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Home >> GMC Truck >> 2000 >> C 6500 TopKick V8-7.4L VIN D >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement

Removal and Replacement




Engine Replacement

Removal Procedure

Tools Required

J 36857 Engine Lift Brackets

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.




2. Remove the air cleaner duct (1) and resonator from the throttle body. Refer to Air Cleaner Assembly Replacement Service and Repair in Engine Controls.
3. Remove the fuel supply lines from the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair in Engine Controls.
4. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling in Engine Cooling.
5. Remove the radiator from the vehicle. Refer to Radiator Replacement Radiator Replacement in Engine Cooling.
6. Disconnect the electrical connectors on the throttle body. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair in Engine Controls.
7. Remove the accelerator cable from the throttle body. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair in Engine Controls.
8. Remove the cruise control cables from the throttle body if equipped. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair in Engine Controls.
9. Remove the vacuum lines from the engine.
10. Remove the electrical connector from the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair in Engine Controls.
11. Remove the generator from the generator mounting bracket. Refer to Generator Replacement (L21/LP4) Generator Replacement (L21/LP4)Generator Replacement (LG5) Generator Replacement (LG5) in Engine Electrical.
12. Remove the engine electrical harness and tie out of the way.
13. Remove the power steering mounting bracket from the engine block. Refer to Accessory Mounting Brackets Replacement (With AC) Accessory Mounting Brackets Replacement (With AC)Accessory Mounting Brackets Replacement (Generator) Accessory Mounting Brackets Replacement (Generator).
14. Remove the hoses from the power steering pump.

* Refer to Power Steering Pump Replacement (Hobourn with LG5 and JE4) Power Steering Pump Replacement (Hobourn with LG5 and JE4)Power Steering Pump Replacement (Hobourn with LG5 and JE3) Power Steering Pump Replacement (Hobourn with LG5 and JE3)Power Steering Pump Replacement (Hobourn with LP4 or L21 and JE3) Power Steering Pump Replacement (Hobourn with LP4 or L21 and JE3)Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE3) Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE3)Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE4) Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE4) in Power Steering.
* Refer to Power Steering Pump Replacement (Hobourn with LG5 and JE4) Power Steering Pump Replacement (Hobourn with LG5 and JE4)Power Steering Pump Replacement (Hobourn with LG5 and JE3) Power Steering Pump Replacement (Hobourn with LG5 and JE3)Power Steering Pump Replacement (Hobourn with LP4 or L21 and JE3) Power Steering Pump Replacement (Hobourn with LP4 or L21 and JE3)Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE3) Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE3)Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE4) Power Steering Pump Replacement (Saginaw with LP4 or L21 and JE4) in Power Steering.
* Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.

15. Remove the ground wires from the engine block. Refer to Engine Ground Strap Replacement Service and Repair in Engine Electrical.
16. Remove the starter motor from the engine block. Refer to Starter Motor Replacement (LP4/L21) Starter Motor Replacement (LP4/L21)Starter Motor Replacement (LG5) Starter Motor Replacement (LG5) in Engine Electrical.




17. Remove the flywheel inspection cover from the transmission if equipped.
18. Remove the bolts from the torque convertor to the flywheel if equipped.

* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmission/Transaxles.
* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Manual Transmission/Transaxles.

Description:




19. Remove the exhaust pipes from the exhaust manifolds.
20. Remove the bolts from the transmission to the engine block.
21. For the automatic transmission.

* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmission/Transaxles.
* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmissions/Transaxles.

22. For the manual transmission. Refer to Transmission Replacement Service and Repair in Manual Transmission/Transaxle.
23. Remove the engine auxiliary oil cooler lines from the engine block. Refer to Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
24. Lower the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.
25. Support the transmission with a suitable jack.




26. Attach J 36857 to the rear of the right cylinder head and the front of the left cylinder head.
Notice: Refer to Damage May Result From The Use Of An Improper Bolt When. in Cautions and Notices.

Notice: Refer to Fastener Notice in Cautions and Notices.

27. Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963.

Tighten the lift bracket bolt to 70 Nm (52 lb ft).

28. Remove the front engine mount through bolts. Refer to Engine Mount Replacement Service and Repair.
29. Remove the engine with a suitable lifting devise.
30. Remove the generator mounting bracket from the engine block. Refer to Accessory Mounting Brackets Replacement (With AC) Accessory Mounting Brackets Replacement (With AC)Accessory Mounting Brackets Replacement (Generator) Accessory Mounting Brackets Replacement (Generator).




31. Remove the lift brackets from the cylinder head.

Installation Procedure




1. Attach J 36857 to the rear of the right cylinder head.
Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963.

Tighten the lift bracket bolts to 70 Nm (52 lb ft).




3. Attach J 36857 to the left front cylinder head and the right rear cylinder head.
Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963.

Tighten the lift bracket bolts to 70 Nm (52 lb ft).

4. Install the engine into the vehicle.
5. Install the engine mount through bolts. Refer to Engine Mount Replacement Service and Repair.
6. Remove the engine lift brackets from the cylinder heads.
7. Install the power steering mounting bracket to the engine block. Refer to Accessory Mounting Brackets Replacement (With AC) Accessory Mounting Brackets Replacement (With AC)Accessory Mounting Brackets Replacement (Generator) Accessory Mounting Brackets Replacement (Generator).
8. Install the generator mounting bracket. Refer to Accessory Mounting Brackets Replacement (With AC) Accessory Mounting Brackets Replacement (With AC)Accessory Mounting Brackets Replacement (Generator) Accessory Mounting Brackets Replacement (Generator).
9. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.
10. Install the bolts from the transmission to the engine block.
11. For the automatic transmission.

* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmissions/Transaxles.
* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmissions/ Transaxles.

12. For the manual transmission. Refer to Transmission Replacement Service and Repair in Manual Transmission/Transaxle.
13. Install the ground straps to the engine block. Refer to Engine Ground Strap Replacement Service and Repair in Engine Electrical.




14. Install the torque converter bolts.

* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmission/Transaxles.
* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmission/ TRansaxles.

15. Install the convertor inspection cover to the transmission.

* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmission/ Transaxles.
* Refer to Transmission Replacement (7.2L with AT545) Transmission Replacement (7.2L with AT545)Transmission Replacement (7.4L with MT643/MT653) Transmission Replacement (7.4L with MT643/MT653)Transmission Replacement (7.4L with AT545) Transmission Replacement (7.4L with AT545)Transmission Replacement (7.2L with MD3060/3560) Transmission Replacement (7.2L with MD3060/3560)Transmission Replacement (7.2L with MD3080/MD358) Transmission Replacement (7.2L with MD3080/MD358) in Automatic Transmission/ Transaxles.

16. Install the starter to the engine block. Refer to Starter Motor Replacement (LP4/L21) Starter Motor Replacement (LP4/L21)Starter Motor Replacement (LG5) Starter Motor Replacement (LG5) in Engine Electrical.
17. Install the oil cooler lines to the engine block if equipped. Refer to Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.

Description:




18. Install the exhaust pipes to the exhaust manifold.
19. Lower the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.
20. Install the hoses to the power steering pump. Refer to Power Steering Cooler Pipe/Hose Replacement Removal and Replacement in Power Steering.
21. Install the fuel lines to the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair in Engine Controls.
22. Install the electrical connector to the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement Service and Repair in Engine Controls.
23. Install the electrical connectors to the throttle body. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair in Engine Controls.
24. Install the accelerator cable to the Throttle Body. Refer to Throttle Body Assembly Replacement (SFI) Service and Repair in Engine Controls.
25. Install the vacuum lines to the engine.
26. Install the generator to the generator mounting bracket. Refer to Generator Replacement (L21/LP4) Generator Replacement (L21/LP4)Generator Replacement (LG5) Generator Replacement (LG5) in Engine Electrical.
27. Install the engine electrical wiring harness to the engine.
28. Install the radiator to the vehicle. Refer to Radiator Replacement Radiator Replacement in Engine Cooling.




29. Install the air cleaner duct (1) and resonator to the throttle body. Refer to Air Cleaner Assembly Replacement Service and Repair in Engine Controls.
30. Fill the radiator with coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling in Engine Cooling.
31. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.
32. Install the oil filter and engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.
33. Before starting a new engine or one that has been repaired. Refer to Engine Set-Up and Testing 91. Engine Set-Up and Testing.

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