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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 23 (Engine Mechanical - 4.8L, 5.3L, And 6.0L (2 Of 4)) >> On-Vehicle REPARI Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Install the J 42451-1  to the engine. See Special Tools .

    Tighten:  Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).

  2. Install an engine hoist to the J 42451-1  . See Special Tools .
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
    6. Fig 1: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  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. 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 42451-1  from the engine. See Special Tools .
  11. Install the left and right exhaust manifolds. Refer to Exhaust Manifold Installation - Left Side and to Exhaust Manifold Installation - Right Side .
  12. Install the intake manifold. Refer to Intake Manifold Installation .
    13. Fig 2: View Of Ignition Coils & Spark Plug Wires
    GM339300Courtesy of GENERAL MOTORS CORP.
  13. Install the ignition coil(s) and the spark plug wire(s). Refer to Ignition Coil Replacement .
  14. Raise the vehicle.
    15. Fig 3: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  15. Remove the J 21366  from the transmission. See Special Tools .
  16. Install the automatic transmission bolt/studs, if equipped.
    17. Fig 4: Identifying Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  17. Install the torque converter bolts, if equipped.

    Tighten: 

    • If equipped with the 4L60-E, tighten the torque converter bolts to 63 N.m (37 lb ft).
    • If equipped with the 4L80-E, tighten the torque converter bolts to 60 N.m (44 lb ft).

    18. Fig 5: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  18. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.

    Tighten:  Tighten the transmission converter bolts to 33 N.m (24 lb ft).

    19. Fig 6: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  19. 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).

    20. Fig 7: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  20. Install the automatic transmission oil level indicator tube, if equipped.
    21. Fig 8: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  21. Install the automatic transmission oil level indicator tube nut, if equipped.

    Tighten:  Tighten the automatic transmission oil level indicator tube nut to 18 N.m (13 lb ft).

    22. Fig 9: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  22. Install the positive battery cable clip and bolt.

    Tighten:  Tighten the positive battery cable clip bolt to 9 N.m (80 lb in).

  23. Install the catalytic converter. Refer to Catalytic Converter Replacement (Dual Exhaust - Left) or Catalytic Converter Replacement (Dual Exhaust - Right) or Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L) .
  24. Connect the following electrical connectors:
    • Crankshaft position sensor
    • Engine oil level sensor
    • Coolant heater, if equipped
  25. Install the starter motor. Starter Motor Replacement (4.8L, 5.3L, and 6.0L) .
  26. Lower the vehicle.
    27. Fig 10: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  27. Position the generator bracket assembly to the front of the engine.
  28. Install the generator bracket assembly. Refer to Generator Bracket Replacement (4.8L, 5.3L, and 6.0L) .

    Tighten:  Tighten the generator bracket bolts to 50 N.m (37 lb ft).

  29. Install the heater hoses to the water pump.
    30. Fig 11: View of A/C Compressor & Bolts
    GM648141Courtesy of GENERAL MOTORS CORP.
  30. Install the air conditioning compressor (2) to the engine.

    Tighten:  Tighten the compressor mounting bolts to 68 N.m (50 lb ft).

  31. Install the air conditioning discharge hose to the compressor.

    Tighten:  Tighten the bolt to 35 N.m (26 lb ft).

  32. Install the engine ground strap to the frame.

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

  33. Install the ground strap and negative battery cable to the engine.

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

  34. Install the clutch fan. Refer to Fan Clutch Replacement .
    35. Fig 12: Drive Belt
    GM678802Courtesy of GENERAL MOTORS CORP.
  35. Install the accessory drive belt.
    36. Fig 13: Fender To Radiator Support Bolts
    GM277531Courtesy of GENERAL MOTORS CORP.
  36. With the aid of an assistant, position the core support assembly to the vehicle.
  37. Install the core support bolts.

    Tighten: 

    • Tighten the core support bolts to 25 N.m (18 lb ft).
    • Tighten the core support nuts to 57 N.m (42 lb ft).

  38. Install the positive battery cable to the underhood fuse panel.

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

  39. Install the G106 to the inner fender. Refer to Power and Grounding Component Views .

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

  40. Connect the C4 to the underhood fuse panel. Refer to Power and Grounding Component Views .
    41. Fig 14: Identifying Condenser Air Conditioning Lines
    GM924812Courtesy of GENERAL MOTORS CORP.
  41. Install the air conditioning lines (2) to the condenser.

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

    42. Fig 15: Identifying Cooler Line & Quick Connect Fitting
    GM104740Courtesy of GENERAL MOTORS CORP.
  42. Install the transmission cooler lines to the radiator.
  43. Install the oil cooler lines to the radiator, if equipped.
  44. Install the radiator hoses to the thermostat housing and water pump.
    45. Fig 16: Identifying Coolant Air Bleed Hose At Throttle Body
    GM220621Courtesy of GENERAL MOTORS CORP.
  45. Install the coolant air bleed to the throttle body.
    46. Fig 17: Identifying Headlamp Capsule
    GM325530Courtesy of GENERAL MOTORS CORP.
  46. Install the headlamp capsules (4). Refer to Headlamp Capsule Replacement .
    47. Fig 18: Bumper To Frame Retaining Bolts
    GM776153Courtesy of GENERAL MOTORS CORP.
  47. Install the front bumper. Refer to Front Bumper Replacement .
    48. Fig 19: View Of Water Outlet Stud Ground Wire
    GM712012Courtesy of GENERAL MOTORS CORP.
  48. Install the air cleaner assembly (4). Refer to Air Cleaner Assembly Replacement .
  49. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement .
  50. Install the sheet metal to the fender supports.

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

  51. Fill the cooling system with coolant. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac N Fill) .
  52. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities or Fluid and Lubricant Recommendations .
  53. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
    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 gage 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.
  54. Close the hood.
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