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Home >> GMC >> 2005 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 186 (Engine Mechanical - 3.6L (Ly7) (3 Of 6)) >> Repair Instructions (On-Vehicle - Part 2 And Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions - Part 2 >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2005 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left and to Engine Mount Bracket Replacement - Right (w/RWD) or Engine Mount Bracket Replacement - Right (W/AWD) .
  2. Use a floor crane in order to install the engine to the frame.
  3. Install the ECM with the ECM bracket. Refer to Engine Control Module (ECM) Replacement in Engine Controls - 3.6L (LY7).
  4. Install the water outlet. Refer to Starter Motor Installation .
  5. Install the block heater. Refer to Coolant Heater Replacement (LH2 (KO5)) or Coolant Heater Replacement (LH2 (KA3)) or Coolant Heater Replacement (LY7, KO5) in Engine Cooling.
  6. Install the flywheel. Refer to Engine Flywheel Installation .
  7. Install the intake manifold. Refer to Intake Manifold Installation .
  8. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation .
  9. Install the right exhaust manifold. Refer to Exhaust Manifold Installation - Right (RWD) or Exhaust Manifold Installation - Right (AWD) .
  10. Install the oil filter adapter. Refer to Oil Filter Adapter Installation .
  11. Install the left exhaust manifold. Refer to Exhaust Manifold Installation - Left .
  12. Install the oil level indicator. Refer to Oil Level Indicator and Tube Installation .
  13. Install the generator and the generator bracket. Refer to Generator Installation .
  14. Install the power steering pump. Refer to Power Steering Pump Installation .
  15. Install the power steering reservoir to the engine. Refer to Remote Power Steering Fluid Reservoir Replacement (LH2) or Remote Power Steering Fluid Reservoir Replacement (LY7) in Power Steering System.
  16. Install the A/C compressor. Refer to Air Conditioning (A/C) Compressor Installation .
  17. Install the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Installation - Left .
  18. Install the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Installation - Right .
  19. Install the drive belts. Refer to Drive Belt Replacement - Generator and Water Pump and to Drive Belt Replacement - Power Steering and Air Conditioning .
  20. Install the bolts that secure the transmission to the engine and the flywheel to the torque convertor. Refer to Transmission Replacement (w/RPO LY7) or Transmission Replacement (w/RPO LH2) in Automatic Transmission - 5L40-E/5L50-E.
  21. Install the starter motor. Refer to Starter Motor Replacement (LY7) or Starter Motor Replacement (LH2) in Engine Electrical.
  22. Remove EN 46114  from the engine. See Special Tools . Refer to Engine Support Fixture .
  23. Install the CRFM with the radiator hoses to the frame.
  24. Connect the power steering cooler hoses to the CRFM. Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
  25. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe. Refer to Radiator Hose Replacement - Inlet (LY7) or Radiator Hose Replacement - Inlet (LH2) in Engine Cooling.
  26. Install the transmission oil cooler pipes to the engine, radiator and the transmission. Refer to Transmission Fluid Cooler Pipe Replacement - Front and to Transmission Fluid Cooler Pipe Replacement - Rear (w/RWD) or Transmission Fluid Cooler Pipe Replacement - Rear (w/AWD) in Automatic Transmission - 5L40-E/5L50-E.
  27. Install the engine wiring harness and related components. Refer to Engine Wiring Harness Assembly Installation .
    28. Fig 1: View Of HO2S Connector Bracket
    GM1343618Courtesy of GENERAL MOTORS CORP.
  28. Install the HO2S connector bracket (1) to the left cylinder head.
  29. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Thermostat Housing Removal .
  30. Install the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left (LY7) and to Catalytic Converter Replacement - Right (LY7) in Engine Exhaust.
  31. Install the fuel lines to the fuel rail and the EVAP purge solenoid. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 3.6L (LY7).
    32. Fig 2: View Of Upper ECM Connector
    GM1343429Courtesy of GENERAL MOTORS CORP.
  32. Connect the ECM chassis side electrical connector. Refer to Engine Control Module (ECM) Replacement in Engine Controls - 3.6L (LY7).
    33. IMPORTANT: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.
  33. With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.
    34. Fig 3: Identifying Frame Mounting Bolts
    GM822362Courtesy of GENERAL MOTORS CORP.
  34. Install the front frame bolts (2). Refer to Frame Replacement - Front in Frame and Underbody.
  35. Install the transmission support to underbody bolts. Refer to Transmission Support Replacement in Frame and Underbody.
  36. Remove the powertrain lift/support table.
    37. Fig 4: View Of Shock Module & Upper Mounting Bolts
    GM742957Courtesy of GENERAL MOTORS CORP.
  37. Install the upper mounting bolts to the right and left shock module. Refer to Shock Module Replacement in Front Suspension.
  38. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
  39. Install the headlamp leveling sensors. Refer to Headlamp Leveling Sensor Replacement - Front in Lighting Systems.
    40. Fig 5: View Of Transmission Shift Linkage
    GM785879Courtesy of GENERAL MOTORS CORP.
  40. Connect the transmission shift linkage to the transmission. Refer to Shift Control Linkage Replacement (RWD) or Shift Control Linkage Replacement (AWD) in Automatic Transmission - 5L40-E/5L50-E.
  41. Connect electrical connector to the low oil level sensor.
    42. Fig 6: Identifying Frame Mounting Nuts
    GM785352Courtesy of GENERAL MOTORS CORP.
  42. Install the lower engine mount nuts. Refer to Engine Mount Replacement - Left and to Engine Mount Replacement - Right (W/RWD) or Engine Mount Replacement - Right (W/AWD) in Engine Mechanical - 3.6L (LY7).
  43. Install the lower intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement - Lower in Steering Wheel and Column.
  44. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  45. Install the front brake pipes and retainers to the underbody.
  46. Connect the rear brake pipes to the BPMV. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System.
  47. Connect the side air baffles to the radiator.
  48. Install the washer bottle bracket. Refer to Solvent Container, Pump, Level Sensor Replacement - Windshield Washer in Wipers/Washer Systems.
  49. Install the air deflector. Refer to Air Deflector Replacement - Front in Body Front End.
  50. Install the propeller shaft. Refer to Propeller Shaft Replacement - Rear (AWD) or Propeller Shaft Replacement - Rear (RWD) in Propeller Shaft.
  51. Install the muffler assembly. Refer to Exhaust System Replacement in Engine Exhaust.
    52. Fig 7: Removing & Installing Master Cylinder
    GM420706Courtesy of GENERAL MOTORS CORP.
  52. Install the master cylinder. Refer to Master Cylinder Replacement in Hydraulic Brakes.
    53. Fig 8: View Of Longitudinal Rail Engine Harness Electrical Connector
    GM1348203Courtesy of GENERAL MOTORS CORP.
  53. Connect the engine harness electrical connector at the longitudinal rail.
    54. Fig 9: View Of Ground Bolt & Wire
    GM1348282Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  54. Install the ground wire and bolt to the longitudinal rail.

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

  55. Connect the wiring harness to the transmission control module. Refer to Transmission Control Module (TCM) Replacement in Automatic Transmission - 5L40-E/5L50-E.
    56. Fig 10: View Of Engine Module Wiring Harness Connectors
    GM1348235Courtesy of GENERAL MOTORS CORP.
  56. Connect the engine module wiring harness connectors (1-3) to the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
  57. Connect and lock the I/P electrical connector to the engine at the rear of the left Bank 2 cylinder head.
  58. Connect the mass air flow sensor electrical connector.
  59. Connect the electrical connector for the brake fluid level switch from the master cylinder.
    60. Fig 11: View Of Vacuum Check Valve & Brake Booster
    GM923830Courtesy of GENERAL MOTORS CORP.
  60. Connect the brake booster vacuum hose (1) to the brake booster (2).
  61. Install the radiator support brackets. Refer to Radiator Support Bracket Replacement in Engine Cooling.
    62. Fig 12: Top Of Engine View
    GM1348201Courtesy of GENERAL MOTORS CORP.
  62. Connect the purge line (3) to the purge solenoid.
  63. Connect the fuel pipe (2) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 3.6L (LY7).
  64. Connect the heater hoses to the heater core. Refer to Heater Hose Replacement - Inlet (LY7) or Heater Hose Replacement - Inlet (LH2) and to Heater Hose Replacement - Outlet (LY7) or Heater Hose Replacement - Outlet (LH2) in Heating, Ventilation and Air Conditioning.
  65. Install the air inlet duct.
  66. Position and secure the surge tank inlet hose to the vehicle.
  67. Connect the surge tank inlet hose to the water outlet housing and to the radiator. Refer to Surge Tank Hose/Pipe Replacement - Outlet (LY7) or Surge Tank Hose/Pipe Replacement - Outlet (LH2) in Engine Cooling.
  68. Connect the outlet hose to the surge tank. Refer to Surge Tank Hose/Pipe Replacement - Inlet (LY7) or Surge Tank Hose/Pipe Replacement - Inlet (LH2) in Engine Cooling.
  69. Connect the electrical connector for the air conditioning pressure switch and the liquid line to the evaporator. Refer to Liquid Line Replacement (LY7) or Liquid Line Replacement (LH2) in Heating, Ventilation and Air Conditioning.
  70. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower. Refer to Suction Hose Replacement (LY7) or Suction Hose Replacement (LH2) in Heating, Ventilation and Air Conditioning.
    71. Fig 13: View Of Air Inlet Duct
    GM1305320Courtesy of GENERAL MOTORS CORP.
  71. Install the air cleaner duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.6L (LY7).
    72. Fig 14: View Of Cooling Fan Wiring Harness & Electrical Connectors
    GM1348241Courtesy of GENERAL MOTORS CORP.
  72. Install the cooling fan wiring harnesses (1, 4) to the fan shroud.
  73. Install the cooling fan electrical connectors (2, 3).
  74. Install the wiper module. Refer to Wiper Motor Module Replacement .
  75. Install the battery. Refer to Battery Replacement in Engine Electrical.
  76. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
    77. Fig 15: View Of Battery Positive & Negative Cables
    GM772424Courtesy of GENERAL MOTORS CORP.
  77. Connect the positive cable to the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement (LY7) or Battery Positive Cable Replacement (LH2) in Engine Electrical.
  78. Connect the negative cable from the battery and the body. Refer to Battery Negative Cable Replacement (LY7) or Battery Negative Cable Replacement (LH2) in Engine Electrical.
    79. Fig 16: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
  79. Remove J 42640  from the steering column. See Special Tools .
  80. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  81. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  82. Bleed the brake rear circuits. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
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