1. Install the J 36857 (1) to the rear o f the left cylinder head with a suitable bolt. See Special Tools .
2. Install the J 3 6 8 5 7 (1) to the front o f the right cylinder head with a suitable bolt. See Special Tools.
3. Install a suitable lifting device. The engine will have to be angled in order to install. Use a load positioning sling to assist in angling the engine.
4. Remove the engine from the stand. Refer to Engine Removal from Stand .
5. Install the following:
• Refer to Engine Flywheel Installation (Automatic Transmission) or Engine Flywheel Installation (Manual Transmission).
• Refer to Exhaust Outlet Installation .
• Refer to Upper Oil Pan Installation .
• Refer to Engine Flywheel Housing Installation .
6 . Install the engine in the vehicle.
IMPORTANT: Do not draw the engine to the transmission using the transmission bolts. If everything is aligned properly the engine and transmission will come together.
7. Loosely install 2 transmission to engine bolts.
8 . Install the left and right side engine mount frame brackets.
Tighten: Tighten the through-bolts to 75 N.m (55 lb ft).
9. Install the engine mount to frame bracket bolts (left side shown).
Tighten: Tighten the bolts to 65 N.m (50 lb ft).
10. Remove the J 36857 from the cylinder heads. See Special Tools .
11. Raise the vehicle.
12.Install the transmission to engine bolts (automatic transmission shown).
Tighten: Tighten the studs and bolts to 50 N.m (37 lb ft).
13. If equipped with an automatic transmission install the torque convertor bolts.
Tighten: Tighten the bolts to 60 N.m (44 lb ft).
16. If equipped with an automatic transmission, install the nut retaining the transmission oil cooler line clip.
Tighten: Tighten the nut to 9 N.m (80 lb in).
17. Install the exhaust pipe to the exhaust outlet.
18. Install the exhaust manifold pipe to the exhaust outlet clamp.
Tighten: Tighten the clamp to 40 N.m (30 lb ft).
19. Lower the vehicle to work through the front fender wheelhouse openings.
20. Install the bolt retaining the battery negative cable and the engine wiring harness ground wire to the left side o f the engine.
Tighten: Tighten the bolt to 34 N.m (25 lb ft).
21. Install the bolts holding the battery cable channel retainer to the lower crankcase.
Tighten: Tighten the bolts to 12 N.m (106 lb ft).
22. Install the bolts holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side o f the engine.
Tighten: Tighten the bolts to 34 N.m (25 lb ft).
23. Install the nut holding the battery cable bracket to the right side o f the lower crankcase.
Tighten: Tighten the nut to 8 N.m (71 lb in).
24. Install the starter. Refer to Starter Motor Replacement (6 .6 L ).
25. Connect the cord for the engine coolant heater.
26. Install the engine oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) .
27. Install the engine shield. Refer to Engine Shield Replacement.
28. Lower the vehicle.
29. Install the bolt and the ground wires at the rear o f the left cylinder head.
Tighten: Tighten the bolt to 34 N.m (25 lb ft).
30. Install the generator mounting bracket and bolts.
Tighten: Tighten the bolts to 50 N.m (37 lb ft).
31. Install the right idler pulley and bolt (1).
Tighten: Tighten the bolt to 43 N.m (32 lb ft).
32. Install the air conditioning compressor and the power steering pump mounting bracket.
Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement.
33. Position the engine wiring harness on the engine.
34. Position the A/C compressor.
35. Install the A/C compressor mounting bolts.
Tighten: Tighten the bolts to 50 N.m (37 lb ft).
36. Install the A/C suction hose to the accumulator.
37. Install the drive belt. Refer to Drive Belt Replacement.
38. Connect the fuel hoses at the engine.
39. Install the nut and the fuel hose bracket to the valve rocker arm cover stud.
Tighten: Tighten the nut to 21 N.m (15 lb ft).
40. Connect the main engine electrical harness connectors.
41. Push down on the latches (1) in order to connect the connectors.
42. Close the harness clip (2).
43. Install the cable junction block and bolt (1) to the power steering pump.
Tighten: Tighten the bolt to 9 N.m (80 lb in).
44. If equipped, install the battery cable to the auxiliary generator.
45. Install the battery cable to the generator.
Tighten: Tighten the nut to 9 N.m (80 lb in).
46. Install the battery cable harness clip to the bracket.
47. Connect the following electrical connectors:
• Generator connector (1)
• A/C refrigerant switch (2)
• Dual generator harness connector (3), if equipped
• A/C compressor clutch (4)
48. Install the harness clip to the A/C compressor bracket.
49. Install the upper radiator support. Refer to Radiator Support Replacement.
50. Install the A/C condenser. Refer to Condenser Replacement.
51. Install the charged air cooler. Refer to Charge Air Cooler Replacement.
52. Install the radiator. Refer to Radiator Replacement (LLM).
53. Install the outlet radiator hose to the radiator and tighten the hose clamp.
54. Install the hose clips to the frame.
55. Install the outlet radiator hose to the engine and tighten the hose clamp.
56. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) .
57. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (Mechanical) or Engine Coolant Fan Upper Shroud Replacement (Automatic Transmission – Diesel).
58. Connect the inlet heater hose (1) to the heater core inlet.
Firmly push to quick connector onto the heater core pipe until you hear an audible click.
59. Install the outlet heater hose to the outlet radiator hose.
60. Install the bolt retaining the heater hose pipe to the bracket.
Tighten: Tighten the bolt to 25 N.m (18 lb ft).
61. Install the radiator inlet hose Radiator Inlet Hose Replacement (Non-HP2) .
62. Install the charged air cooler pipes and hoses to the turbocharger and the charged air cooler.
Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement.
63. Install both fender wheelhouse inner panels (1). Refer to Front Wheelhouse Liner Replacement – Right Side (GMC) or Front Wheelhouse Liner Replacement – Right Side (Chevrolet) and Front Wheelhouse Liner Replacement – Left Side (Chevrolet) or Front Wheelhouse Liner Replacement – Left Side (GMC) .
64. Install both front tires and wheels. Refer to Tire and W heel Removal and Installation .
65. Install the surge tank. Refer to Radiator Surge Tank Replacement (N on-H P2) .
66. Install the air cleaner. Refer to Air Cleaner Assembly Replacement.
67. Connect the following engine wire harness connectors:
• Install the engine wire harness clips to the wheelhouse inner panel (3).
• A/c pressure cycling switch (2)
• Surge tank switch (1)
68. Connect the batteries negative cables. Refer to Battery Negative Cable Disconnection and Connection (w/Single Battery ) or Battery Negative Cable Disconnection and Connection (w/Auxilian Battery) or Battery 7 Negative Cable Disconnection and Connection (w/Dual Batteries).
69. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill).
70. Prelube the engine. Refer to Engine Prelubing .
71. Operate the engine, inspect for coolant, oil, fuel, and exhaust leaks.
72. Inspect for proper oil pressure.
73. Inspect for proper engine operation.
74. With the aid o f the assistant raise the hood slightly until the hood hinge bolts can be removed from the service position notch (1).
75. With the aid o f an assistant lower the hood and install the hood hinge bolts (2) to the hood hinges.
Tighten: Tighten the bolts to 25 N.m (18 lb ft).
76. Install the air inlet grille end caps (1), push down the end cap in order to engage the retainers, (left side shown, right side similar).
77. Install the ground strap to the hood stud.
78. Install the ground strap nut at the hood stud.
Tighten: Tighten the nut to 9 N.m (80 lb in).
79. Close the hood.
80. Road test the vehicle for normal operation.
81. Inspect for coolant, oil, or exhaust leaks.
