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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 160 (Engine Mechanical - 4.8L, 5.3L, 6.0L And 6.2L (3 Of 5)) >> On-Vehicle Repair Instructions (2 Of 2) >> Engine Replacement >> Installation Procedure

Installation Procedure

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    Fig 1: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  1. Install the J 41798  to the engine. See Special Tools .

    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  . See Special Tools .
  3. Remove the engine from the engine stand.
  4. Remove the J 21366  from the transmission. See Special Tools .
  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: View Of Engine Mount Bracket Bolts
    GM1701018Courtesy of GENERAL MOTORS CORP.
  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: View Of Engine Mount To Frame Bolts
    GM1701017Courtesy of GENERAL MOTORS CORP.
  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: View Of Engine Mount To Frame Bolts
    GM1701016Courtesy of GENERAL MOTORS CORP.
  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: View Of Transmission Bolts/Studs
    GM1701040Courtesy of GENERAL MOTORS CORP.
  13. If equipped with the 6L80-E automatic transmission, install the transmission bolts/studs.

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

    14. Fig 6: View Of Transmission Bolts/Studs
    GM1701039Courtesy of GENERAL MOTORS CORP.
  14. If equipped with the 4L80-E automatic transmission, install the transmission bolts/studs.

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

    15. Fig 7: View Of Transmission Bolts/Studs
    GM1701038Courtesy of GENERAL MOTORS CORP.
  15. If equipped with the 4L60-E/4L70-E automatic transmission, install the transmission bolts/studs.

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

    16. Fig 8: View Of Transfer Case Vent Hose Bracket & Nut
    GM1701049Courtesy of GENERAL MOTORS CORP.
  16. Position the transfer case vent hose bracket and hose and install the bracket to the stud, if equipped.
  17. For the 4L60-E/4L70-E/6L80-E automatic transmission, 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).

  18. For the 4L80-E automatic transmission, install the transfer case vent hose bracket (1) nut to the stud, if equipped.

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

    19. Fig 9: View Of Fuel/Evaporative Emission Pipe & Bracket
    GM1701047Courtesy of GENERAL MOTORS CORP.
  19. Position the fuel/EVAP pipe bracket and install the bracket to the stud. (typical installation shown).
  20. Install the fuel/EVAP pipe bracket nut to the transmission stud

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

    21. Fig 10: View Of Flywheel To Torque Converter Bolts
    GM1701022Courtesy of GENERAL MOTORS CORP.
  21. Align the torque converter bolt holes to the flywheel bolt holes.
  22. Install the flywheel to torque converter bolts.

    Tighten: 

    • For the 4L60-E/4L70-E/6L80-E automatic transmission, tighten the bolts to 63 N.m (47 lb ft).
    • For the 4L80-E automatic transmission, tighten the bolts to 60 N.m (44 lb ft).

    23. Fig 11: View Of Oil Cooler Line Clip & Bolt
    GM1698074Courtesy of GENERAL MOTORS CORP.
  23. 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).

  24. Install the catalytic converter. Refer to one of the following:
  25. Lower the vehicle.
    26. Fig 12: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  26. Remove the J 41798  from the cylinder heads. See Special Tools .
  27. Install the ignition coil(s) and spark plug wire(s), as required. Refer to Ignition Coil Replacement .
    28. Fig 13: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  28. Install the transmission oil level indicator tube.
    29. Fig 14: View Of Transmission Oil Level Indicator Tube Nut
    GM1701027Courtesy of GENERAL MOTORS CORP.
  29. Install the transmission oil level indicator tube nut (1).

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

    30. Fig 15: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  30. Position the generator bracket (with power steering pump) to the engine.
  31. Install the generator bracket bolts.

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

    32. Fig 16: View Of Power Steering Pump-To-Engine Block Bolt
    GM1699607Courtesy of GENERAL MOTORS CORP.
  32. 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).

  33. Raise the vehicle.
    34. Fig 17: View Of Coolant Heater Cord
    GM1699547Courtesy of GENERAL MOTORS CORP.
  34. Connect the coolant heater cord to the coolant heater, if equipped.
    35. Fig 18: View Of Electrical Connectors & Clips
    GM1698087Courtesy of GENERAL MOTORS CORP.
  35. Connect the engine harness electrical connector (1) to the CKP sensor.
  36. Connect the engine harness electrical connector (2) to the knock sensor.
  37. Connect the engine harness electrical connector (4) to the oil level sensor.
  38. Install the engine harness clip (3) to the transmission oil cooler line bracket.
  39. Install the starter motor. Refer to Starter Motor Replacement .
    40. Fig 19: View Of Electrical Connectors
    GM1699539Courtesy of GENERAL MOTORS CORP.
  40. Connect the engine harness electrical connector (1) to the A/C refrigerant pressure sensor.
    41. Fig 20: View Of Electrical Connector, Cable Channel Bolt & Pin
    GM1697734Courtesy of GENERAL MOTORS CORP.
  41. Slide the channel pin (3) into the oil pan tab.
  42. Install the battery cable channel bolt (2).

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

  43. Connect the engine harness electrical connector (1) to the CMP sensor wire harness.
    44. Fig 21: View Of Engine Harness Components
    GM1699536Courtesy of GENERAL MOTORS CORP.
  44. Connect the engine harness electrical connector (4) to the knock sensor.
  45. Position the engine harness grounds (3) to the engine block.
  46. Install the engine harness ground stud (2) to the engine block.

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

  47. Install the engine harness clip (1) to the ground stud.
  48. Lower the vehicle.
    49. Fig 22: View Of Battery Cable Terminals & Stud
    GM1699543Courtesy of GENERAL MOTORS CORP.
  49. Position the negative battery cable terminal (2) and the engine harness ground (3) to the right cylinder head.
  50. Install the negative battery cable stud (1) to the right cylinder head.

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

    51. Fig 23: View Of Engine Ground Strap & Bolt
    GM1699550Courtesy of GENERAL MOTORS CORP.
  51. Position the engine ground strap to the cylinder head.
  52. Install the engine ground strap bolt to the rear of the left cylinder head.

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

    53. Fig 24: View Of Engine Wiring Harness, Clip, Bolt & Connector
    GM1696914Courtesy of GENERAL MOTORS CORP.
  53. Connect the engine harness electrical connector (2) to the ECT sensor.
  54. Install the engine harness clip bolt (1) to the generator/power steering pump bracket.

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

    55. Fig 25: View Of Engine Harness Electrical Connectors & Inlet Hose Clamp
    GM1697098Courtesy of GENERAL MOTORS CORP.
  55. Connect the engine harness electrical connector (1) to the oil pressure sensor.
  56. Connect the engine harness electrical connector (2) to the lifter oil manifold.
  57. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Hose Replacement - Outlet .
    58. Fig 26: View Of Radiator Outlet Hose
    GM1699336Courtesy of GENERAL MOTORS CORP.
  58. Install the radiator outlet hose to the water pump.
  59. Position the radiator outlet hose clamp at the water pump.
    60. Fig 27: View Of Radiator Vent Inlet Hose Clamp At Water Pump
    GM1696566Courtesy of GENERAL MOTORS CORP.
  60. Install the radiator inlet hose to the water pump.
  61. Position the radiator inlet hose clamp (3) at the water pump.
    62. Fig 28: View Of Radiator Vent Inlet Hose & Clamps
    GM1699347Courtesy of GENERAL MOTORS CORP.
  62. Position and install the radiator vent inlet hose (2) to the air bleed pipe.
  63. Position the radiator vent inlet hose clamp (1) at the air bleed pipe.
  64. Install the radiator vent inlet hose (2) to the radiator inlet hose clip (3).
    65. Fig 29: View Of Generator Battery Jumper Cable & Components
    GM1699546Courtesy of GENERAL MOTORS CORP.
  65. Position the generator battery jumper to the engine.
  66. Install the generator battery jumper clip (1) to the stud.
  67. Install the intake manifold. Refer to Intake Manifold Replacement (RPOs LC9/LMG/LY5/L76/L92) or Intake Manifold Replacement (RPOs LY2/LY6) .
  68. Raise the vehicle.
  69. Install the A/C compressor. Refer to Compressor Replacement .
    70. Fig 30: View Of Oil Pan Skid Plate & Bolts
    GM1698083Courtesy of GENERAL MOTORS CORP.
  70. 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).

    71. Fig 31: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  71. 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).

    72. Fig 32: View Of Engine Shield & Bolts
    GM1696602Courtesy of GENERAL MOTORS CORP.
  72. Install the engine shield and bolts.

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

  73. Lower the vehicle.
  74. Install the radiator support. Refer to Radiator Support Replacement .
    75. Fig 33: View Of Service Piston Notch
    GM1711844Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: There is a positive stop which limits the hood from being opened too far.
  75. With the aid of the assistant raise the hood slightly until the hood hinge bolts can be removed from the service position notch (1).
    76. Fig 34: View Of Hood Strut Rod, Grille End Caps & Hood Hinge Bolts
    GM1711842Courtesy of GENERAL MOTORS CORP.
  76. With the aid of an assistant lower the hood and install the hood hinge bolts (3) to the hood hinges.

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

  77. Install the hood strut rod (1) to the hood strut bracket stud.
  78. Install the air inlet grille end caps (2), push down the end cap in order to engage the retainers. (left side shown, right side similar).
    79. Fig 35: View Of Ground Strap & Nut
    GM1823089Courtesy of GENERAL MOTORS CORP.
  79. Install the ground strap to the hood stud.
  80. Install the ground strap nut at the hood stud.

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

  81. Prelube the engine. Refer to Engine Prelubing .
  82. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
    IMPORTANT: After an overhaul the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
    • Disable the ignition system.
    • Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    • Enable the ignition system.
    • Start the engine and listen for unusual noises.
    • Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    • Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
    • Listen for sticking lifters or other unusual noises.
    • Inspect for fuel, oil and/or coolant leaks while the engine is running.
    • Perform a final inspection for the proper oil and coolant levels.
  83. Close the hood.
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