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Home >> GMC >> 2005 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 4.8L, 5.3L & 6.0L (Repair Instructions - 1 Of 3) >> Repair Instructions (On-Vehicle And Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Engine Replacement (4.8L, 5.3L & 6.0L Engines) >> Installation Procedure

Installation Procedure

NOTE: Refer to Fastener Notice in Cautions and Notices.
    Fig 1: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  1. Install the J 41798  to the engine. See Special Tools .

    Tighten: 

    • Tighten the M8 bolts to 25 N.m (18 lb ft).
    • Tighten the M10 bolts to 50 N.m (37 lb ft).

  2. Install an engine hoist to the J 41798  . 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 2: 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 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. Fig 3: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  10. Remove the J 41798  from the engine. See Special Tools .
    11. Fig 4: View Of Ignition Coils & Spark Plug Wires
    GM339300Courtesy of GENERAL MOTORS CORP.
  11. Install the ignition coils and the spark plug wires. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L & 6.0L.
  12. Raise the vehicle.
    13. Fig 5: View Of Clutch Pressure Plate & Disc
    GM685828Courtesy of GENERAL MOTORS CORP.
  13. Install the disc and clutch pressure plate and bolts until snug, if equipped.
  14. Using J 5824-A  , align the clutch disc splines with the pilot bearing. See Special Tools .
  15. Align the marks made during removal.
    16. Fig 6: Clutch Pressure Plate Bolts Tightening Sequence (4.8L, 5.3L & 6.0L Engines)
    GM71490Courtesy of GENERAL MOTORS CORP.
  16. Tighten the clutch pressure plate bolts in the sequence shown, evenly over 3 increments with the fourth increment to the final specification.

    Tighten:  Tighten the bolts to 70 N.m (52 lb ft).

    17. Fig 7: View Of Clutch Line & Concentric Slave Cylinder
    GM33768Courtesy of GENERAL MOTORS CORP.
  17. Install the clutch line to the concentric slave cylinder.
    18. Fig 8: View Of Transmission Mounting Bolts (Manual Transmission)
    GM394442Courtesy of GENERAL MOTORS CORP.
  18. Install the manual transmission bolt/studs, if equipped.
    19. Fig 9: View Of Manual Transmission Stud (Right Side)
    GM394444Courtesy of GENERAL MOTORS CORP.
  19. Install the manual transmission stud on the right side of the transmission, if equipped.

    Tighten:  Tighten the bolt/studs to 50 N.m (37 lb ft).

    20. Fig 10: View Of Automatic Transmission Bolt/Studs (4.8L, 5.3L & 6.0L Engines)
    GM859003Courtesy of GENERAL MOTORS CORP.
  20. Remove the J 21366  from the transmission. See Special Tools .
  21. Install the automatic transmission, if equipped.
    22. Fig 11: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  22. If equipped with a 4L80-E transmission, install the transmission converter cover bolts.
    23. Fig 12: View of Transmission Bolt & Stud (4L60-E)
    GM859004Courtesy of GENERAL MOTORS CORP.
  23. If equipped with a 4L60-E transmission, install the transmission bolt and stud on the right side.

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

    24. Fig 13: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  24. Install the automatic transmission oil level indicator tube, if equipped.
    25. Fig 14: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  25. Install the automatic transmission oil level indicator tube nut, if equipped.

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

    26. Fig 15: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  26. Install the torque converter bolts, if equipped.

    Tighten: 

    • If equipped with a 4L60-E transmission, tighten the bolts to 63 N.m (47 lb ft)
    • If equipped with a 4L80-E transmission, tighten the bolts to 60 N.m (44 lb ft).

    27. Fig 16: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  27. Install the positive cable clip and bolt.

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

  28. Install the catalytic converter. Refer to Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) or Catalytic Converter Replacement (6.0L and 8.1L Engines) or Catalytic Converter Replacement (6.6L Engine) in Engine Exhaust.
  29. Install the starter motor. Refer to Starter Motor Replacement (4.3L Engine) or Starter Motor Replacement (4.8L, 5.3L & 6.0L Engines) or Starter Motor Replacement (6.6L (LLY) Engine) or Starter Motor Replacement (8.1L Engine) in Engine Electrical.
    30. Fig 17: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  30. Install the oil pan skid plate and bolts, if equipped.

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

    31. Fig 18: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  31. Install the engine shield and bolts.

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

  32. Lower the vehicle.
    33. Fig 19: View Of Vacuum Brake Booster Hose To Intake Manifold Rear
    GM1236362Courtesy of GENERAL MOTORS CORP.
  33. Install the vacuum brake booster hose.
    34. Fig 20: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  34. Position the generator bracket to the front of the engine.
  35. Install the generator bracket bolts until snug.
  36. Install the rear power steering pump to engine block bolt until snug.

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

  37. Route the engine wiring harness to the lower engine area.
  38. Raise the vehicle.
    39. Fig 21: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  39. Slide the channel pin into the oil pan tab.
  40. Install the battery cable channel bolt.

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

    41. Fig 22: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  41. Connect the following electrical connectors:
    • The CKP sensor (1)
    • The engine oil level sensor (3)
    • The coolant heater, if equipped
  42. Lower the vehicle.
  43. Connect the fuel pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 4.8L, 5.3L & 6.0L.
    44. Fig 23: View Of EVAP Tube Ends (4.8L, 5.3L & 6.0L Engines)
    GM832127Courtesy of GENERAL MOTORS CORP.
  44. Install the EVAP purge solenoid vent tube to the solenoid (1).
  45. Install the EVAP tube to the vapor pipe (2).
    46. Fig 24: View Of Battery Cable Junction Block (4.8L, 5.3L & 6.0L Engines)
    GM662505Courtesy of GENERAL MOTORS CORP.
  46. Install the battery cable junction block to the junction block bracket.
  47. Clip all of the engine wiring harness clips to their correct location.
    48. Fig 25: View Of Oil Pressure Sensor, Harness Ground & CMP Sensor Electrical Connector
    GM1236366Courtesy of GENERAL MOTORS CORP.
  48. Connect the following electrical connectors:
    • The oil pressure sensor (1)
    • The CMP sensor (3)
  49. Position the harness ground and the engine ground strap to the block.
  50. Install the harness ground bolt at the left rear of the engine block.
  51. Position the harness ground and auxiliary negative battery cable, if equipped, to the block.
  52. Install the harness ground bolt at the right rear of the engine block.

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

    53. Fig 26: View Of Engine Wiring Harness Ground Bolt, ECT Sensor Electrical Connector, Negative Battery Cable & Harness Ground (4.8L, 5.3L & 6.0L Engines)
    GM1235684Courtesy of GENERAL MOTORS CORP.
  53. Connect the following electrical connectors:
    • The ECT sensor (5)
    • The electronic variable orifice switch
  54. Position the harness ground and negative battery cable to the block.
  55. Install the harness ground bolt.

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

    56. Fig 27: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  56. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    57. Fig 28: View Of CPA Retainer, Harness Clips, ETC, Coil Harness & Fuel Injectors Electrical Connectors
    GM1235686Courtesy of GENERAL MOTORS CORP.
  57. Connect the following electrical connectors:
    • The main coil harness (4)
    • The fuel injectors (3)
    • The ETC (2)
    58. Fig 29: View Of Main Ignition Coil Wire Harness Connector & Clips
    GM757686Courtesy of GENERAL MOTORS CORP.
  58. Connect the main coil harness (2) and fuel injector electrical connectors on the left side.
    59. Fig 30: View Of Generator Cable & Nut
    GM395686Courtesy of GENERAL MOTORS CORP.
  59. Install the generator cable to the generator. Perform the following procedure:
    1. Install the generator cable.
    2. Install the generator cable nut to the terminal stud.

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

    3. Slide the boot over the terminal stud.
    60. Fig 31: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  60. Install the radiator vent inlet hose to the throttle body.
  61. Position the vent inlet hose clamp at the throttle body.
    62. Fig 32: View Of EVAP Canister Purge Solenoid & Generator Electrical Connectors & Bracket Nut
    GM1235683Courtesy of GENERAL MOTORS CORP.
  62. Install the engine wiring harness bracket and nut (2).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  63. Connect the following electrical connectors:
    • The EVAP canister purge solenoid (1)
    • The generator (3)
  64. Install the heater hoses. Refer to Heater Hose Replacement - Inlet (L18) or Heater Hose Replacement - Inlet (LB7) or Heater Hose Replacement - Inlet (LR4,LM7,LQ4) or Heater Hose Replacement - Inlet (LU3) or Heater Hose Replacement - Inlet (W/ HP2 Front) or Heater Hose Replacement - Inlet (W/ HP2 Rear) and Heater Hose Replacement - Outlet (LB7) or Heater Hose Replacement - Outlet (LR4,LM7,LQ4) or Heater Hose Replacement - Outlet (LU3) or Heater Hose Replacement - Outlet (L18) in Heating, Ventilation and Air Conditioning.
    65. Fig 33: View Of Radiator Outlet Hose (4.8L, 5.3L & 6.0L Engines)
    GM846668Courtesy of GENERAL MOTORS CORP.
  65. Open the hose clamp and install the radiator outlet hose to the water pump.
    66. Fig 34: View Of Radiator Inlet Hose
    GM846666Courtesy of GENERAL MOTORS CORP.
  66. Open the hose clamp and install the radiator inlet hose to the water pump.
  67. Install the radiator support. Refer to Radiator Support Replacement in Body Front End.
  68. Install the A/C compressor. Refer to Compressor Replacement (L18) or Compressor Replacement (LR4, LM7, and LQ4) or Compressor Replacement (LLY) in HVAC Systems - Manual.
    69. Fig 35: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  69. Remove the hood hinge bolts from the service position (2).
  70. Lower the hood to the normal position.
  71. Install the hood hinge bolts.

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

  72. Remove the fender covers.
  73. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid or Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  74. Bleed the hydraulic clutch, if equipped. Refer to Hydraulic Clutch Bleeding in Clutch.
  75. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 4.8L, 5.3L & 6.0L.
    76. IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is install in the vehicle.
  76. Test the vehicle using the following procedure:
    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 lifters 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 an coolant levels.
  77. Install the engine shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L & 6.0L W/RPO LQ4)  or Engine Sight Shield Replacement (6.0L W/RPO LQ9) .
  78. Close the hood.
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