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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 344 (Engine Mechanical - 5.3L, 6.0L & 6.2L - Repair Instructions - On Vehicle) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

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    Fig 1: Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS CORP.
  1. Install the J 41798  Engine Lift Bracket to the engine.
    2. CAUTION:

    Refer to Fastener Caution .

  2. Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
  3. Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).
  4. Position and install the engine hoist to the J 41798  Engine Lift Bracket.
  5. Remove the engine from the engine stand.
  6. Remove the J 21366  Converter Holding Strap from the transmission.
  7. Install the engine to the vehicle.
  8. Align and install the engine to the transmission. Raise or lower the transmission as required using the floor jack.
  9. Once aligned and mated together completely lower and remove the engine hoist.
    10. Fig 2: Engine Mount Bracket Bolts
    GM1701018Courtesy of GENERAL MOTORS CORP.
    NOTE:

    Start with the middle bolt then either side bolt.

  10. For 2500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to engine mount to frame bolts (1) and tighten to 65 N.m (48 lb ft).
    11. Fig 3: Engine Mount And Bolts - Left Side
    GM1701017Courtesy of GENERAL MOTORS CORP.
    NOTE:

    Start with the middle bolt then either side bolt.

  11. 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) and tighten to 65 N.m (48 lb ft).
    12. Fig 4: Engine Mount To Frame Bolts
    GM1701016Courtesy of GENERAL MOTORS CORP.
    NOTE:

    Start with the middle bolt then either side bolt.

  12. For 1500 series vehicles with a 4.8L engine, install the left and right engine mount to frame bolts (1) tighten to 65 N.m (48 lb ft).
  13. Remove the floor jack from under the transmission.
  14. Raise the vehicle.
    15. Fig 5: Automatic Transmission Bolts And Studs
    GM1701040Courtesy of GENERAL MOTORS CORP.
  15. If equipped with the 6L80-E automatic transmission, install the transmission bolts/studs and tighten to 50 N.m (37 lb ft).
    16. Fig 6: Automatic Transmission Bolts/Studs
    GM1701039Courtesy of GENERAL MOTORS CORP.
  16. If equipped with the 4L80-E automatic transmission, install the transmission bolts/studs and tighten to 50 N.m (37 lb ft).
    17. Fig 7: Transmission Bolts/Studs
    GM1701038Courtesy of GENERAL MOTORS CORP.
  17. If equipped with the 4L60-E/4L70-E automatic transmission, install the transmission bolts/studs and tighten to 50 N.m (37 lb ft).
    18. Fig 8: Transfer Case Vent Hose Bracket
    GM1701049Courtesy of GENERAL MOTORS CORP.
  18. Position the transfer case vent hose bracket and hose and install the bracket to the stud, if equipped.
  19. For the 4L60-E/4L70-E/6L80-E automatic transmission, install the transfer case vent hose bracket (2) nut to the stud, if equipped and tighten to 20 N.m (15 lb ft).
  20. For the 4L80-E automatic transmission, install the transfer case vent hose bracket (1) nut to the stud, if equipped and tighten to 20 N.m (15 lb ft).
    21. Fig 9: Fuel/Evaporative Emission Pipe And Bracket
    GM1701047Courtesy of GENERAL MOTORS CORP.
  21. Position the fuel/EVAP pipe bracket and install the bracket to the stud. (typical installation shown).
  22. Install the fuel/EVAP pipe bracket nut to the transmission stud and tighten to 20 N.m (15 lb ft).
    23. Fig 10: Flywheel And Torque Converter Bolts
    GM1701022Courtesy of GENERAL MOTORS CORP.
  23. Align the torque converter bolt holes to the flywheel bolt holes.
  24. Install the flywheel to torque converter bolts.
  25. For the 4L60-E/4L70-E/6L80-E automatic transmission, tighten the bolts to 63 N.m (47 lb ft).
  26. For the 4L80-E automatic transmission, tighten the bolts to 60 N.m (44 lb ft).
  27. Install the catalytic converter. Refer to Catalytic Converter Replacement (with Exhaust Clamp) , or Three-Way Catalytic Converter Replacement .
  28. Lower the vehicle.
    29. Fig 11: Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS CORP.
  29. Remove the J 41798  Engine Lift Bracket from the cylinder heads.
  30. Install the ignition coil(s) and spark plug wire(s), as required. Refer to Ignition Coil Replacement .
    31. Fig 12: Transmission Oil Level Indicator Tube And Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  31. Install the transmission oil level indicator tube.
    32. Fig 13: Transmission Oil Level Indicator Tube Nut
    GM1701027Courtesy of GENERAL MOTORS CORP.
  32. Install the transmission oil level indicator tube nut (1) and tighten to 18 N.m (13 lb ft).
    33. Fig 14: Generator Bracket And Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  33. Position the generator bracket (with power steering pump) to the engine.
  34. Install the generator bracket bolts and tighten to 50 N.m (37 lb ft).
    35. Fig 15: Power Steering Pump And Engine Block Bolt
    GM1699607Courtesy of GENERAL MOTORS CORP.
  35. Install the rear power steering pump-to-engine block bolt (1500 series shown, 2500 series similar) and tighten to 50 N.m (37 lb ft).
  36. Raise the vehicle.
    37. Fig 16: Coolant Heater Cord
    GM1699547Courtesy of GENERAL MOTORS CORP.
  37. Connect the coolant heater cord to the coolant heater, if equipped.
    38. Fig 17: Engine Wiring Harness Electrical Connector And Components
    GM1698087Courtesy of GENERAL MOTORS CORP.
  38. Connect the engine harness electrical connector (1) to the CKP sensor.
  39. Connect the engine harness electrical connector (2) to the knock sensor.
  40. Connect the engine harness electrical connector (4) to the oil level sensor.
  41. Install the engine harness clip (3) to the transmission oil cooler line bracket.
  42. Install the starter motor. Refer to Starter Replacement .
    43. Fig 18: Engine Harness Electrical Connectors
    GM1699539Courtesy of GENERAL MOTORS CORP.
  43. Connect the engine harness electrical connector (1) to the A/C refrigerant pressure sensor.
    44. Fig 19: Electrical Connector, Cable Channel Bolt And Pin
    GM1697734Courtesy of GENERAL MOTORS CORP.
  44. Slide the channel pin (3) into the oil pan tab.
  45. Install the battery cable channel bolt (2) and tighten to 12 N.m (106 lb in).
  46. Connect the engine harness electrical connector (1) to the CMP sensor wire harness.
    47. Fig 20: Transmission Oil Cooler Line Clip And Bolt
    GM1698074Courtesy of GENERAL MOTORS CORP.
  47. Position the transmission oil cooler line clip to the oil pan and install the bolt, if equipped and tighten to 9 N.m (80 lb in).
    48. Fig 21: Engine Harness Components
    GM1699536Courtesy of GENERAL MOTORS CORP.
  48. Connect the engine harness electrical connector (4) to the knock sensor.
  49. Position the engine harness grounds (3) to the engine block.
  50. Install the engine harness ground stud (2) to the engine block and tighten to 16 N.m (12 lb ft).
  51. Install the engine harness clip (1) to the ground stud.
  52. Lower the vehicle.
    53. Fig 22: Negative Battery Cable Terminal And Stud
    GM1699543Courtesy of GENERAL MOTORS CORP.
  53. Position the negative battery cable terminal (2) and the engine harness ground (3) to the right cylinder head.
  54. Install the negative battery cable stud (1) to the right cylinder head and tighten to 25 N.m (18 lb ft).
    55. Fig 23: Engine Ground Strap And Bolt
    GM1699550Courtesy of GENERAL MOTORS CORP.
  55. Position the engine ground strap to the cylinder head and cowl.
  56. Install the engine ground strap bolt to the rear of the left cylinder head and cowl and tighten to 16 N.m (12 lb ft).
    57. Fig 24: Engine Harness Electrical Connectors And Inlet Hose Clamp
    GM1697098Courtesy of GENERAL MOTORS CORP.
  57. Connect the engine harness electrical connector (1) to the oil pressure sensor.
  58. Connect the engine harness electrical connector (2) to the lifter oil manifold.
  59. Install the heater hoses. Refer to Heater Inlet Hose Replacement (Non-HP2) , and Heater Outlet Hose Replacement (Non-HP2) .
    60. Fig 25: Radiator Outlet Hose
    GM1699336Courtesy of GENERAL MOTORS CORP.
  60. Install the radiator outlet hose to the water pump.
  61. Position the radiator outlet hose clamp at the water pump.
    62. Fig 26: Radiator Vent Inlet Hose Clamp At Water Pump
    GM1696566Courtesy of GENERAL MOTORS CORP.
  62. Install the radiator inlet hose to the water pump.
  63. Position the radiator inlet hose clamp (3) at the water pump.
    64. Fig 27: Radiator Vent Inlet Hose
    GM1699347Courtesy of GENERAL MOTORS CORP.
  64. Position and install the radiator vent inlet hose (2) to the air bleed pipe.
  65. Position the radiator vent inlet hose clamp (1) at the air bleed pipe.
  66. Install the radiator vent inlet hose (2) to the radiator inlet hose clip (3).
  67. Position the generator battery jumper to the engine.
  68. Install the intake manifold. Refer to Intake Manifold Replacement (RPOs LC9, LMG, LY5, L76) , Intake Manifold Replacement (RPOs LY2, LY6) , Intake Manifold Replacement (Except RPOs LY2, LY6, LC9, LMG, LY5) .
    69. Fig 28: Oil Pan Skid Plate And Bolts
    GM1698083Courtesy of GENERAL MOTORS CORP.
  69. For 2500 series vehicles, install the oil pan skid plate and bolts, if equipped and tighten to 28 N.m (21 lb ft).
    70. Fig 29: Oil Pan Skid Plate And Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  70. For 1500 series vehicles, install the oil pan skid plate and bolts, if equipped and tighten to 28 N.m (21 lb ft).
    71. Fig 30: Engine Shield And Bolts
    GM1696602Courtesy of GENERAL MOTORS CORP.
  71. Install the engine shield and bolts and tighten to 20 N.m (15 lb ft).
  72. Lower the vehicle.
  73. Install the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement .
  74. Install the hood latch. Refer to Hood Primary and Secondary Latch Replacement .
  75. Remove the hood from the service position. Refer to Hood Service Positioning .
  76. Prelube the engine. Refer to Engine Prelubing .
  77. 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.

    • 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.
  78. Close the hood.
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