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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1072 (Engine Mechanical - 6.6L (2 Of 5)) >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: In order to remove the engine the vehicle needs to be on a hoist. The front wheels and tires will also require removal. The vehicle will have to be supported by the frame when the tires are removed.
    Fig 1: View Of Ground Strap & Nut
    GM1823089Courtesy of GENERAL MOTORS CORP.
  1. Open the hood.
  2. Remove the ground strap from the stud.
    3. Fig 2: View Of Hood Strut Rod, Grille End Caps & Hood Hinge Bolts
    GM1711842Courtesy of GENERAL MOTORS CORP.
  3. Assemble 2 sets of the following: an M6 bolt, 2 each 19.05 mm (0.75 in) flat washers and an M6 nut.
  4. Release the retainer securing the hood strut rod to the hood strut bracket stud.
  5. Remove the air inlet grille end caps (1), lift the end cap up in order to disengage the retainers. (left side shown, right side similar).
  6. Have an assistant support the hood.
  7. Remove the hood hinge bolts (2) and set aside.
    8. Fig 3: View Of Service Piston Notch
    GM1711844Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: There is a positive stop which limits the hood from being opened too far.
  8. Raise the hood until the service position notch (1) in the upper hinge is reached.
  9. Install the 2 sets of the M6 bolts to both the left and right side service notches and tighten finger tight.
    10. NOTE: Refer to Fastener Notice .
  10. Lower the hood until the bolts rest against the lower hinge, tighten the bolts to secure the hood.

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

  11. The hood is now set in the service position.
  12. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging .
  13. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (w/Single Battery) or Battery Negative Cable Disconnection and Connection (w/Auxiliary Battery) or Battery Negative Cable Disconnection and Connection (w/Dual Batteries) .
  14. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
    15. Fig 4: View Of Engine Wire Harness Clips, A/C Pressure Cycling Switch & Surge Tank Switch
    GM1873637Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the following engine wire harness connectors:
    • Surge tank switch (1)
    • A/C pressure cycling switch (2)
    • Remove the engine wire harness clips from the wheelhouse inner panel (3).
  16. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  17. Remove the surge tank. Refer to Radiator Surge Tank Replacement (Non-HP2) .
  18. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  19. Remove both front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  20. Remove both fender wheelhouse inner panels. Refer to Front Wheelhouse Liner Replacement - Right Side (GMC) or Front Wheelhouse Liner Replacement - Right Side (Chevrolet) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) or Front Wheelhouse Liner Replacement - Left Side (GMC) .
  21. Lower the vehicle.
  22. Remove the charged air cooler pipes. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement .
  23. Remove the radiator inlet hose Radiator Inlet Hose Replacement (Non-HP2) .
  24. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (Mechanical) or Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission - Diesel) .
  25. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) .
    26. Fig 5: View Of Radiator Outlet Hose & Outlet Heater Hose
    GM674543Courtesy of GENERAL MOTORS CORP.
  26. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
  27. Disconnect the outlet heater hose from the outlet radiator hose.
  28. Remove the hose clips from the frame.
    29. Fig 6: View Of Radiator Outlet Hose At Engine
    GM674559Courtesy of GENERAL MOTORS CORP.
  29. Loosen the hose clamp and remove the radiator outlet hose from the engine.
  30. Remove the outlet heater hose pipe bolt from the bracket.
  31. Remove the outlet heater hose pipe nut.
  32. Move the heater hose and secure aside.
  33. Remove the upper radiator support. Refer to Radiator Support Replacement .
  34. Remove the radiator. Refer to Radiator Replacement (LLM) .
  35. Remove the charged air cooler. Refer to Charge Air Cooler Replacement .
  36. Remove the A/C condenser. Refer to Condenser Replacement .
    37. Fig 7: View Of A/C & Generator Electrical Connectors
    GM1369550Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the following electrical connectors:
    • Generator connector (1)
    • A/C refrigerant switch (2)
    • Dual generator harness connector (3), if equipped
    • A/C compressor clutch (4)
  38. Remove the harness clip from the A/C compressor bracket.
    39. Fig 8: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  39. Remove the battery cable to the generator.
  40. If equipped, remove the battery cable to the auxiliary generator.
  41. Remove the battery cable harness clip from the bracket.
  42. Remove the battery cable junction block bolt (1) from the power steering pump.
  43. Move and secure the battery cables out of the way.
    44. Fig 9: View Of Main Engine Electrical Harness Connector Latches & Clips
    GM1873022Courtesy of GENERAL MOTORS CORP.
  44. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  45. Open the harness clip (2).
  46. Remove the main engine electrical harness connectors.
    47. Fig 10: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  47. Disconnect the fuel lines at the engine. Refer to Metal Collar Quick Connect Fitting Service .
  48. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
  49. Secure the fuel lines out of the way.
  50. Remove the drive belt. Refer to Drive Belt Replacement .
  51. Disconnect the suction hose from the accumulator. The compressor end can remain on the compressor.
  52. Remove the A/C compressor bolts.
  53. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
  54. Move the wiring harness to the left side of the vehicle and secure out to the way.
    55. Fig 11: View Of Power Steering Pump Front Bracket & Bolts
    GM698146Courtesy of GENERAL MOTORS CORP.
  55. Remove the bolts retaining the power steering pump front bracket to the power steering pump and the air conditioner compressor mounting bracket.
  56. Remove the air conditioning and power steering pump mounting bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement .

    When the battery cables are removed from the engine the power steering pump can be removed further out of the way.

    57. Fig 12: View Of Right Side Idler & Center Idler Pulley Bolts
    GM1409331Courtesy of GENERAL MOTORS CORP.
  57. Remove the right idler pulley bolt (1) and pulley.
    58. Fig 13: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  58. Remove the generator mounting bracket and secure to the side.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
    59. Fig 14: Identifying Heater Hose To Heater Core Fittings
    GM362171Courtesy of GENERAL MOTORS CORP.
  59. Use the J 43181  in order to disconnect the inlet heater hose from the heater core inlet. See Special Tools .
  60. Remove the bolt and the ground wires at the rear of the left cylinder head.
  61. Raise the vehicle.
  62. Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) .
  63. Remove the engine shield from the vehicle, if equipped. Refer to Engine Shield Replacement .
    64. Fig 15: View Of Engine Wiring Harness Ground Wire & Battery Negative Cable (Left Side Of Engine)
    GM674628Courtesy of GENERAL MOTORS CORP.
  64. Remove the bolt for the battery negative cable and the engine wiring harness ground wire from the left side of the engine.
    65. Fig 16: View Of Battery Cable Bracket Bolts At Lower Crankcase
    GM673564Courtesy of GENERAL MOTORS CORP.
  65. Remove the bolts holding the battery cable channel retainer to the lower crankcase.
    66. Fig 17: View Of Engine Coolant Heater Cord
    GM674570Courtesy of GENERAL MOTORS CORP.
  66. Disconnect the cord for the engine coolant heater.
  67. Remove the starter. Refer to Starter Motor Replacement (6.6L) .
    68. Fig 18: View Of Battery Cable Bracket Nut
    GM673568Courtesy of GENERAL MOTORS CORP.
  68. Remove the nut holding the battery cable bracket to the right side of the lower crankcase.
    69. Fig 19: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness Ground Wires Bolt (Right Side Of Engine)
    GM674624Courtesy of GENERAL MOTORS CORP.
  69. Remove the bolt holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.
  70. Move and secure the battery cables out of the way.
    71. Fig 20: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  71. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  72. Drain the engine oil.
  73. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
  74. If vehicle is 4-wheel drive (4WD) remove the lower oil pan. Refer to Lower Oil Pan Replacement .
    75. Fig 21: View Of Torque Convertor Bolt
    GM702519Courtesy of GENERAL MOTORS CORP.
  75. If equipped with an automatic transmission, mark the flywheel and torque converter relationship for assembly purposes.
  76. Remove the torque convertor bolts through the starter opening.
    77. Fig 22: View Of Transmission Oil Cooler Lines, Bracket & Bolt
    GM686706Courtesy of GENERAL MOTORS CORP.
  77. If equipped with an automatic transmission, remove the transmission oil line clip nut.
    78. Fig 23: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  78. If equipped with an automatic transmission, remove the nuts retaining transmission fluid fill tube bracket.
    79. Fig 24: View of Transmission To Engine Stud & Bolts
    GM686685Courtesy of GENERAL MOTORS CORP.
  79. Remove the transmission to engine stud and bolts (automatic transmission shown). Note the location of the studs and any brackets attached to the studs.
    80. Fig 25: View Of Engine Mount To Engine Mount Frame Bracket
    GM657625Courtesy of GENERAL MOTORS CORP.
  80. Lower the vehicle to work through the wheelhouse opening.
  81. Remove the engine mount to frame bracket bolts (left side shown).
  82. Lower the vehicle.
    83. Fig 26: View Of J 36857 & Bolt At Rear Of Left Cylinder Head
    GM674699Courtesy of GENERAL MOTORS CORP.
  83. Install the J 36857  (1) to the rear of the left cylinder head with a suitable bolt. See Special Tools .
    84. Fig 27: View Of J 36857 & Bolt At Front Of Right Cylinder Head
    GM674703Courtesy of GENERAL MOTORS CORP.
  84. Install the J 36857  (1) to the front of the right cylinder head with a suitable bolt. See Special Tools .
  85. Install a suitable lifting device. The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.
    86. Fig 28: Identifying Engine Mount Frame Bracket Through Bolt
    GM1602047Courtesy of GENERAL MOTORS CORP.
  86. Raise the vehicle off of the engine mounts.
  87. Remove the left and right engine mount frame brackets.
  88. Remove the engine from the vehicle.
  89. In order to secure the engine to an engine stand remove the following and follow the special procedures:
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