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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Open the hood.
  2. Place fender covers over both fenders.
  3. Raise the hood to the service position, then perform the following:
    1. Remove the hood hinge bolts (1).
    2. Raise the hood until vertical.
    3. Install the hood hinge bolts until snug in the service position (2).
    4. Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  4. Remove the air conditioning (AC) compressor. Refer to Compressor Replacement (LR4, LM7, and LQ4) in HVAC Systems - Manual.
  5. Remove the radiator supports. Refer to Radiator Support Replacement in Body Front End.
  6. Reposition the radiator inlet hose clamp at the water pump.
  7. Remove the radiator inlet hose from the water pump.
    8. Fig 2: View Of Inlet Hose & Water Pump
    GM659418Courtesy of GENERAL MOTORS CORP.
  8. Reposition the radiator outlet hose clamp at the water pump.
  9. Remove the radiator outlet hose from the water pump.
    10. Fig 3: View Of Radiator Outlet Hose
    GM308983Courtesy of GENERAL MOTORS CORP.
  10. Remove 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.
  11. If equipped with the 4.8L, 5.3L, or 6.0L regular production option (RPO) LQ4, loosen the intake manifold sight shield bolt.
  12. Remove the sight shield from the retainer.
    13. Fig 4: View Of Engine Sight Shield (4.8L, 5.3L & 6.0L - RPO LQ4)
    GM832094Courtesy of GENERAL MOTORS CORP.
  13. If equipped with the 6.0L with RPO LQ9, perform the following:
    1. Loosen the intake manifold sight shield bolt.
    2. Loosen the left fuel rail cover bolts.
    3. Remove the left fuel rail cover.
    4. Loosen the right fuel rail cover bolts.
    5. Remove the right fuel rail cover.
    6. Remove the sight shield from the retainer.
    14. Fig 5: View Of Engine Sight Shield (6.0L - RPO LQ9)
    GM832097Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the following electrical connectors:
    • Evaporative emissions (EVAP) canister purge solenoid (1)
    • Generator (3)
  15. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.
    16. Fig 6: View Of EVAP Canister Purge Solenoid & Generator Electrical Connectors & Bracket Nut
    GM1235683Courtesy of GENERAL MOTORS CORP.
  16. Reposition the vent inlet hose clamp at the throttle body.
  17. Remove the radiator vent inlet hose from the throttle body.
    18. Fig 7: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  18. Remove the generator cable from the generator, perform the following:
    1. Slide the boot down revealing the terminal stud.
    2. Remove the generator cable nut from the terminal stud.
    3. Remove the generator cable.
    19. Fig 8: View Of Generator Cable & Nut
    GM395686Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    20. Fig 9: View Of Main Coil Harness & Fuel Injector Electrical Connectors (Left Side)
    GM679597Courtesy of GENERAL MOTORS CORP.
  20. Remove the connector position assurance (CPA) retainer (5).
  21. Disconnect the following electrical connectors:
    • The main coil harness (4)
    • The fuel injectors (3)
    • The electronic throttle control (ETC) (2)
    22. Fig 10: View Of CPA Retainer, Harness Clips, ETC, Coil Harness & Fuel Injectors Electrical Connectors
    GM1235686Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.
    23. Fig 11: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  23. Remove the harness ground bolt.
  24. Reposition the harness ground and negative battery cable from the block.
  25. Disconnect the following electrical connectors:
    • The coolant temperature sensor (5)
    • The electronic variable orifice switch
    26. Fig 12: 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.
  26. Remove the harness ground bolt at the right rear of the engine block.
  27. Reposition the harness ground, and auxiliary negative battery cable, if equipped from the block.
  28. Remove the harness ground bolt at the left rear of the engine block.
  29. Reposition the harness ground, and engine ground strap from the block.
  30. Disconnect the following electrical connectors:
    • The oil pressure sensor (1)
    • The camshaft position (CMP) sensor (3)
  31. Unclip all of the engine harness clips from the engine.
    32. Fig 13: View Of Oil Pressure Sensor, Harness Ground & CMP Sensor Electrical Connector
    GM1236366Courtesy of GENERAL MOTORS CORP.
  32. Remove the battery cable junction block from the junction block bracket.
    33. Fig 14: View Of Battery Cable Junction Block To Bracket
    GM662505Courtesy of GENERAL MOTORS CORP.
  33. Remove the EVAP purge solenoid vent tube, perform the following:
    1. Remove the EVAP tube end from the solenoid (1).
    2. Remove the EVAP tube end from the vapor pipe (2).
    34. Fig 15: View Of EVAP Tube To Solenoid & Vapor Pipe
    GM1285743Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the fuel pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 4.8L, 5.3L, and 6.0L.
  35. Raise the vehicle.
  36. Disconnect the following electrical connectors:
    • The crankshaft position (CKP) sensor (1)
    • The engine oil level sensor (3)
    • The coolant heater, if equipped
    37. Fig 16: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  37. Remove the battery cable channel bolt.
  38. Slide the channel pin out of the oil pan tab.
  39. Gather all branches of the engine wiring harness and reposition off to the side.
    40. Fig 17: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  40. Lower the vehicle.
  41. Remove the rear power steering pump-to-engine block bolt.
  42. Remove the generator bracket mounting bolts.
  43. Position the bracket aside.
    44. Fig 18: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  44. Remove the vacuum brake booster hose.
    45. Fig 19: View Of Vacuum Brake Booster Hose To Intake Manifold Rear (5.3L Engine w/RPO HP2)
    GM1236362Courtesy of GENERAL MOTORS CORP.
  45. Remove the ignition coil, as required for the proper fit of the J 41798  before lifting the engine. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
    46. NOTE: Refer to Fastener Notice in Cautions and Notices.
    Fig 20: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  46. Install the J 41798  to the cylinder heads.

    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).

  47. Remove the left and right engine mount-to-engine mount bracket bolts.
    48. Fig 21: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  48. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  49. Remove the engine shield bolts and shield.
    50. Fig 22: View Of Engine Protection Shield
    GM349061Courtesy of GENERAL MOTORS CORP.
  50. Remove the oil pan skid plate bolts and plate, if equipped.
    51. Fig 23: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  51. Drain the engine oil.
  52. Remove the starter motor. Refer to Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines) in Engine Electrical.
  53. Remove 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.
  54. Remove the positive battery cable clip bolt and clip.
    55. Fig 24: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  55. Remove the flywheel to torque converter bolts.
    56. Fig 25: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  56. Remove the transmission oil level indicator tube nut, if equipped.
    57. Fig 26: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  57. Remove the transmission oil level indicator tube, if equipped.
    58. Fig 27: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  58. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.
    59. Fig 28: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  59. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.
    60. Fig 29: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  60. Remove the automatic transmission bolt/studs, if equipped.
    61. Fig 30: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  61. Separate the engine from the automatic transmission.

    Install the J 21366  to the transmission in order to hold the torque converter.

  62. Lower the vehicle.
  63. Install an engine hoist to the J 41798  .
  64. Install a floor jack under the transmission for support.
    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.
  65. Remove the engine.
  66. Install the engine to an engine stand.
  67. Remove the engine hoist.
  68. Remove the J 41798  from the engine.
    69. Fig 31: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
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