Home » 2008 6.6L Duramax » 2008 6.6L Duramax – ENGINE REPLACEMENT – Removal Procedure

2008 6.6L Duramax – ENGINE REPLACEMENT – Removal Procedure

1. Open the hood.
2. Remove the ground strap from the stud.

3. Assemble 2 sets o f the following: an M 6 bolt, 2 each 19.05 mm (0.75 in) flat washers and an M 6 nut.
4. Release the retainer securing the hood strut rod to the hood strut bracket stud.

5. Remove the air inlet grille end caps (1), lift the end cap up in order to disengage the retainers, (left side shown,             right side similar).
6 . Have an assistant support the hood.
7. Remove the hood hinge bolts (2) and set aside.

8 . Raise the hood until the service position notch (1) in the upper hinge is reached.
9. Install the 2 sets o f the M6 bolts to both the left and right side service notches and tighten finger tight.

NOTE: Refer to Fastener Notice.

10. Lower the hood until the bolts rest against the lower hinge, tighten the bolts to secure the hood.
Tighten: Tighten the bolts to 20 N.m (15 lb ft).
11. The hood is now set in the service position.
12. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging .
13. Disconnect the negative battery 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).
14. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining          and Filling (Static Fill).

15. Disconnect the following engine wire harness connectors:
• Surge tank switch (1)
• A/C pressure cycling switch (2)
• Remove the engine wire harness clips from the wheelhouse inner panel (3).
16. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement.
17. Remove the surge tank. Refer to Radiator Surge Tank Replacement (N on-H P2).
18. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
19. Remove both front tires and wheels. Refer to Tire and Wheel Removal and Installation.

20. Remove both fender wheelhouse inner panels. 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) .
21. Lower the vehicle.
22. Remove the charged air cooler pipes. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler          Outlet Pipe Replacement.
23. Remove the radiator inlet hose Radiator Inlet Hose Replacement (Non-HP2) .
24. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (Mechanical) or Engine         Coolant Fan Upper Shroud Replacement (Automatic Transmission – Diesel).
25. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical).

26. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
27. Disconnect the outlet heater hose from the outlet radiator hose.
28. Remove the hose clips from the frame.

29. Loosen the hose clamp and remove the radiator outlet hose from the engine.
30. Remove the outlet heater hose pipe bolt from the bracket.
31. Remove the outlet heater hose pipe nut.
32. Move the heater hose and secure aside.
33. Remove the upper radiator support. Refer to Radiator Support Replacement.
34. Remove the radiator. Refer to Radiator Replacement (L L M ).
35. Remove the charged air cooler. Refer to Charge Air Cooler Replacement.
36. Remove the A/C condenser. Refer to Condenser Replacement.

37. Disconnect the following electrical connectors:
• Generator connector (1)
• A/C refrigerant switch (2)
• Dual generator harness connector (3), i f equipped
• A/C compressor clutch (4)
38. Remove the harness clip from the A/C compressor bracket.

39. Remove the battery cable to the generator.
40. If equipped, remove the battery cable to the auxiliary generator.
41. Remove the battery cable harness clip from the bracket.
42. Remove the battery cable junction block bolt (1) from the power steering pump.
43. Move and secure the battery cables out o f the way.

44. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the               connectors.
45. Open the harness clip (2).

46. Remove the main engine electrical harness connectors.

47. Disconnect the fuel lines at the engine. Refer to Metal Collar Quick Connect Fitting Service.
48. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
49. Secure the fuel lines out o f the way.

50. Remove the drive belt. Refer to Drive Belt Replacement.
51. Disconnect the suction hose from the accumulator. The compressor end can remain on the compressor.
52. Remove the A/C compressor bolts.
53. Move the A/C compressor with the hoses attached to the right side o f the engine compartment.
54. Move the wiring harness to the left side o f the vehicle and secure out to the way.

55. Remove the bolts retaining the power steering pump front bracket to the power steering pump and the air                     conditioner compressor mounting bracket.
56. Remove the air conditioning and power steering pump mounting bracket. Refer to Air Conditioning (A/C)                    Compressor and Power Steering Pump Bracket Replacement.
When the battery cables are removed from the engine the power steering pump can be removed further out of              the way.

57. Remove the right idler pulley bolt (1) and pulley.

58. Remove the generator mounting bracket and secure to the side.
• The generator does not require removal.
• The drive belt tensioner does not require removal.

59. Use the J 43181 in order to disconnect the inlet heater hose from the heater core inlet. See Special Tools.
60. Remove the bolt and the ground wires at the rear o f the left cylinder head.
61. Raise the vehicle.
62. Remove the oil pan skid plate. Refer to Oil Pan Skid Plate Replacement (2500/3500 with RPO N Z Z ).
63. Remove the engine shield from the vehicle, if equipped. Refer to Engine Shield Replacement.

64. Remove the bolt for the battery negative cable and the engine wiring harness ground wire from the left side o f             the engine.

65. Remove the bolts holding the battery cable channel retainer to the lower crankcase.

66. Disconnect the cord for the engine coolant heater.
67. Remove the starter. Refer to Starter Motor Replacement (6 .6 L ).

68. Remove the nut holding the battery cable bracket to the right side of the lower crankcase.

69. Remove the bolt holding the auxiliary battery negative cable and the engine wiring harness ground wires to the           right side o f the engine.
70. Move and secure the battery cables out o f the way.

71. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
72. Drain the engine oil.
73. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.

74. If vehicle is 4-wheel drive (4W D ) remove the lower oil pan. Refer to Lower Oil Pan Replacement.

75. If equipped with an automatic transmission, mark the flywheel and torque converter relationship for assembly             purposes.
76. Remove the torque convertor bolts through the starter opening.

77. If equipped with an automatic transmission, remove the transmission oil line clip nut.

78. If equipped with an automatic transmission, remove the nuts retaining transmission fluid fill tube bracket.

79. Remove the transmission to engine stud and bolts (automatic transmission shown). Note the location of the                 studs and any brackets attached to the studs.

80. Lower the vehicle to work through the wheelhouse opening.
81. Remove the engine mount to frame bracket bolts (left side shown).
82. Lower the vehicle.

83. Install the J 36857 (1) to the rear o f the left cylinder head with a suitable bolt. See Special Tools .

84. Install the J 36857 (1) to the front o f the right cylinder head with a suitable bolt. See Special Tools.
85. Install a suitable lifting device. The engine will have to be angled in order to remove. Use a load positioning sling         to assist in angling the engine.

86 . Raise the vehicle off o f the engine mounts.
87. Remove the left and right engine mount frame brackets.
88 . Remove the engine from the vehicle.
89. In order to secure the engine to an engine stand remove the following and follow the special procedures:
• Refer to Engine Flywheel Removal (Automatic Transmission) or Engine Flywheel Removal (Manual Transmission).
• Refer to Exhaust Outlet Rem oval.
• Refer to Upper Oil Pan Rem oval.

• Refer to Engine Flywheel Housing Rem oval.
• Refer to Engine Mounting to Stand.