Removal and Replacement

Removal Procedure





1. Remove the hood. Refer to Hood Replacement in Body and Frame.
2. Disconnect both the battery negative cables from the batteries. Refer to Battery Replacement.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Drain the engine of motor oil.
5. Remove the upper intake manifold cover.





6. Remove the air conditioning compressor from the accessory mounting bracket vehicle and secure out of the way.





7. Remove the generator from the right accessory mounting bracket and secure to the side.
8. Remove the auxiliary generator from the left accessory mounting bracket (for vehicle equipped with the ambulance package only).





9. Remove the radiator assembly from the vehicle. Refer to Radiator Replacement in Cooling System.
10. Remove the power steering lines from the power steering pump. Refer to Power Steering Hoses Replacement in Steering and Suspension.





11. Disconnect the fuel lines from the fuel manager/filter.





12. Disconnect the engine wiring harness assembly at the left rear of the engine block.





13. Remove the ground straps from the right rear cylinder head.





14. Remove the heater hoses from the heater core (non-auxiliary shown).





15. Remove the radiator hoses from the engine assembly.





16. Install the engine lift bracket to the rear of the right cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

17. Install J 36857 along with GM P/N 94282217 bolt and GM P/N 15650963 washer to the right rear cylinder head.
^ Tighten the lift bracket bolt to 40 Nm (30 ft. lbs.).
18. Raise the vehicle and support the vehicle with safety stands. Refer to Vehicle Lifting.
19. Remove the front drive shaft from the vehicle (4 wheel drive only).
19.1. For vehicles equipped without the NP8 front axle, refer to Propeller Shaft Replacement (Front Axle-All Except NP8).
19.2. For vehicles equipped with the NP8 front axle, refer to Propeller Shaft Replacement (Front Axle-NP8).





20. Remove the oil filter adapter from the vehicle (4 wheel drive vehicle only).
21. Remove the starter from the engine block. Refer to Starter Motor Replacement (Diesel, 6.5L).
22. Remove the bolts from the torque converter.





23. Remove the exhaust pipe from the turbocharger.





24. Disconnect the electrical connector for the block heater.





25. Remove the battery ground in the front of the engine block.





26. Disconnect the oil cooler lines from the engine block.
27. Remove the engine oil cooler lines and secure out of the way.

Important: Anytime the oil cooler lines are disconnected from the quick connectors or the engine block, the retaining clip must be replaced.

28. Remove the transmission oil cooler lines from the radiator and the auxiliary transmission cooler (if equipped).
29. Secure the transmission cooler lines out of the way.
30. Remove the bellhousing bolts from the transmission to the engine block.
^ For the 4L80 E automatic transmission, refer to Transmission Replacement in Transmission and Drivetrain.
^ For the NV 4500 manual transmission, refer to Transmission Replacement in Transmission and Drivetrain.
31. Remove the safety stands and lower the vehicle. Refer to Vehicle Lifting.
32. Attach a suitable lifting devise from the lifting bracket to the left accessory mounting bracket.





33. Remove the inner splash shield from the wheel house and the frame (right side shown).
34. Raise the engine enough to remove the engine mount through bolt.





Important: It maybe necessary to remove the engine mount bracket from the engine block in order to gain enough clearance to remove the engine assembly.

35. Remove the left engine mount through bolt.





36. Remove the right engine mount through bolt.
37. Support the transmission assembly with a suitable support.
38. Remove the engine from the vehicle.





Important: It maybe necessary to remove the clutch assembly (if equipped) and flywheel from the engine assembly before the engine can be installed on the suitable engine stand.

39. Remove the clutch assembly from the flywheel (if equipped).
40. Remove the flywheel from the engine assembly. Refer to Engine Flywheel Removal.
41. Install the engine in a suitable engine stand.
42. Remove the J 36857 from the right rear cylinder head.
43. Remove the lifting devise from the engine.





44. Remove the left accessory bracket from the engine block.





45. Remove the right accessory bracket from the engine block.


Installation Procedure

Notice: Refer to Damage May Result From The Use Of An Improper Bolt When in Service Precautions.

Notice: Refer to Fastener Notice in Service Precautions.





1. Install J 36857 along with GM P/N 94282217 bolt and GM P/N 15650963 washer to the right rear cylinder head.
^ Tighten the lift bracket bolt to 40 Nm (30 ft. lbs.).
2. Install the left accessory bracket to the engine block.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





3. Install the right accessory bracket to the engine block.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
4. Install the lifting device to the engine assembly.
5. Remove the engine assembly from the engine stand.
6. Install the flywheel to the crankshaft. Refer to Engine Flywheel Installation.
7. Install the clutch assembly (if equipped). Refer to Clutch Assembly Replacement in Transmission and Drivetrain.
8. Install the engine assembly in the vehicle.





9. Install the left engine mount bracket (if removed)
^ Tighten the engine mount bracket bolts to 54 Nm (40 ft. lbs.).





10. Install the right engine mount bracket (if removed).
^ Tighten the engine mount bracket bolts to 54 Nm (40 ft. lbs.).





11. Install the left engine mount through bolt.
^ Tighten the engine mount through bolts to 59 Nm (44 ft. lbs.).





12. Install the right engine mount through bolt.
^ Tighten the engine mount through bolts to 59 Nm (44 ft. lbs.).
13. Remove the lifting device from the engine assembly.





14. Remove the lifting bracket from the rear of the right cylinder head.
15. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting.
16. Install the bellhousing bolts from the engine block to the transmission.
^ For the 4L80-E automatic transmission, refer to Transmission Replacement in Transmission and Drivetrain.
^ For the NV 4500 NV 4500 manual transmission, refer to Transmission Replacement in Transmission and Drivetrain.
17. Install the starter on the engine block. Refer to Starter Motor Replacement (Diesel, 6.5L).
18. Install the transmission cooler lines to the radiator and the auxiliary transmission cooler (if equipped).
19. Install the bolts from the flywheel to the torque convertor.
20. Install the exhaust pipe from the turbocharger to the catalytic convertor. Refer to Catalytic Converter Replacement (Diesel) in Exhaust System.
21. Install the oil filter adapter and filter to the engine block (4 wheel drive vehicles only). Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement.
22. Install the power steering lines to the power steering pump. Refer to Power Steering Hoses Replacement in Steering and Suspension.
23. Install the front drive shaft in the vehicle (4 wheel drive only).
23.1. For vehicles equipped without the NP 8 front axle, refer to Propeller Shaft Replacement (Front Axle-All Except NP8).
23.2. For vehicles equipped with the NP 8 front axle, refer to Propeller Shaft Replacement (Front Axle-NP8).





24. Reconnect the electrical connector for the block heater.
25. Install the engine oil cooler lines to the engine assembly. Refer to Engine Oil Cooler Line Replacement in Cooling System.





26. Install the ground strap in the right front corner of the engine.
27. Remove the safety stands and lower the vehicle. Refer to Vehicle Lifting.





28. Install the inner splash shields on the vehicle.





29. Install the ground straps at the right rear cylinder head.





30. Install the fuels lines to the fuel manager/filter.





31. Install the heater lines in the vehicle (non auxiliary shown).
32. Install the radiator hoses on the engine block. Refer to Radiator Hose Replacement (6.5L Diesel) in Cooling System.
33. Install the radiator in the vehicle. Refer to Radiator Replacement in Cooling System.
34. Install the generator to the right accessory mounting bracket. Refer to Generator Replacement.
35. Install the auxiliary generator on the left accessory mounting bracket (for vehicles equipped with the ambulance package only), Refer to Generator Replacement - Auxiliary.
36. Reposition the A/C compressor on the left accessory mounting bracket. Refer to Compressor Replacement (6.5L) in Heating and Air Conditioning.





37. Reconnect the engine wiring harness gray connector at the left rear of the engine.
38. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
39. Fill the Engine crankcase with the proper motor oil. Refer to Capacities - Approximate Fluid.
40. Connect the battery cables to the battery terminals. Refer to Battery Replacement.
41. Install a scan tool and check fro DTC's.
42. Check and adjust the timing for the fuel injection pump. Refer to Injection Timing Adjustment-6.5L-L65.
43. Perform the TDC offset timing procedure. Refer to TDC Offset Adjustment-6.5L-L65.





44. Install the upper engine cover on the engine assembly.
45. Install the hood on the vehicle. Refer to Hood Replacement in Body and Frame.