LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1401 (Engine Mechanical - 6.6L (2 Of 5)) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of J 36857 & Bolt At Rear Of Left Cylinder Head
    GM674699Courtesy of GENERAL MOTORS CORP.
  1. Install the J 36857  (1) to the rear of the left cylinder head with a suitable bolt. See Special Tools .
    2. Fig 2: View Of J 36857 & Bolt At Front Of Right Cylinder Head
    GM674703Courtesy of GENERAL MOTORS CORP.
  2. Install the J 36857  (1) to the front of the right cylinder head with a suitable bolt. See Special Tools .
  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. NOTE: Do not draw the engine to the transmission using the transmission bolts. If everything is aligned properly the engine and transmission will come together easily.
  7. Loosely install 2 transmission to engine bolts.
    8. Fig 3: Identifying Engine Mount Frame Bracket Through Bolt
    GM1602047Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  8. Install the left and right side engine mount frame brackets, if equipped.

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

    9. Fig 4: View Of Engine Mount To Engine Mount Frame Bracket
    GM657625Courtesy 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. Remove the J 36857  from the cylinder heads. See Special Tools .
  11. Raise the vehicle.
    12. Fig 5: View of Transmission To Engine Stud & Bolts
    GM686685Courtesy of GENERAL MOTORS CORP.
  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 6: View Of Torque Convertor Bolt
    GM702519Courtesy 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 7: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy 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. If the vehicle is 4WD equipped, install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) or Differential Carrier Assembly Replacement (2500 4WD) .
    16. Fig 8: View Of Transmission Oil Cooler Lines, Bracket & Bolt
    GM686706Courtesy of GENERAL MOTORS CORP.
  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 9: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy 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. Lower the vehicle to work through the front fender wheelhouse openings.
    20. Fig 10: View Of Engine Wiring Harness Ground Wire & Battery Negative Cable (Left Side Of Engine)
    GM674628Courtesy of GENERAL MOTORS CORP.
  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 11: View Of Battery Cable Bracket Bolts At Lower Crankcase
    GM673564Courtesy 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 12: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness Ground Wires Bolt (Right Side Of Engine)
    GM674624Courtesy 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 13: View Of Battery Cable Bracket Nut
    GM673568Courtesy 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. Install the starter. Refer to Starter Replacement (6.6L) .
    25. Fig 14: View Of Engine Coolant Heater Cord
    GM674570Courtesy of GENERAL MOTORS CORP.
  25. Connect the cord for the engine coolant heater.
  26. Install the engine oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) .
  27. Install the engine shield. Refer to Engine Shield Replacement .
  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. Install the upper exhaust gas recirculation cooling pipe. Refer to Exhaust Gas Recirculation Cooling Pipe Replacement - Upper (LMM) .
  31. Install the generator bracket. Refer to Generator Bracket Replacement (6.6L) .
    32. Fig 15: View Of Right Side Idler & Center Idler Pulley Bolts
    GM1409331Courtesy of GENERAL MOTORS CORP.
  32. Install the right idler pulley and bolt (1).

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

  33. Install the air conditioning compressor and the power steering pump mounting bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement .
  34. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LLY/LMM) .
  35. Position the engine wiring harness on the engine.
  36. Install the A/C suction hose to the accumulator.
  37. Install the drive belt. Refer to Drive Belt Replacement .
    38. Fig 16: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  38. Connect the fuel hoses at the engine.
  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. Fig 17: View Of Main Engine Electrical Harness Connector Latches & Clips
    GM1873022Courtesy of GENERAL MOTORS CORP.
  40. Connect the main engine electrical harness connectors.
  41. Push down on the latches (1) in order to connect the connectors.
  42. Close the harness clip (2).
    43. Fig 18: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy 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. 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 upper air intake tube.
    47. Fig 19: View Of A/C & Generator Electrical Connectors
    GM1369550Courtesy of GENERAL MOTORS CORP.
  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. Install the harness clip to the oil fill pipe.
  49. Install the radiator support. Refer to Radiator Support Replacement .
  50. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Diesel) .
  51. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) .
  52. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) .
    53. Fig 20: View Of Inlet Heater Hose
    GM651356Courtesy of GENERAL MOTORS CORP.
  53. 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.

  54. Install the outlet heater hose to the outlet radiator hose.
  55. Install the bolt retaining the heater hose pipe to the bracket.

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

  56. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Diesel) .
  57. Install the charged air cooler pipes and hoses to the turbocharger and the charged air cooler. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement .
  58. Install both fender wheelhouse inner panels (1). Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) or Front Wheelhouse Liner Replacement - Right Side (GMC) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) or Front Wheelhouse Liner Replacement - Left Side (GMC) .
  59. Install both front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  60. Install the surge tank. Refer to Radiator Surge Tank Replacement (Non-HP2) .
  61. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
    62. Fig 21: View Of Engine Wire Harness Clips, A/C Pressure Cycling Switch & Surge Tank Switch
    GM1873637Courtesy of GENERAL MOTORS CORP.
  62. Connect the following engine wire harness connectors:
    • Install the engine wire harness clips to the wheelhouse inner panel (3).
    • A/C pressure cycling switch (2)
    • Surge tank switch (1)
  63. Connect the batteries negative cables. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) , Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) or Battery Negative Cable Disconnection and Connection (With Dual Batteries) .
  64. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
  65. Prelube the engine. Refer to Engine Prelubing .
  66. Operate the engine, inspect for coolant, oil, fuel, and exhaust leaks.
  67. Inspect for proper oil pressure.
  68. Inspect for proper engine operation.
    69. Fig 22: View Of Service Piston Notch
    GM1711844Courtesy of GENERAL MOTORS CORP.
    NOTE: There is a positive stop which limits the hood from being opened too far.
  69. With the aid of the assistant raise the hood slightly until the hood hinge bolts can be removed from the service position notch (1).
    70. Fig 23: View Of Hood Strut Rod, Grille End Caps & Hood Hinge Bolts
    GM1711842Courtesy of GENERAL MOTORS CORP.
  70. With the aid of an assistant lower the hood and install the hood hinge bolts (2) to the hood hinges.

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

  71. Install the air inlet grille end caps (1), push down the end cap in order to engage the retainers. (left side shown, right side similar).
    72. Fig 24: View Of Ground Strap & Nut
    GM1823089Courtesy of GENERAL MOTORS CORP.
  72. Install the ground strap to the hood stud.
  73. Install the ground strap nut at the hood stud.

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

  74. Close the hood.
  75. Road test the vehicle for normal operation.
  76. Inspect for coolant, oil, or exhaust leaks.
scientia non olet · About LEMON Manuals