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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 >> Removal Procedure

Removal 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.
  1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim .
  2. Remove the air conditioning (AC) compressor. Refer to COMPRESSOR REPLACEMENT (4.8L, 5.3L, 6.0L) or COMPRESSOR REPLACEMENT (4.3L) .
  3. Remove the radiator supports. Refer to Radiator Support Replacement in Body Front End .
  4. Reposition the radiator inlet hose clamp at the water pump.
  5. Remove the radiator inlet hose from the water pump.
    Fig 1: Removing Radiator Inlet Hose
    G02078621Courtesy of GENERAL MOTORS CORP.
  6. Reposition the radiator outlet hose clamp at the water pump.
  7. Remove the radiator outlet hose from the water pump.
  8. Remove the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET and HEATER HOSE REPLACEMENT - OUTLET .
    Fig 2: Removing Radiator Outlet Hose
    G02078622Courtesy of GENERAL MOTORS CORP.
  9. Unsnap the cruise control cable from the throttle body lever, if equipped.
  10. Remove the cruise control cable from the bracket, if equipped.
    Fig 3: Removing Cruise Control Cable
    G02078623Courtesy of GENERAL MOTORS CORP.
  11. Remove the cruise control cable clip from the sight shield retainer, if equipped.
    Fig 4: Removing Cruise Control Cable Clip
    G02078624Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the accelerator control cable from the throttle body lever, if required.
  13. Remove the accelerator control cable from the bracket, if required.
    Fig 5: Removing Accelerator Control Cable
    G02078625Courtesy of GENERAL MOTORS CORP.
  14. Remove the accelerator control cable from the sight shield retainer, if required.
  15. Remove the upper intake manifold sight shield retainer bolts and retainer, if necessary.
    Fig 6: Removing Upper Intake Manifold Sight Shield Retainer Bolts & Retainer
    G02078626Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the following electrical connectors:
    • Evaporative emissions (EVAP) canister purge solenoid (1)
    • Generator (3)
  17. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.
    Fig 7: Disconnecting Electrical Connectors & Removing Harness Bracket Nut
    G02078627Courtesy of GENERAL MOTORS CORP.
  18. Reposition the vent inlet hose clamp at the throttle body.
  19. Remove the radiator vent inlet hose from the throttle body.
    Fig 8: Removing Radiator Vent Inlet Hose
    G02078628Courtesy of GENERAL MOTORS CORP.
  20. Remove the generator cable from the generator, perform the following:
    • Slide the boot down revealing the terminal stud.
    • Remove the generator cable nut from the terminal stud.
    • Remove the generator cable.
      Fig 9: Removing Generator Cable
      G02078629Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the main coil harness (2) and fuel injector electrical connectors on the left side.
    Fig 10: Disconnecting Main Coil Harness On Left Side
    G02078630Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the following electrical connectors:
    • Main coil harness (1)
    • Fuel injectors (2)
    • Electronic throttle control (ETC) (3)
    • Exhaust gas recirculation (EGR) valve (4), if equipped
      Fig 11: Disconnecting Main Coil Harness, Fuel Injectors, ETC & EGR Valve
      G02078631Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
    Fig 12: Disconnecting TP Sensor & IAC Valve Electrical Connectors
    G02078632Courtesy of GENERAL MOTORS CORP.
  24. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.
    Fig 13: Disconnecting MAP Sensor & Knock Sensor Electrical Connectors
    G02078633Courtesy of GENERAL MOTORS CORP.
  25. Remove the harness ground bolt.
  26. Reposition the harness ground and negative battery cable from the block.
  27. Disconnect the following electrical connectors:
    • Coolant temperature sensor (1)
    • Electronic variable orifice switch (2)
      Fig 14: Disconnecting Coolant Temperature Sensor & Electronic Variable Orifice Switch
      G02078634Courtesy of GENERAL MOTORS CORP.
  28. Remove the harness ground bolt at the right rear of the engine block.
  29. Reposition the harness ground, and auxiliary negative battery cable, (if equipped) from the block.
  30. Remove the harness ground bolt at the left rear of the engine block.
  31. Reposition the harness ground, and engine ground strap from the block.
  32. Disconnect the following electrical connectors:
    • Oil pressure sensor (1)
    • Camshaft position (CMP) sensor (2)
  33. Unclip all of the engine harness clips from the engine.
    Fig 15: Disconnecting Oil Pressure Sensor & CMP Sensor
    G02078635Courtesy of GENERAL MOTORS CORP.
  34. Remove the EVAP purge solenoid vent tube, perform the following:
    • Remove the EVAP tube end (2) from the solenoid (1).
    • Remove the EVAP tube end (3) from the vapor pipe.
  35. Disconnect the fuel pipes. Refer to QUICK CONNECT FITTINGS .
  36. Raise the vehicle.
    Fig 16: Removing EVAP Purge Solenoid Vent Tube
    G02078636Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the following electrical connectors:
    • The crankshaft position (CKP) sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
      Fig 17: Disconnecting CKP Sensor, Engine Oil Level Sensor & Coolant Heater Connectors
      G02078637Courtesy of GENERAL MOTORS CORP.
  38. Remove the battery cable channel bolt.
  39. Slide the channel pin out of the oil pan tab.
  40. Gather all branches of the engine wiring harness and reposition off to the side.
  41. Lower the vehicle.
    Fig 18: Removing Battery Cable Channel Bolt
    G02078638Courtesy of GENERAL MOTORS CORP.
  42. Remove the rear power steering pump-to-engine block bolt.
  43. Remove the generator bracket mounting bolts.
  44. Position the bracket aside.
    Fig 19: Removing Generator Bracket Mounting Bolts & Bracket
    G02078639Courtesy of GENERAL MOTORS CORP.
  45. Remove the vacuum brake booster hose.
  46. Remove the ignition coil(s) (as required) for the proper fit of the J 42451-1  before lifting the engine. Refer to IGNITION COIL .
  47. Remove the left and right exhaust manifolds.
  48. Remove the intake manifold.
    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.
  49. Install the J 42451-1  to the cylinder heads.

    Tighten 

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

    Fig 20: Removing Vacuum Brake Booster Hose
    G02078640Courtesy of GENERAL MOTORS CORP.
  50. Remove the left and right engine mount-to-engine mount bracket bolts.
  51. Raise and suitably support the vehicle.
  52. Drain the engine oil.
  53. Remove the starter motor. Refer to STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L) or STARTER MOTOR REPLACEMENT (4.3L) .
  54. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (4.3L) or CATALYTIC CONVERTER REPLACEMENT (DUAL EXHAUST - RIGHT) or CATALYTIC CONVERTER REPLACEMENT (DUAL EXHAUST - LEFT) .
    Fig 21: Removing Left & Right Engine Mount-To-Engine Mount Bracket Bolts
    G02078641Courtesy of GENERAL MOTORS CORP.
  55. Remove the positive battery cable clip bolt and clip.
    Fig 22: Removing Positive Battery Cable Clip Bolt & Clip
    G02078642Courtesy of GENERAL MOTORS CORP.
  56. Remove the torque converter bolts.
    Fig 23: Removing Torque Converter Bolts
    G02078643Courtesy of GENERAL MOTORS CORP.
  57. Remove the transmission oil level indicator tube nut.
    Fig 24: Removing Transmission Oil Level Indicator Tube Nut
    G02078644Courtesy of GENERAL MOTORS CORP.
  58. Remove the transmission oil level indicator tube.
    Fig 25: Removing Transmission Oil Level Indicator Tube
    G02078645Courtesy of GENERAL MOTORS CORP.
  59. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.
    Fig 26: Removing Transmission Bolt & Stud (4L60-E)
    G02078646Courtesy of GENERAL MOTORS CORP.
  60. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.
    Fig 27: Removing Transmission Converter Cover Bolts (4L80-E)
    G02078647Courtesy of GENERAL MOTORS CORP.
  61. Remove the automatic transmission bolt/studs, if equipped.
  62. Separate the engine from the automatic transmission, if equipped.

    Install the J 21366  to the transmission in order to hold the torque converter.

  63. Lower the vehicle.
  64. Install an engine hoist to the J 42451-1  .
  65. Install a floor jack under the transmission for support.
    CAUTION: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.
  66. Remove the engine.
  67. Install the engine to an engine stand.
  68. Remove the engine hoist.
  69. Remove the J 42451-1  from the engine.
    Fig 28: Removing Automatic Transmission Bolt/Studs
    G02078648Courtesy of GENERAL MOTORS CORP.
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