How to replace Engine on Chevrolet Avalanche and GM Savana?

Covers All U.S. And Canadian Models Of Chevrolet Avalanche, Chevrolet Express Van, and GM Savana car models.

In this chapter the details are there for following Engine model removal:----

•  6.6L Engine.
• 8.1L Engine.

The details and diagrams are as follows:----

6.6L Engine

CAUTION

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove the engine cover.
3. Disconnect the negative battery cable.
4. Recover the HVAC refrigerant.
5. Drain the cooling system.
6. Remove the cooling fan and accessory drive belt.
7. Unplug the generator electrical connector. Unbolt and reposition the generator to access the output wire nut. Remove the generator.
8. Disconnect the RH engine wiring harness connector. Remove the 2 RH engine wiring harness bracket bolts and position aside. Remove the 2 wiring harness routing bolts.
9. Remove the transmission tube bolt and reposition the transmission tube. Remove the oil indicator tube bracket bolt.
10. Remove the drive belt tensioner bolt and tensioner.
11. Remove the bolts and the generator mounting bracket.
12. If equipped, remove the auxiliary generator. Remove the auxiliary generator bracket bolt and bracket.
13. If equipped with a dual generator system, remove the bolt from the left side idler pulley and remove the idler pulley.
14. Unplug the A/C compressor clutch electrical connector and the A/C cut out switch electrical connector.
15. Disconnect the A/C suction and discharge lines at the compressor. Remove the A/C compressor.
16. Remove the power steering pump and bracket bolts. Position the power steering pump aside and secure.
17. Remove the A/C and power steering bracket mounting nuts/bolts and bracket.
18. Remove the fuel line bolt and position the fuel line aside.
19. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.
20. Remove the oil fill tube bolts and the oil fill tube.
21. Remove the Exhaust Gas Recirculation (EGR) valve coolant pipe to thermostat housing bolt.
22. Unplug the coolant temperature sensor electrical connector.
23. Remove the fuel pipe bracket bolt.
24. Remove the thermostat housing crossover bolts/nuts and the thermostat housing crossover. Remove the thermostat pipe.
25. Unplug the intake air heater electrical connector.
26. Disconnect the engine harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
27. Disconnect the positive cable from the IAH.
28. Remove the intake manifold tube with the stud.
29. Remove and discard the 2 metal EGR gaskets from the EGR valve.
30. Remove and discard the O-ring seal from the center intake manifold.
31. Remove the air intake pipe.
32. Remove the right and left exhaust pipes.
33. Remove the EGR coolant hose.
34. Compress the clamp and disconnect the EGR heater inlet hose/pipe from the EGR cooler tube. Remove the EGR cooler tube bracket bolts.
35. Remove the crankcase ventilation hose/pipe.
36. Unplug the EGR solenoid electrical connector. Remove the EGR valve and EGR cooler tube as an assembly. Remove the 2 bolts and the EGR cooler tube bracket.
37. Unplug the engine wiring harness electrical connector from the turbocharger vane position sensor and solenoid valve.
38. Remove the turbocharger upper heat shield.
39. Reposition the turbocharger coolant outlet pipe clamp and remove the hose from the turbocharger pipe. Disconnect the fuel feed and return pipes.
40. Disconnect the positive battery cable from the glow plug control module. Remove the glow plug control module.
41. Remove the glow plug control module bracket bolts. Remove the fuel line bracket bolt.
42. Remove the turbocharger coolant inlet pipe bolt and remove the hose from the turbocharger.
43. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer. Reposition and secure the turbocharger oil fed pipe out of the way.
44. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
45. Remove the turbocharger (with the oil return pipe).
46. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing. Remove the turbocharger lower heat shield, oil feed pipe, washer, and pipe.
47. Unplug the LH main engine wiring harness connector and remove the bracket bolts.
48. Remove the LH glow plug nuts and the routing bolts.
49. Unplug the fuel injector electrical connectors, the Intake Air Temperature (IAT) sensor and fuel rail temperature sensor electrical connectors.
50. Unplug the Engine Coolant Temperature (ECT) wiring harness electrical connector and the oil pressure sensor electrical wiring harness electrical connector. Position the engine wiring harness over the RH side of engine.
51. Remove the fuel feed/return pipe bracket bolt. Disconnect the fuel hoses from the fuel pipe.
52. Remove the fuel line bracket bolt. Disconnect the fuel pump hose from the fuel pipe.
53. Disconnect the fuel injector return hoses from the return pipe assembly. Remove the fuel pipe. Remove the fuel pipe clamp bolt and turbocharger coolant inlet pipe bracket bolt.
54. Remove the center intake manifold.
55. Remove the fuel pump to LH fuel rail pipe. Compress the clamp and remove the fuel pressure relief hose. Remove the fuel pipe bracket bolt, disconnect the hose at the fuel pump and remove the fuel pipe/hose assembly.
56. Remove the LH to RH fuel rail pipe. Remove the LH fuel injector feed pipes. Remove the 2 bolts and the LH fuel rail.
57. Unplug the Fuel Rail Pressure (FRP) sensor electrical connector. Remove the RH fuel injector feed pipes. Remove the 2 bolts and the RH fuel rail.
58. Remove the 2 bolts and the turbocharger cooling outlet pipe.
59. Remove the intake manifolds.
60. Unplug the fuel pump electrical connector. Remove the 4 bolts and fuel injection pump.
61. Remove the transmission fill tube. Remove the engine oil indicator tube.
62. Remove the transmission.
63. Remove the engine flywheel.
64. Remove the upper oil pan.
65. Remove the engine flywheel housing.
66. Remove the oil pump pickup tube. Remove the oil filter adapter and the oil cooler assembly.
67. Remove the exhaust manifolds.
68. Disconnect any remaining ground straps from the engine.
69. Using tool J 36857 or similar engine lift hooks, install a suitable lifting device.
    
    NOTE

    The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.
70. Raise the engine off the engine mounts.
71. Remove the left engine mount to engine mount frame bracket bolts. Remove the left engine mount to engine bolts. Remove the left engine mount bracket to frame bolts.
72. Remove the right engine mount to engine mount frame bracket bolts. Remove the right engine mount to engine bolts. Remove the right engine mount bracket to frame bolts. 
    
    
    
    Fig. Engine mount to frame mounting bolts-6.6L engines
    
    
    
    
    Fig. Engine mount to engine mounting bolts-6.6L engines
73. Remove the engine from the vehicle.

To install:

1. Installation is the reverse of removal. Note the following and observe the following torque specifications:
   
   
   Engine mount bracket to frame bolts to 48 ft. lbs. (65 Nm)

   Engine mount to engine bolts to 43 ft. lbs. (58 Nm)

   Engine mount to engine mount bracket bolts to 48 ft. lbs. (65 Nm)
2. Fill the engine to the proper level with oil and coolant. Prime the fuel system.
3. Check for and correct any leaks. Recharge the A/C system if equipped.

8.1L Engine

1. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
2. Release the fuel system pressure.
3. Remove or disconnect the following:
   
   
   Negative, then positive battery cables

   Coolant

   A/C refrigerant

   Engine oil cooler lines from the engine block

   Transmission-to-engine bolts

   Clutch pressure plate bolts, if equipped

   Torque converter bolts, if equipped

   Catalytic converter

   Exhaust manifold pipe

   Hoses from power steering pump, then plug the lines and ports

   Starter motor
   
   
   
   
4. Raise the vehicle.
   
   
   Engine electrical harness and tie aside

   Alternator

   Ground cable bolt from engine block

   Exhaust Gas Recirculation (EGR) valve adapter

   Vacuum lines (tag before removal)

   Throttle Actuator Control (TAC) module electrical connector
5. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head. 
   
   
   
   Fig. Install suitable lift brackets to the rear of the right head and the front of the left head
6. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
7. Remove or disconnect the following:
   
   
   Engine mount heat shield bolt and shields

   Engine mount-to-engine mount bracket bolts

   Engine from the vehicle, using a suitable lifting device. Place on a suitable stand.

   A/C compressor/power steering pump bracket from the cylinder head

   Lift brackets from the cylinder head

To install:

1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
2. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
3. Install or connect the following:
   
   
   A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).

   Alternator bracket

   Engine into the vehicle

   Engine mount-to-engine mount bracket bolts

   Engine mount heat shield and bolts
4. Remove the lift hooks from the cylinder heads, then raise the vehicle.
   
   
   Engine oil cooler lines

   Transmission-to-engine bolts

   Clutch pressure plate bolts, if equipped

   Torque converter bolts, if equipped

   Catalytic converter

   Exhaust manifold pipe

   Hoses to the power steering pump

   Starter motor
5. Lower the vehicle.
   
   
   Engine electrical harness. Make sure the harness is properly routed.

   Alternator

   Ground cable bolt to engine block and tighten to 12 ft. lbs. (16 Nm)

   EGR valve adapter

   Vacuum lines, as tagged during removal

   TAC module electrical connector

   Radiator

   A/C compressor

   Fuel feed and return lines

   Ignition coils

   Positive, then negative battery cables

   Air cleaner outlet duct and secure with the clamp
6. Lower the hood from the service position.
7. Properly recharge the A/C system.
8. Fill the engine with oil.
9. Fill the engine with coolant.
10. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2. With the scan tool, select the crankshaft position variation learn procedure.
    3. Observe the fuel cut-off for the 8.1L engine.
    4. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    5. Enable the crankshaft position system variation learn procedure.
       
       NOTE

       While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.
    6. Slowly increase the engine speed to the RPM that you observed.
    7. Immediately release the throttle when fuel cut-out is reached.
    8. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    9. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
11. Start and run the engine, then check for leaks.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html