Part 2

Installation Procedure

1. Remove the engine from the stand.
2. Install the engine to the vehicle.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the right engine mount bracket to frame bolts and tighten to 65 Nm (48 lb ft).




4. Install the right engine mount to engine bolts and tighten to 58 Nm (43 lb ft).




5. Install the right engine mount to engine mount bracket bolts and tighten to 65 Nm (48 lb ft).
6. Install the left engine mount bracket to frame bolts and tighten to 65 Nm (48 lb ft).




7. Install the left engine mount to engine bolts and tighten to 58 Nm (43 lb ft).




8. Install the left engine mount to engine mount bracket bolts and tighten to 65 Nm (48 lb ft).
9. Lower the engine onto the engine mounts.
10. Remove the lifting device and the J 36857 engine lift hooks.
11. Install the G102, G103 and G108. Tighten the ground bolts to 34 Nm (25 lb ft).
12. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (4.3L) (Exhaust Manifold Replacement - Right Side)Exhaust Manifold Replacement - Right Side (4.8L/5.3L/6.0L) (Exhaust Manifold Replacement - Right Side)Exhaust Manifold Replacement - Right Side (6.6L) (Exhaust Manifold Replacement - Right Side).
13. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (4.3L) (Exhaust Manifold Replacement - Left Side)Exhaust Manifold Replacement - Left Side (4.8L/5.3L/6.0L) (Exhaust Manifold Replacement - Left Side)Exhaust Manifold Replacement - Left Side (6.6L) (Exhaust Manifold Replacement - Left Side).
14. Install the oil filter adapter and oil cooler assembly replacement. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement (Service and Repair).
15. Install the oil pump pickup tube. Refer to Oil Pump Suction Pipe and Screen Assembly Removal (Overhaul).
16. Install the engine flywheel housing. Refer to Engine Flywheel Housing Replacement (Engine Flywheel Housing Replacement).
17. Install the upper oil pan. Refer to Upper Oil Pan Replacement (Upper Oil Pan Replacement).
18. Install the engine flywheel. Refer to Engine Flywheel Replacement (Engine Flexplate/Flywheel Replacement).
19. Install the transmission. Refer to Transmission Replacement (Removal and Replacement).
20. Install the engine oil indicator tube. Refer to Oil Level Indicator Tube Replacement (LLY, LBZ) (Oil Level Indicator Tube Replacement (LLY, LBZ))Oil Level Indicator Tube Replacement (LMM) (Oil Level Indicator Tube Replacement (LMM)).
21. Install the transmission fill tube.
22. Position the fuel injection pump and install the 4 bolts and tighten to 25 Nm (18 lb ft).




23. Connect the fuel pump electrical connector.




24. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the right intake manifold mating surface.




25. Install the right intake manifold.
26. Install the intake manifold bolts/nuts.

Right:

27. Tighten the right intake manifold bolts/nuts in sequence to 25 Nm (18 lb ft).




28. Apply a 2-3 mm wide by 0.5-1.5 mm high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the left intake manifold mating surface.




29. Install the left intake manifold.

Left:

30. Tighten the left intake manifold bolts/nuts in sequence to 25 Nm (18 lb ft).




31. Position the turbocharger cooling outlet pipe and install the 2 bolts and tighten to 9 Nm (80 lb in).




32. Position the right fuel rail and install the 2 bolts and tighten to 25 Nm (18 lb ft).




33. Install the right fuel injector feed pipes and tighten to 41 Nm (30 lb in).
34. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.




35. Connect the fuel rail pressure (FRP) sensor electrical connector (1).




36. Position the left fuel rail and install the 2 bolts and tighten to 25 Nm (18 lb ft).




37. Install the left fuel injector feed pipes and tighten the fittings to 41 Nm (30 lb ft).
38. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.




39. Install the left to right fuel rail pipe and tighten the fittings to 41 Nm (30 lb ft).
40. After installing the fuel pipes, clean the pipes and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.




41. Position the fuel pipe/hose assembly and connect the hose (1) at the fuel pump.
42. Install the fuel pipe bracket bolt (2) and tighten to 25 Nm (18 lb ft).




43. Compress the clamp and install the fuel system pressure relief hose.




44. Install the fuel pump to the left fuel rail pipe and tighten the fittings to 41 Nm (30 lb ft).
45. After installing the fuel pipe, clean the pipe and apply sealant GM P/N 97720043, at the fitting to prevent moisture and debris from collecting between the line and fitting.
46. Install NEW center intake manifold gaskets to the center intake.
47. Install the center intake manifold.

Note: The center intake manifold lower nuts MUST be installed and tightened first.

48. Install the center intake manifold lower 4 nuts and tighten to 10 Nm (89 lb in).
49. Install the center intake manifold upper 4 nuts and tighten to 10 Nm (89 lb in).




50. Install the fuel pipe clamp bolt (2) and turbocharger coolant inlet pipe bracket bolt (3) and tighten to 25 Nm (18 lb ft).




51. Install the fuel pipe.




52. Connect the fuel pump hose to the fuel pipe.




53. Install the fuel line bracket bolt and tighten to 25 Nm (18 lb ft).




54. Connect the fuel hoses to the fuel pipe.




55. Install the fuel feed/return bracket bolt and tighten to 25 Nm (18 lb ft).




56. Position the bracket, and install the nut and the 2 bolts.
57. Position the engine wiring harness over from the right side of the engine.




58. Connect the ECT wiring harness electrical connector (1) and the oil pressure sensor electrical wiring harness electrical connector (2).




59. Connect the intake air temperature sensor No. 2 and the fuel rail temperature sensor electrical connector.




60. Connect the fuel injector electrical connectors.




61. Install the left glow plug nuts (2) and the routing bolts (1). Tighten the glow plug nut to 1.7 Nm (15 lb in).




62. Connect the left main engine wiring harness connector and install the bracket bolts (1).





Note: Lubricate the NEW washer with diesel fuel before installing.

63. Position the oil fed pipe and a NEW washer into place.
64. Install the oil feed pipe bolt and tighten to 34 Nm (25 lb ft).
65. Position the turbocharger lower heat shield.
66. Install a new turbocharger oil return pipe gasket at the flywheel housing.
67. Install the turbocharger (with the oil return pipe).




68. Install the turbocharger bolts and tighten to 108 Nm (80 lb ft).




69. Install the turbocharger oil return pipe nuts (1) at the top of the flywheel housing and tighten to 21 Nm (15 lb ft).




70. Install the turbocharger oil feed pipe banjo bolt and a NEW washer and tighten to 34 Nm (25 lb ft).





Note: Use care not to damage this hose during the procedure.

71. Position the turbocharger coolant inlet pipe hose to the turbocharger and install the bolt with NEW washers and tighten to 25 Nm (18 lb ft).




72. Install the fuel line to the bracket bolt and tighten to 25 Nm (18 lb ft).
73. Position the glow plug control module bracket.




74. Install the glow plug control module bracket bolts (2) and tighten to 10 Nm (89 lb in).
75. Install the fuel line bracket bolt (1) and tighten to 25 Nm (18 lb ft).
76. Position the glow plug control module and install the glow plug control module bolts and tighten to 10 Nm (89 lb in).
77. Connect the positive battery cable to the glow plug control module.
78. Connect the fuel feed and return plugs.





Note: Use care not to damage this hose during the procedure.

79. Position the turbocharger coolant outlet pipe clamp (1) and install the hose to the turbocharger pipe.




80. Install the turbocharger upper heat shield.
81. Install the turbocharger upper heat shield bolts and tighten to 9 Nm (80 lb in).
82. Connect the engine wiring harness electrical connector to the turbocharger vane control solenoid valve.




83. Connect the engine wiring harness electrical connector to the turbocharger vane position sensor.




84. Install the EGR cooler tube bracket and the 2 bolts and tighten to 25 Nm (18 lb ft).




85. If necessary, remove the EGR bracket, nut, and the EGR bracket bolt. Tighten the EGR bracket bolt and nut to 25 Nm (18 lb ft).
86. Install the EGR valve and EGR cooler tube assembly.




87. Install the EGR nut (1) and bolt (2) and tighten to 50 Nm (37 lb ft).




88. Connect the EGR solenoid electrical connector.
89. Install the crankcase ventilation hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Service and Repair).




90. Install the EGR cooler tube bracket bolt and tighten to 25 Nm (18 lb ft).




91. Compress the clamp and connect the EGR heater inlet hose/pipe to the EGR cooler tube.
92. Install the EGR coolant hose. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY/LBZ) (Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement).
93. Install the left exhaust pipe. Refer to Exhaust Pipe Replacement - Left Side (6.6L (LMM)) (Exhaust Pipe Replacement - Left Side).
94. Install the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side (6.6L (LMM)) (Exhaust Pipe Replacement - Right Side).
95. Install the air intake pipe. Refer to Air Intake Pipe Replacement (Air Intake Pipe Replacement).
96. Install a NEW O-ring seal to the center intake manifold.
97. Install 2 NEW metal EGR gaskets to the EGR valve.




98. Install the intake manifold tube with the stud and tighten to 25 Nm (18 lb ft).




99. Install the intake manifold tube bolts (2, 4) and nut (1) and tighten to 25 Nm (18 lb ft).
100. Install the EGR cooler water pipe bracket bolt (5) and tighten to 15 Nm (11 lb ft).
101. Install the engine wiring harness clip to the intake manifold tube and tighten to 15 Nm (11 lb ft).
102. Install the engine wiring harness clip to the intake manifold tube.




103. Install the rear intake manifold tube nut (2) and tighten to 25 Nm (18 lb ft).
104. Install the 2 rear intake manifold tube bolts (3) and tighten to 25 Nm (18 lb ft).
105. Install the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.




106. Connect the positive cable to the IAH by performing the following:

1. Position the positive battery cable to the IAH stud.
2. Install the positive battery cable nut to the IAH and tighten to 10 Nm (89 lb in).

107. Reposition the positive battery cable boot.




108. Connect the engine harness electrical connector to the MAP sensor.




109. Connect the IAH electrical connector.
110. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement (Service and Repair).




111. Position the thermostat housing crossover with the NEW gaskets.
112. Install the 8 thermostat housing crossover bolts and tighten to 25 Nm (18 lb ft).




113. Connect the coolant temperature sensor electrical connector.
114. Install the fuel pipe bracket bolt and tighten to 25 Nm (18 lb ft).
115. Install the EGR valve coolant pipe to the thermostat housing bolt.




116. Install the oil fill tube and the oil fill tube bolts and tighten to 25 Nm (18 lb ft).




117. Compress the clamp and connect the turbocharger inlet cooling hose/pipe.




118. Position the fuel line and install the fuel line bolt.
119. Position the A/C compressor and power steering pump bracket.
120. Install the A/C compressor and power steering pump bracket bolts and tighten to 46 Nm (34 lb ft).
121. Position the power steering pump and loosely install the front bracket bolts.

Note: Tighten the front bracket bolts before the rear bracket bolts, to ensure pulley alignment.

122. Loosely install the rear power steering pump bracket bolts.

* Tighten the front bolts to 50 Nm (37 lb ft).
* Tighten the rear bolts to 50 Nm (37 lb ft).

123. Install the A/C compressor.




124. Install the A/C compressor bolts and tighten to 50 Nm (37 lb ft).
125. Connect the A/C cut out switch electrical connector.
126. Connect the A/C compressor clutch electrical connector.
127. If equipped with dual generator system, install the idler pulley and the bolt and tighten to 50 Nm (37 lb ft).




128. Install the auxiliary generator bracket and bolt, if equipped and tighten to 50 Nm (37 lb ft).
129. If equipped, install the auxiliary generator. Refer to Auxiliary Generator Replacement (Auxiliary Generator Replacement).




130. Install the generator mounting bracket and bolts and tighten to 50 Nm (37 lb ft).




131. Install the drive belt tensioner and tensioner belt and tighten to 50 Nm (37 lb ft).




132. Install the oil indicator tube bracket bolt and tighten to 21 Nm (15 lb ft).




133. Install the 2 wiring harness routing bolts and tighten to 10 Nm (89 lb in).




134. Install the 2 right engine wiring harness bracket bolts.
135. Connect the right engine wiring main harness connector.




136. Install the generator (2) and the generator bolts (1) and tighten to 50 Nm (37 lb ft).
137. Install the positive battery cable to the generator, perform the following:

1. Install the positive cable.
2. Install the positive cable nut and tighten to 9 Nm (80 lb in).

138. Position the boot to cover the terminal stud.
139. Connect the generator electrical connector.
140. Install the drive belt. Refer to Drive Belt Replacement (Service and Repair).
141. Install the cooling fan. Refer to Fan Replacement (Service and Repair).
142. Install the cooling layer. Refer to Cooling Layer Installation (Service and Repair).
143. Run the vehicle to verify correct engine operation and inspect for engine fluid leaks.
144. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair).