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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 the J 36857  (1) to the rear of the left cylinder head with a suitable bolt.
    2. Fig 1: View Of J 36857 At Rear Of Left Cylinder Head
    GM674699Courtesy of GENERAL MOTORS CORP.
  2. Install the J 36857  (1) to the front of the right cylinder head with a suitable bolt.
    3. Fig 2: View Of J 36857 At Front Of Right Cylinder Head
    GM674703Courtesy of GENERAL MOTORS CORP.
  3. Install a suitable lifting device. The engine will have to be angled in order to install. Use a load positioning sling to assist in angling the engine.
  4. Remove the engine from the stand. Refer to Engine Removal from Stand .
  5. Install the following:
  6. Install the engine in the vehicle.
    7. IMPORTANT: Do not draw the engine to the transmission using the transmission bolts. If everything is aligned properly the engine and transmission will come together.
  7. Loosely install 2 transmission to engine bolts.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the left and right side engine mount frame brackets.

    Tighten:  Tighten the through-bolts to 75 N.m (55 lb ft).

    9. Fig 3: View Of Engine Mount, Frame Bracket & Bolts
    GM657623Courtesy of GENERAL MOTORS CORP.
  9. Install the engine mount to frame bracket bolts (left side shown).

    Tighten:  Tighten the bolts to 65 N.m (50 lb ft).

    10. Fig 4: View Of Engine Mount To Engine Mount Frame Bracket
    GM657625Courtesy of GENERAL MOTORS CORP.
  10. Remove the J 36857  from the cylinder heads.
  11. Raise the vehicle.
  12. Install the transmission to engine bolts (automatic transmission shown).

    Tighten:  Tighten the studs and bolts to 50 N.m (37 lb ft).

    13. Fig 5: View Of Transmission To Engine Stud & Bolts
    GM686685Courtesy of GENERAL MOTORS CORP.
  13. If equipped with an automatic transmission install the torque convertor bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    14. Fig 6: View Of Torque Convertor Bolts Through Starter Opening
    GM702519Courtesy of GENERAL MOTORS CORP.
  14. If equipped with an automatic transmission, install the nuts retaining the transmission fluid fill tube bracket.

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

    15. Fig 7: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  15. If the vehicle is 4WD, install the lower oil pan. Refer to Oil Pan Replacement - Lower .
  16. If equipped with an automatic transmission, install the nut retaining the transmission oil cooler line clip.

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

    17. Fig 8: View Of Transmission Oil Cooler Lines, Bracket & Bolt
    GM686706Courtesy of GENERAL MOTORS CORP.
  17. Install the exhaust pipe to the exhaust outlet.
  18. Install the exhaust manifold pipe to the exhaust outlet clamp.

    Tighten:  Tighten the clamp to 40 N.m (30 lb ft).

    19. Fig 9: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  19. Lower the vehicle to work through the front fender wheelhouse openings.
  20. Install the bolt retaining the battery negative cable and the engine wiring harness ground wire to the left side of the engine.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

    21. Fig 10: View Of Battery Negative Cable & Engine Wiring Harness Ground Wire
    GM674628Courtesy of GENERAL MOTORS CORP.
  21. Install the bolts holding the battery cable channel retainer to the lower crankcase.

    Tighten:  Tighten the bolts to 12 N.m (106 lb ft).

    22. Fig 11: View Of Battery Cable Bracket & Bolts
    GM673564Courtesy of GENERAL MOTORS CORP.
  22. Install the bolts holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    23. Fig 12: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness Ground Wires
    GM674624Courtesy of GENERAL MOTORS CORP.
  23. Install the nut holding the battery cable bracket to the right side of the lower crankcase.

    Tighten:  Tighten the nut to 8 N.m (71 lb in).

    24. Fig 13: View Of Battery Cable Bracket Nut
    GM673568Courtesy of GENERAL MOTORS CORP.
  24. Install the starter. Refer to Starter Motor Replacement (6.6L (LLY) Engine) in Engine Electrical.
  25. Connect the cord for the engine coolant heater.
    26. Fig 14: View Of Engine Coolant Heater
    GM674570Courtesy of GENERAL MOTORS CORP.
  26. Install the engine oil pan skid plate.

    Tighten:  Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).

    27. Fig 15: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  27. Install the engine shield.

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

  28. Lower the vehicle.
  29. Install the bolt and the ground wires at the rear of the left cylinder head.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

    30. Fig 16: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  30. Install the generator mounting bracket and bolts.

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

    31. Fig 17: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  31. Install the right idler pulley and bolt (1).

    Tighten:  Tighten the bolt to 43 N.m (32 lb ft).

    32. Fig 18: View Of Right Side Idler & Center Idler Pulley Bolts
    GM1409331Courtesy of GENERAL MOTORS CORP.
  32. Install the air conditioning compressor and the power steering pump mounting bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement .
  33. Position the engine wiring harness on the engine.
  34. Position the A/C compressor.
  35. Install the A/C compressor mounting bolts.

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

    36. Fig 19: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  36. Install the A/C suction hose to the accumulator.
  37. Install the drive belt. Refer to Drive Belt Replacement .
  38. Connect the fuel hoses at the engine.
    39. Fig 20: View Of Fuel Lines At Engine
    GM1378747Courtesy of GENERAL MOTORS CORP.
  39. Install the nut and the fuel hose bracket to the valve rocker arm cover stud.

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

  40. Connect the main engine electrical harness connectors.
  41. Push down on the latches (1) in order the connect the connectors.
  42. Close the harness clip (2).
    43. Fig 21: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  43. Install the cable junction block and bolt (1) to the power steering pump.

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

    44. Fig 22: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  44. If equipped, install the battery cable to the auxiliary generator.
  45. Install the battery cable to the generator.

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

  46. Install the battery cable harness clip to the bracket.
  47. Connect the following electrical connectors:
    • Generator connector (1)
    • A/C refrigerant switch (2)
    • Dual generator harness connector (3), if equipped
    • A/C compressor clutch (4)
    48. Fig 23: View Of A/C & Generator Electrical Connectors
    GM1369550Courtesy of GENERAL MOTORS CORP.
  48. Install the harness clip to the A/C compressor bracket.
  49. Install the upper radiator support. Refer to Radiator Support Replacement in Body Front End.
  50. Install the A/C condenser. Refer to Condenser Replacement in Heating, Ventilation and Air Conditioning.
  51. Install the charged air cooler. Refer to Charged Air Cooler Replacement .
  52. Install the radiator. Refer to Radiator Replacement (EXC 8.1L) or Radiator Replacement (8.1L) in Engine Cooling.
  53. Install the outlet radiator hose to the radiator and tighten the hose clamp.
    54. Fig 24: View Of Outlet Heater Hose & Outlet Radiator Hose
    GM674543Courtesy of GENERAL MOTORS CORP.
  54. Install the hose clips to the frame.
  55. Install the outlet radiator hose to the engine and tighten the hose clamp.
    56. Fig 25: View Of Outlet Heater Hose Pipe & Nut
    GM674559Courtesy of GENERAL MOTORS CORP.
  56. Install the lower fan shroud. Refer to Fan Shroud Replacement - Lower in Engine Cooling.
  57. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74) or Fan Shroud Replacement - Upper (W/M74) in Engine Cooling.
  58. Connect the inlet heater hose (1) to the heater core inlet.

    Firmly push to quick connector onto the heater core pipe until you hear an audible click.

    59. Fig 26: View Of Inlet Heater Hose
    GM651356Courtesy of GENERAL MOTORS CORP.
  59. Install the outlet heater hose to the outlet radiator hose.
  60. Install the bolt retaining the heater hose pipe to the bracket.

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

  61. Install the outlet radiator hose to the radiator and the engine and tighten the hose clamps.
    62. Fig 27: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  62. Install the charged air cooler pipes and hoses to the turbocharger and the charged air cooler. Refer to Charged Air Cooler Hoses/Pipes Replacement (Left)  or Charged Air Cooler Hoses/Pipes Replacement (Right) .
  63. Install both fender wheelhouse inner panels (1). Refer to Wheelhouse Panel Replacement in Body Front End.
  64. Install both front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  65. Install the surge tank. Refer to Surge Tank Replacement in Engine Cooling.
  66. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6L (LLY).
  67. Connect the following engine wire harness connectors:
    • Mass air flow switch (1)
    • Air continuation pressure cycling switch (2)
    • Surge tank switch (6)
  68. Install the engine wire harness clip to the accumulator (3).
  69. Install the engine wire harness clips to the wheelhouse inner panel (4).
  70. Install the engine wire harness clip to the engine bracket (5).
    71. Fig 28: View Of Engine Wire Harness Connectors & Clips
    GM674588Courtesy of GENERAL MOTORS CORP.
  71. Connect the batteries negative cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  72. Fill the engine coolant. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  73. Prelube the engine. Refer to Engine Prelubing .
  74. Operate the engine, inspect for coolant, oil, fuel, and exhaust leaks.
  75. Inspect for proper oil pressure.
  76. Inspect for proper engine operation.
  77. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).

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

    78. Fig 29: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  78. Road test the vehicle for normal operation.
  79. Inspect for coolant, oil, or exhaust leaks.
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