LEMON Manuals: Even more car manuals for everyone
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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Recover the HVAC refrigerant. Refer to Refrigerant Recovery and Recharging .
  4. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac N Fill) .
  5. Remove the sheet metal to radiator support bolts and supports from the vehicle.
  6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  7. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement .
  8. Remove the right and left headlamp capsules. Refer to Headlamp Capsule Replacement .
  9. Remove the front bumper. Refer to Front Bumper Replacement .
    10. Fig 1: View Of Inlet Hose & Water Pump
    GM659418Courtesy of GENERAL MOTORS CORP.
  10. Reposition the radiator inlet hose clamp at the water pump.
  11. Remove the radiator inlet hose from the water pump.
    12. Fig 2: View Of Radiator Outlet Hose
    GM308983Courtesy of GENERAL MOTORS CORP.
  12. Reposition the radiator outlet hose clamp at the water pump.
  13. Remove the radiator outlet hose from the water pump.
    14. Fig 3: Removing Retaining Ring For The Quick Connect Fitting
    GM104739Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the transmission cooler lines from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
  15. Disconnect the oil cooler line from the radiator, if equipped.
  16. Disconnect the HVAC lines from the condenser.
  17. Disconnect the ground G106 from the right hand inner fender. Refer to Power and Grounding Component Views .
  18. Disconnect the C4 at the underhood fuse block. Refer to Power and Grounding Component Views .
  19. Disconnect the positive battery cable from the underhood fuse block and position aside.
    20. Fig 4: Identifying Core Support Retaining Bolt
    GM314968Courtesy of GENERAL MOTORS CORP.
  20. Remove the core support retaining bolt (3).
  21. With the aid of an assistant, remove the core support assembly with the radiator, condenser radiator hoses and fan shroud intact.
  22. Remove the clutch fan. Refer to Fan Clutch Replacement .
  23. Remove the accessory drive belt.
    24. Fig 5: Identifying Coolant Air Bleed Hose & Pipe
    GM790766Courtesy of GENERAL MOTORS CORP.
  24. Remove the air bleed hose (1) from the throttle body.
    25. Fig 6: Identifying Generator Bracket Assembly
    GM663649Courtesy of GENERAL MOTORS CORP.
  25. Remove the generator bracket from the engine. Refer to Generator Bracket Replacement (4.8L, 5.3L, and 6.0L) . Leave the generator and power steering pump retained to the bracket. Use a suitable strap and position the bracket assembly aside.
    26. Fig 7: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  26. Remove the radiator vent inlet hose from the throttle body.
    27. Fig 8: View Of Battery Negative Cable & Ground Strap To Front Of Engine Bolt
    GM105211Courtesy of GENERAL MOTORS CORP.
  27. Remove the ground strap from the frame and engine.
  28. Remove G104 and G105 from the engine. Refer to Power and Grounding Component Views .
    29. Fig 9: View of A/C Compressor & Bolts
    GM648141Courtesy of GENERAL MOTORS CORP.
  29. Remove the air conditioning compressor (2). Refer to Compressor Replacement (4.8L, 5.3L, 6.0L) .
    30. Fig 10: View Of Water Pump Heater Hoses
    GM301617Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the heater hoses from the water pump.
  31. Remove the intake manifold. Refer to Intake Manifold Removal .
  32. Remove the ignition coils from the engine. Refer to Ignition Coil Replacement .
    33. Fig 11: Identifying Coolant Air Bleed Pipe And Bolts
    GM741555Courtesy of GENERAL MOTORS CORP.
  33. Remove the coolant air bleed pipe (2) from the engine. Refer to Coolant Air Bleed Pipe Assembly Replacement (4.8L, 5.3L, and 6.0L Engines) .
  34. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  35. Remove the oil drain plug and drain the oil into a suitable container.
    36. Fig 12: View Of Transmission Cover Bolt
    GM663487Courtesy of GENERAL MOTORS CORP.
  36. Remove the starter motor. Refer to Starter Motor Replacement (4.8L, 5.3L, and 6.0L) .
  37. Disconnect the catalytic converter pipe from the exhaust manifolds. 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) .
  38. Disconnect the following electrical connectors:
    • The crankshaft position (CKP) sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
    39. Fig 13: View Of Positive Battery Cable, Channel & Bolt
    GM662508Courtesy of GENERAL MOTORS CORP.
  39. Remove the battery cable channel bolt.
  40. Slide the channel pin out of the oil pan tab.
  41. Gather all branches of the engine wiring harness and reposition off to the side.
    42. Fig 14: View Of Lower 6 Bell Housing To Engine Studs & Bolts
    GM609370Courtesy of GENERAL MOTORS CORP.
  42. Remove the lower 6 bell housing to engine studs and bolts. Leave the top 2 studs in place.
    43. Fig 15: Identifying Torque Converter Bolts
    GM609366Courtesy of GENERAL MOTORS CORP.
  43. Remove the torque converter bolts.
  44. Lower the vehicle.
  45. Remove the left and right exhaust manifolds.
    46. NOTE: Refer to Fastener Notice .
  46. Install the J 42451-1  to the cylinder heads. See Special Tools .

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

    47. Fig 16: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  47. Remove the left and right engine mount-to-engine mount bracket bolts.
    48. Fig 17: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  48. Remove the transmission oil level indicator tube nut.
    49. Fig 18: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  49. Remove the transmission oil level indicator tube.
    50. Fig 19: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  50. Remove the top 2 automatic transmission studs.
  51. Install a floor jack under the transmission for support.
  52. Install an engine hoist to the J 42451-1  . See Special Tools .
  53. Separate the engine from the automatic transmission, if equipped.

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

  54. Remove the engine.
  55. Install the engine to an engine stand.
  56. Remove the engine hoist.
  57. Remove the J 42451-1  from the engine. See Special Tools .
scientia non olet · About LEMON Manuals