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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 994 (Engine Mechanical - 6.6L (LLY)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Flywheel Housing Replacement >> Installation Procedure

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.
  1. Install NEW O-ring seals to the flywheel housing, if necessary.
    2. Fig 1: View Of Flywheel Housing O-Ring Seals
    GM663771Courtesy of GENERAL MOTORS CORP.
  2. Apply a 2 mm (1/8 in) wide bead of sealant (3) GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the flywheel housing sealing surfaces.
    3. Fig 2: View Of Flywheel Housing Sealing Surfaces
    GM663922Courtesy of GENERAL MOTORS CORP.
  3. Install a NEW oil cooler adapter gasket.
  4. Install a NEW oil cooler adapter to flywheel housing gasket.
  5. Install the oil cooler adapter to the flywheel housing.
    6. Fig 3: View Of Oil Cooler Adapter
    GM1334855Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the oil cooler adapter bolts.

    Tighten:  Tighten the bolts/nuts to 21 N.m (15 lb ft).

    7. Fig 4: View Of Engine Rear Cover Bolts & Flywheel Housing To Upper Oil Pan Bolts
    GM660335Courtesy of GENERAL MOTORS CORP.
  7. Install the flywheel housing bolts, denoted by the black circles.

    Tighten:  Tighten the bolts to 90 N.m (67 lb ft).

    8. Fig 5: View Of Oil Filter
    GM660299Courtesy of GENERAL MOTORS CORP.
  8. Install the oil filter.
  9. Install the upper oil pan. Refer to Oil Pan Replacement - Upper .
  10. Install a NEW gasket to the turbocharger oil return pipe.
  11. Install the turbocharger oil return pipe to flywheel housing nuts.

    Tighten:  Tighten the nuts to 21 N.m (15 lb ft).

    12. Fig 6: View Of Turbocharger Oil Return Pipe Nuts
    GM1334852Courtesy of GENERAL MOTORS CORP.
  12. Install the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement .
  13. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
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