LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 148 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  1. Install the J 42451-1  to the engine.

    Tighten 

    Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).

  2. Install an engine hoist to the J 42451-1  .
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
  6. Install the left and right engine mount-to-engine mount bracket bolts.

    Tighten 

    Tighten the engine mount-to-engine mount bracket 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. Remove the J 42451-1  from the engine.
  11. Install the left and right exhaust manifolds.
  12. Install the intake manifold. Refer to Intake Manifold Installation .
    Fig 1: Installing Left & Right Engine Mount-To-Engine Mount Bracket Bolts
    G02078649Courtesy of GENERAL MOTORS CORP.
  13. Install the ignition coil(s) and the spark plug wire(s). Refer to IGNITION COIL .
  14. Raise the vehicle.
    Fig 2: Installing Ignition Coil(s) & Spark Plug Wire(s)
    G02078650Courtesy of GENERAL MOTORS CORP.
  15. Remove the J 21366  from the transmission
  16. Install the automatic transmission bolt/studs, if equipped.
    Fig 3: Removing Automatic Transmission Bolt/Studs
    G02078651Courtesy of GENERAL MOTORS CORP.
  17. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.

    Tighten 

    Tighten the transmission converter bolts to 33 N.m (24 lb ft).

    Fig 4: Installing Transmission Converter Bolts (4L80-E)
    G02078652Courtesy of GENERAL MOTORS CORP.
  18. If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side.

    Tighten 

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

    Fig 5: Installing Transmission Bolt & Stud (4L60-E)
    G02078653Courtesy of GENERAL MOTORS CORP.
  19. Install the automatic transmission oil level indicator tube, if equipped.
    Fig 6: Installing Automatic Transmission Oil Level Indicator Tube
    G02078654Courtesy of GENERAL MOTORS CORP.
  20. Install the automatic transmission oil level indicator tube nut, if equipped.

    Tighten 

    Tighten the automatic transmission oil level indicator tube nut to 18 N.m (13 lb ft).

    Fig 7: Installing Automatic Transmission Oil Level Indicator Tube Nut
    G02078655Courtesy of GENERAL MOTORS CORP.
  21. Install the torque converter bolts, if equipped.

    Tighten 

    • If equipped with the 4L60-E, tighten the torque converter bolts to 63 N.m (37 lb ft).
    • If equipped with the 4L80-E, tighten the torque converter bolts to 60 N.m (44 lb ft).
      Fig 8: Installing Torque Converter Bolts
      G02078656Courtesy of GENERAL MOTORS CORP.
  22. Install the positive battery cable clip and bolt.

    Tighten 

    Tighten the positive battery cable clip bolt to 9 N.m (80 lb in).

    Fig 9: Installing Positive Battery Cable Clip & Bolt
    G02078657Courtesy of GENERAL MOTORS CORP.
  23. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (4.3L) or CATALYTIC CONVERTER REPLACEMENT (DUAL EXHAUST - RIGHT) or CATALYTIC CONVERTER REPLACEMENT (DUAL EXHAUST - LEFT) .
  24. Install the starter motor. Refer to STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L) or STARTER MOTOR REPLACEMENT (4.3L) .
  25. Lower the vehicle.
  26. Install the vacuum brake booster hose.
    Fig 10: Installing Vacuum Brake Booster Hose
    G02078658Courtesy of GENERAL MOTORS CORP.
  27. Position the generator bracket to the front of the engine.
  28. Install the generator bracket bolts until snug.
  29. Install the rear power steering pump-to-engine block bolt until snug.

    Tighten 

    • Tighten the rear power steering pump bolt to 50 N.m (37 lb ft).
    • Tighten the generator bracket bolts to 50 N.m (37 lb ft).
  30. Route the engine wiring harness to the lower engine area.
  31. Raise the vehicle.
    Fig 11: Installing Generator Bracket & Bolts
    G02078659Courtesy of GENERAL MOTORS CORP.
  32. Slide the channel pin into the oil pan tab.
  33. Install the battery cable channel bolt.

    Tighten 

    Tighten the battery cable channel bolt to 12 N.m (106 lb in).

    Fig 12: Installing Battery Cable Channel Bolt
    G02078660Courtesy of GENERAL MOTORS CORP.
  34. Connect the following electrical connectors:
    • The CKP sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
  35. Lower the vehicle.
  36. Connect the fuel pipes.
    Fig 13: Connecting CKP Sensor, Engine Oil Level Sensor & Coolant Heater Connectors
    G02078661Courtesy of GENERAL MOTORS CORP.
  37. Install the EVAP purge solenoid vent tube to the solenoid (1).
  38. Install the EVAP tube end (3) to the vapor pipe.
    Fig 14: Installing EVAP Purge Solenoid Vent Tube
    G02078662Courtesy of GENERAL MOTORS CORP.
  39. Clip all of the engine wiring harness clips to their correct location.
  40. Connect the following electrical connectors:
    • Oil pressure sensor (1)
    • CMP sensor (2)
  41. Position the harness ground and the engine ground strap to the block.
  42. Install the harness ground bolt at the left rear of the engine block.
  43. Position the harness ground, and auxiliary negative battery cable (if equipped) to the block.
  44. Install the harness ground bolt at the right rear of the engine block.

    Tighten 

    Tighten the harness ground bolts at the rear of the block to 16 N.m (12 lb ft).

    Fig 15: Connecting Oil Pressure Sensor & CMP Sensor Connectors
    G02078663Courtesy of GENERAL MOTORS CORP.
  45. Connect the following electrical connectors:
    • Coolant temperature sensor (1)
    • Electronic variable orifice switch (2)
  46. Position the harness ground and negative battery cable to the block.
  47. Install the harness ground bolt.

    Tighten 

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

    Fig 16: Connecting Coolant Temperature Sensor & Electronic Variable Orifice Switch
    G02078664Courtesy of GENERAL MOTORS CORP.
  48. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    Fig 17: Connecting MAP Sensor & Knock Sensor Electrical Connectors
    G02078665Courtesy of GENERAL MOTORS CORP.
  49. Connect the TP sensor and IAC valve electrical connectors.
    Fig 18: Connecting TP Sensor & IAC Valve Electrical Connectors
    G02078666Courtesy of GENERAL MOTORS CORP.
  50. Connect the following electrical connectors:
    • Main coil harness (1)
    • Fuel injectors (2)
    • ETC (3)
    • EGR valve (4), if equipped
      Fig 19: Connecting Main Coil Harness, Fuel Injectors, ETC & EGR Valve Connectors
      G02078667Courtesy of GENERAL MOTORS CORP.
  51. Connect the main coil harness (2) and fuel injector electrical connectors on the left side.
    Fig 20: Connecting Main Coil Harness & Fuel Injector Electrical Connectors
    G02078668Courtesy of GENERAL MOTORS CORP.
  52. Install the generator cable to the generator, perform the following:
    • Install the generator cable.
    • Install the generator cable nut to the terminal stud.

      Tighten 

      Tighten the generator output terminal nut to 9 N.m (80 lb in).

    • Slide the boot over the terminal stud.
      Fig 21: Installing Generator Cable
      G02078669Courtesy of GENERAL MOTORS CORP.
  53. Install the radiator vent inlet hose to the throttle body.
  54. Position the vent inlet hose clamp at the throttle body.
    Fig 22: Installing Radiator Vent Inlet Hose
    G02078670Courtesy of GENERAL MOTORS CORP.
  55. Install the engine wiring harness bracket and nut (2).

    Tighten 

    Tighten the engine wiring harness bracket nut to 5 N.m (44 lb in).

  56. Connect the following electrical connectors:
    • EVAP canister purge solenoid (1)
    • Generator (3)
    Fig 23: Installing Engine Wiring Harness Bracket & Nut, EVAP Canister Purge Solenoid & Generator Connectors
    G02078671Courtesy of GENERAL MOTORS CORP.
    WARNING: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
    CAUTION: In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
  57. Install a NEW accelerator control cable (if required).
  58. Install the cruise control cable clip to the sight shield retainer, if equipped.
    Fig 24: Installing Cruise Control Cable Clip
    G02078672Courtesy of GENERAL MOTORS CORP.
  59. Install the cruise control cable to the bracket, if equipped.
  60. Snap the cruise control cable to the throttle body lever, if equipped.
  61. Install the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET and HEATER HOSE REPLACEMENT - OUTLET .
    Fig 25: Installing Cruise Control Cable
    G02078673Courtesy of GENERAL MOTORS CORP.
  62. Install the radiator outlet hose to the water pump.
  63. Position the radiator outlet hose clamp at the water pump.
    Fig 26: Installing Radiator Outlet Hose
    G02078674Courtesy of GENERAL MOTORS CORP.
  64. Install the radiator inlet hose to the water pump.
  65. Position the radiator inlet hose clamp at the water pump.
    Fig 27: Installing Radiator Inlet Hose
    G02078675Courtesy of GENERAL MOTORS CORP.
  66. Install the radiator supports. Refer to Radiator Support Replacement in Body Front End .
  67. Install the A/C compressor. Refer to COMPRESSOR REPLACEMENT (4.8L, 5.3L, 6.0L) or COMPRESSOR REPLACEMENT (4.3L) .
  68. Fill the crankcase with the proper quantity and grade of engine oil.
  69. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE .

    Important:  After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

    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 1000 RPM until the engine has reached normal operating temperature.
    7. Listen for sticking lifter 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 and coolant levels.
  70. Close the hood.
scientia non olet · About LEMON Manuals