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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 9 (Engine Mechanical - 6.6L - On Vehicle Repair Instructions) >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
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.
  1. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging .
  2. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  3. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
    Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  4. Drain the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) or Draining and Filling Cooling System (w/o RPO HP2) .
  5. Disconnect the following engine wire harness connectors:
    • Mass air flow switch (1)
    • A/C pressure cycling switch (2)
    • Surge tank switch (6)
    Fig 2: View Of Engine Wire Harness Connectors
    GM674588Courtesy of GENERAL MOTORS CORP.
  6. Remove the engine wire harness clip from the accumulator (3).
  7. Remove the engine wire harness clips from the wheelhouse inner panel (4).
  8. Remove the engine wire harness clip from the engine bracket (5).
  9. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  10. Remove the surge tank. Refer to Surge Tank Replacement .
  11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  12. Remove both front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  13. Remove both fender wheelhouse inner panels. Refer to Wheelhouse Panel Replacement .
  14. Lower the vehicle.
  15. Remove the charged air cooler pipes. Refer to Charged Air Cooler Hoses/Pipes Replacement (Left)  or Charged Air Cooler Hoses/Pipes Replacement (Right) .
  16. Loosen the hose clamps and remove the radiator inlet hose from the radiator and the engine.
    Fig 3: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  17. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper (w/RPO HP2) or Fan Shroud Replacement - Upper (Automatic Transmission - Diesel) or Fan Shroud Replacement - Upper (Manual Transmission - Diesel) .
  18. Remove the lower fan shroud. Refer to Fan Shroud Replacement - Lower .
  19. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
    Fig 4: View Of Radiator Outlet Hose & Outlet Heater Hose
    GM674543Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the outlet heater hose from the outlet radiator hose.
  21. Remove the hose clips from the frame.
  22. Loosen the hose clamp and remove the radiator outlet hose from the engine.
    Fig 5: View Of Radiator Outlet Hose At Engine
    GM674559Courtesy of GENERAL MOTORS CORP.
  23. Remove the outlet heater hose pipe bolt from the bracket.
  24. Remove the outlet heater hose pipe nut (1).
  25. Move the heater hose and secure aside.
  26. Remove the upper radiator support. Refer to Radiator Support Replacement .
  27. Remove the radiator. Refer to Radiator Replacement (Diesel) .
  28. Remove the charged air cooler. Refer to Charged Air Cooler Replacement .
  29. Remove the A/C condenser. Refer to Condenser Replacement .
  30. Disconnect the following electrical connectors:
    Fig 6: View Of A/C & Generator Electrical Connectors
    GM1369550Courtesy of GENERAL MOTORS CORP.
    • Generator connector (1)
    • A/C refrigerant switch (2)
    • Dual generator harness connector (3), if equipped
    • A/C compressor clutch (4)
  31. Remove the harness clip from the A/C compressor bracket.
  32. Remove the battery cable to the generator.
  33. If equipped, remove the battery cable to the auxiliary generator.
  34. Remove the battery cable harness clip from the bracket.
  35. Remove the battery cable junction block bolt (1) from the power steering pump.
    Fig 7: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  36. Move and secure the battery cables out of the way.
  37. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
    Fig 8: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  38. Open the harness clip (2).
  39. Remove the main engine electrical harness connectors.
  40. Disconnect the fuel lines at the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    Fig 9: View Of Fuel Lines At Engine
    GM1378747Courtesy of GENERAL MOTORS CORP.
  41. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
  42. Secure the fuel lines out of the way.
  43. Remove the drive belt. Refer to Drive Belt Replacement .
  44. Disconnect the suction hose from the accumulator. The compressor end can remain on the compressor.
  45. Remove the A/C compressor bolts.
    Fig 10: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  46. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
  47. Move the wiring harness to the left side of the vehicle and secure out to the way.
  48. Remove the bolts retaining the power steering pump front bracket to the power steering pump and the air conditioner compressor mounting bracket.
    Fig 11: View Of Power Steering Pump Front Bracket & Bolts
    GM698146Courtesy of GENERAL MOTORS CORP.
  49. Remove the air conditioning and power steering pump mounting bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement .

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

  50. Remove the right idler pulley bolt (1) and pulley.
    Fig 12: View Of Right Side Idler & Center Idler Pulley Bolts
    GM1409331Courtesy of GENERAL MOTORS CORP.
  51. Remove the generator mounting bracket and secure to the side.
    Fig 13: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
    • The generator does not require removal.
    • The drive belt tensioner does not require removal.
  52. Use the J 43181  in order to disconnect the inlet heater hose from the heater core inlet. See Special Tools .
    Fig 14: Identifying Heater Hose To Heater Core Fittings
    GM362171Courtesy of GENERAL MOTORS CORP.
  53. Remove the bolt and the ground wires at the rear of the left cylinder head.
  54. Raise the vehicle.
  55. Remove the oil pan skid plate.
    Fig 15: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  56. Remove the engine shield from the vehicle, if equipped.
  57. Remove the bolt for the battery negative cable and the engine wiring harness ground wire from the left side of the engine.
    Fig 16: View Of Engine Wiring Harness Ground Wire & Battery Negative Cable (Left Side Of Engine)
    GM674628Courtesy of GENERAL MOTORS CORP.
  58. Remove the bolts holding the battery cable channel retainer to the lower crankcase.
    Fig 17: View Of Battery Cable Bracket Bolts At Lower Crankcase
    GM673564Courtesy of GENERAL MOTORS CORP.
  59. Disconnect the cord for the engine coolant heater.
    Fig 18: View Of Engine Coolant Heater Cord
    GM674570Courtesy of GENERAL MOTORS CORP.
  60. Remove the starter. Refer to Starter Motor Replacement (6.6L (LLY) Engine) .
  61. Remove the nut holding the battery cable bracket to the right side of the lower crankcase.
    Fig 19: View Of Battery Cable Bracket Nut
    GM673568Courtesy of GENERAL MOTORS CORP.
  62. Remove the bolt holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.
    Fig 20: View Of Auxiliary Battery Negative Cable & Engine Wiring Harness Ground Wires
    GM674624Courtesy of GENERAL MOTORS CORP.
  63. Move and secure the battery cables out of the way.
  64. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  65. Drain the engine oil.
  66. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
    Fig 21: View Of Turbocharger Exhaust Pipe & Clamp
    GM668379Courtesy of GENERAL MOTORS CORP.
  67. If vehicle is 4-wheel drive (4WD) remove the lower oil pan. Refer to Oil Pan Replacement - Lower .
  68. If equipped with an automatic transmission, mark the flywheel and torque converter relationship for assembly purposes.
  69. Remove the torque convertor bolts through the starter opening.
    Fig 22: View Of Torque Convertor Bolt
    GM702519Courtesy of GENERAL MOTORS CORP.
  70. If equipped with an automatic transmission, remove the transmission oil line clip nut.
    Fig 23: View Of Transmission Oil Cooler Lines, Bracket & Bolt
    GM686706Courtesy of GENERAL MOTORS CORP.
  71. If equipped with an automatic transmission, remove the nuts retaining transmission fluid fill tube bracket.
    Fig 24: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  72. Remove the transmission to engine stud and bolts (automatic transmission shown). Note the location of the studs and any brackets attached to the studs.
    Fig 25: View of Transmission To Engine Stud & Bolts
    GM686685Courtesy of GENERAL MOTORS CORP.
  73. Lower the vehicle to work through the wheelhouse opening.
  74. Remove the engine mount to frame bracket bolts (left side shown).
    Fig 26: View Of Engine Mount To Engine Mount Frame Bracket
    GM657625Courtesy of GENERAL MOTORS CORP.
  75. Lower the vehicle.
  76. Install the J 36857  (1) to the rear of the left cylinder head with a suitable bolt. See Special Tools .
    Fig 27: Installing J 36857 At Rear Of Left Cylinder Head
    GM674699Courtesy of GENERAL MOTORS CORP.
  77. Install the J 36857  (1) to the front of the right cylinder head with a suitable bolt. See Special Tools .
    Fig 28: Installing J 36857 At Front Of Right Cylinder Head
    GM674703Courtesy of GENERAL MOTORS CORP.
  78. 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.
  79. Raise the vehicle off of the engine mounts.
  80. Remove the left and right engine mount frame brackets.
    Fig 29: Identifying Engine Mount Frame Bracket Through Bolt
    GM1602047Courtesy of GENERAL MOTORS CORP.
  81. Remove the engine from the vehicle.
  82. In order to secure the engine to an engine stand remove the following and follow the special procedures:
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