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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1667 (Engine Mechanical - 4.8L, 5.3L, 6.0L, 6.2L - Repair Instructions - On Vehicle) >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Fastener Caution .

  1. Install the J-41798  engine lifting brackets to the engine.

    Tighten 

    • Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
    • Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).
  2. Position and install the engine hoist to the J-41798  engine lifting brackets.
  3. Remove the engine from the engine stand.
  4. Remove the J-21366  converter holding strap from the transmission.
  5. Install the engine to the vehicle.
  6. Align and install the engine to the transmission. Raise or lower the transmission as required using the floor jack.
  7. Once aligned and mated together completely lower and remove the engine hoist.
    8. Fig 2: Engine Mount Bracket Bolts
    GM1701018Courtesy of GENERAL MOTORS COMPANY
  8. For 2500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to engine mount bracket bolts (1).

    Tighten 

    Tighten the bolts to 65 N.m (48 lb ft) starting with the middle bolt then either side bolt.

    9. Fig 3: Engine Mount And Bolts - Left Side
    GM1701017Courtesy of GENERAL MOTORS COMPANY
  9. For 1500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to frame bolts (1).

    Tighten 

    Tighten the bolts to 65 N.m (48 lb ft) starting with the middle bolt then either side bolt.

    10. Fig 4: Engine Mount To Frame Bolts
    GM1701016Courtesy of GENERAL MOTORS COMPANY
  10. For 1500 series vehicles with a 4.8L engine, install the left and right engine mount to frame bolts (1).

    Tighten 

    Tighten the bolts to 65 N.m (48 lb ft) starting with the middle bolt then either side bolt.

  11. Remove the floor jack from under the transmission.
  12. Raise the vehicle.
    13. Fig 5: Manual Transmission Bolts And Studs
    G00613115Courtesy of GENERAL MOTORS COMPANY
  13. If equipped with a manual transmission, install the transmission and the clutch housing.

    Tighten 

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

    14. Fig 6: Transmission Bolts/Studs
    GM1701038Courtesy of GENERAL MOTORS COMPANY
  14. Install the transmission bolts/studs.

    Tighten 

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

    15. Fig 7: Transfer Case Vent Hose Bracket
    GM1701049Courtesy of GENERAL MOTORS COMPANY
  15. Position the transfer case vent hose bracket and hose and install the bracket to the stud, if equipped.
  16. Install the transfer case vent hose bracket (2) nut to the stud, if equipped.

    Tighten 

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

    17. Fig 8: Fuel/Evaporative Emission Pipe And Bracket
    GM1701047Courtesy of GENERAL MOTORS COMPANY
  17. Position the fuel/EVAP pipe bracket and install the bracket to the stud. (typical installation shown).
  18. Install the fuel/EVAP pipe bracket nut to the transmission stud

    Tighten 

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

    19. Fig 9: Flywheel And Torque Converter Bolts
    GM1701022Courtesy of GENERAL MOTORS COMPANY
  19. Align the torque converter bolt holes to the flywheel bolt holes.
  20. Install the flywheel to torque converter bolts and tighten the bolts to 63 N.m (47 lb ft).
  21. Install the catalytic converter. Refer to one of the following procedures:
  22. Lower the vehicle.
    23. Fig 10: Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS COMPANY
  23. Remove the J-41798  engine lifting brackets from the cylinder heads.
  24. Install the ignition coil(s) and spark plug wire(s), as required. Refer to Ignition Coil Replacement .
    25. Fig 11: Transmission Oil Level Indicator Tube And Seal
    GM396798Courtesy of GENERAL MOTORS COMPANY
  25. Install the transmission oil level indicator tube.
    26. Fig 12: Transmission Oil Level Indicator Tube Nut
    GM1701027Courtesy of GENERAL MOTORS COMPANY
  26. Install the transmission oil level indicator tube nut (1).

    Tighten 

    Tighten the nut to 18 N.m (13 lb ft).

  27. Install the air conditioning compressor. Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 AND LMG)
    28. Fig 13: Generator Bracket And Bolts
    GM310813Courtesy of GENERAL MOTORS COMPANY
  28. Position the generator bracket (with power steering pump) to the engine.
  29. Install the generator bracket bolts.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

    30. Fig 14: Power Steering Pump And Engine Block Bolt
    GM1699607Courtesy of GENERAL MOTORS COMPANY
  30. Install the rear power steering pump-to-engine block bolt (1500 series shown, 2500 series similar).

    Tighten 

    Tighten the bolt to 50 N.m (37 lb ft).

  31. Raise the vehicle.
    32. Fig 15: Coolant Heater Cord
    GM1699547Courtesy of GENERAL MOTORS COMPANY
  32. Connect the coolant heater cord to the coolant heater, if equipped.
    33. Fig 16: Engine Wiring Harness Electrical Connector And Components
    GM1698087Courtesy of GENERAL MOTORS COMPANY
  33. Connect the engine harness electrical connector (1) to the CKP sensor.
  34. Connect the engine harness electrical connector (2) to the knock sensor.
  35. Connect the engine harness electrical connector (4) to the oil level sensor.
  36. Install the engine harness clip (3) to the transmission oil cooler line bracket.
  37. Install the starter motor. Refer to Starter Replacement (V8) or Starter Replacement (V6) or Starter Replacement (6.6L) .
    38. Fig 17: Engine Harness Electrical Connectors
    GM1699539Courtesy of GENERAL MOTORS COMPANY
  38. Connect the engine harness electrical connector (1) to the A/C refrigerant pressure sensor.
    39. Fig 18: Electrical Connector, Cable Channel Bolt And Pin
    GM1697734Courtesy of GENERAL MOTORS COMPANY
  39. Slide the channel pin (3) into the oil pan tab.
  40. Install the battery cable channel bolt (2).

    Tighten 

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

  41. Connect the engine harness electrical connector (1) to the CMP sensor wire harness.
    42. Fig 19: Transmission Oil Cooler Line Clip And Bolt
    GM1698074Courtesy of GENERAL MOTORS COMPANY
  42. Position the transmission oil cooler line clip to the oil pan and install the bolt, if equipped.

    Tighten 

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

    43. Fig 20: Engine Harness Components
    GM1699536Courtesy of GENERAL MOTORS COMPANY
  43. Connect the engine harness electrical connector (4) to the knock sensor.
  44. Position the engine harness grounds (3) to the engine block.
  45. Install the engine harness ground stud (2) to the engine block.

    Tighten 

    Tighten the stud to 16 N.m (12 lb ft).

  46. Install the engine harness clip (1) to the ground stud.
  47. Lower the vehicle.
    48. Fig 21: Negative Battery Cable Terminal And Stud
    GM1699543Courtesy of GENERAL MOTORS COMPANY
  48. Position the negative battery cable terminal (2) and the engine harness ground (3) to the right cylinder head.
  49. Install the negative battery cable stud (1) to the right cylinder head.

    Tighten 

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

    50. Fig 22: Engine Ground Strap And Bolt
    GM1699550Courtesy of GENERAL MOTORS COMPANY
  50. Position the engine ground strap to the cylinder head and cowl.
  51. Install the engine ground strap bolt to the rear of the left cylinder head and cowl.

    Tighten 

    Tighten the bolt to 16 N.m (12 lb ft).

    52. Fig 23: Engine Harness Electrical Connectors And Inlet Hose Clamp
    GM1697098Courtesy of GENERAL MOTORS COMPANY
  52. Connect the engine harness electrical connector (1) to the oil pressure sensor.
  53. Connect the engine harness electrical connector (2) to the lifter oil manifold.
  54. Install the heater hoses. Refer to Heater Inlet Hose Replacement (Non-HP2) and Heater Outlet Hose Replacement (Non-HP2) .
    55. Fig 24: Radiator Outlet Hose
    GM1699336Courtesy of GENERAL MOTORS COMPANY
  55. Install the radiator outlet hose to the water pump.
  56. Position the radiator outlet hose clamp at the water pump.
    57. Fig 25: Radiator Vent Inlet Hose Clamp At Water Pump
    GM1696566Courtesy of GENERAL MOTORS COMPANY
  57. Install the radiator inlet hose to the water pump.
  58. Position the radiator inlet hose clamp (3) at the water pump.
    59. Fig 26: Radiator Vent Inlet Hose And Clamps
    GM1699347Courtesy of GENERAL MOTORS COMPANY
  59. Position and install the radiator vent inlet hose (2) to the air bleed pipe.
  60. Position the radiator vent inlet hose clamp (1) at the air bleed pipe.
  61. Install the radiator vent inlet hose (2) to the radiator inlet hose clip (3).
  62. Position the generator battery jumper to the engine.
  63. Install the intake manifold. Refer to Intake Manifold Replacement (Without AFM)  or Intake Manifold Replacement (With AFM) .
    64. Fig 27: Oil Pan Skid Plate And Bolts
    GM1698083Courtesy of GENERAL MOTORS COMPANY
  64. For 2500 series vehicles, install the oil pan skid plate and bolts, if equipped.

    Tighten 

    Tighten the bolts to 28 N.m (21 lb ft).

    65. Fig 28: Oil Pan Skid Plate And Bolts
    GM1698082Courtesy of GENERAL MOTORS COMPANY
  65. For 1500 series vehicles, install the oil pan skid plate and bolts, if equipped.

    Tighten 

    Tighten the bolts to 28 N.m (21 lb ft).

    66. Fig 29: Engine Shield And Bolts
    GM1696602Courtesy of GENERAL MOTORS COMPANY
  66. Install the engine shield and bolts.

    Tighten 

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

  67. Lower the vehicle.
  68. Install the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement .
  69. Install the hood latch. Refer to Hood Primary and Secondary Latch Replacement .
  70. Remove the hood from the service position. Refer to Hood Service Positioning.
    71. NOTE: Prelube is necessary if the engine is replaced or overhauled.
  71. If the engine is replaced with a new engine or has been overhauled, perform the Engine Prelubing procedure. Refer to Engine Prelubing .
  72. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
    NOTE:

    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 gauge or light and confirm that the engine has acceptable oil pressure.
    6. Run the engine speed at about 1, 000 RPM until the engine has reached normal operating temperature.
    7. Listen for sticking lifters or 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 oil and coolant levels.
  73. Close the hood.
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