remove the hood hinge bolts from the service position (2).
  69. Lower the hood to the normal position.
  70. Install the hood hinge bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    71. Fig 32: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  71. Remove the fender covers.
  72. Perform the engine prelubing procedure. Refer to Engine Prelubing .
  73. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 4.8L, 5.3L, and 6.0L.
    IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
    1. Disable the ignition system.
    2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    3. Enable the ignition system.
    4. 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.
    6. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
    7. Listen for sticking lifter and other unusual noises.
    8. Inspect for fuel, oil and/or coolant leaks while the engine is running.
    9. Perform a final inspection for the proper engine oil and coolant levels.
  74. Close the hood.
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