GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Chevrolet C-Series Medium Duty Truck B7 🢒 Engine 🢒 Engine Mechanical - 7.2L (Caterpillar) 🢒 Engine Replacement

Removal Procedure

    Object Number: 204729 Size: SH
  1. Disconnect the battery negative cables from the battery. Refer to Battery Cable Replacement in Engine Electrical.
  2. Remove the hood from the vehicle. Refer to Hood Replacement Hood Replacement in Body and Accessories.
  3. Remove both left and right wheel house panels from the vehicle. Refer to Wheelhouse Panel Replacement in Body and Accessories.

    4. Object Number: 198949 Size: SH
  4. Remove the air cleaner assembly from the vehicle.
  5. Disconnect the air inlet tube (1). Refer to Caterpillar® 3126 Unit Repair Manual.
  6. Drain the air reservoir for the air brakes (if equipped). Refer to Draining Reservoirs in Air Brakes.
  7. Disconnect the air lines from the air compressor to the air brake reservoir. Refer to Caterpillar® 3126 Unit Repair Manual.
  8. Drain the cooling system. Refer to Cooling System Draining and Filling .
  9. Disconnect the turbo boost charge air cooler tube (turbocharger to charge air cooler). Refer to Caterpillar® 3126 Unit Repair Manual.
  10. Disconnect the boost charge air cooler tube (charge air cooler to the air inlet manifold). Refer to Caterpillar® 3126 Unit Repair Manual.
  11. Remove the radiator assembly from the vehicle.
  12. Remove the lower radiator mounting panel from the vehicle.
  13. Remove the radiator inlet hose from the vehicle.
  14. Remove the radiator outlet hose from the vehicle. Refer to Radiator Hose Replacement in Engine Cooling.
  15. Remove the surge tank inlet hose from the vehicle. Refer to Surge Tank Pipe Replacement - Inlet in Engine Cooling.
  16. Remove the surge tank outlet hose from the vehicle. Refer to Surge Tank Pipe Replacement - Outlet in Engine Cooling.
  17. Disconnect the power steering lines from the reservoir. Refer to Caterpillar® 3126 Unit Repair Manual.
  18. Disconnect the wiring harness from all retainers and brackets.
  19. Disconnect the wiring harness from all electrical connectors.
  20. Disconnect the wiring harness from the Electronic Control Module (ECM electric diesel only). Refer to Caterpillar® 3126 Unit Repair Manual.
  21. Disconnect the throttle linkage (non electric diesel). Refer to Caterpillar® 3126 Unit Repair Manual.
  22. Disconnect the lines from the air compressor. Refer to Caterpillar® 3126 Unit Repair Manual.
  23. Disconnect the fuel heater lines from the rear of the engine. Refer to Caterpillar® 3126 Unit Repair Manual.
  24. Disconnect the fuel supply and return lines. Refer to Caterpillar® 3126 Unit Repair Manual.
  25. Raise the vehicle.
  26. Drain the crankcase. Refer to Caterpillar® 3126 Unit Repair Manual.

    27. Object Number: 213161 Size: SH
  27. Disconnect the exhaust pipe from the turbocharger and position to the side.

    28. Object Number: 219328 Size: LH
  28. Remove the front engine mounts.
  29. Disconnect the bypass oil filter Lubrifiner® supply and return lines from the oil pan. Refer to Caterpillar® 3126 Unit Repair Manual.
  30. Remove the starter from the vehicle. Refer to Starter Motor Replacement in Engine Electrical.

    31. Object Number: 9096 Size: SH
  31. Remove the torque converter bolts from the torque converter through the starter opening.
  32. Remove the vacuum modulator vacuum line (for automatic transmission only).
  33. Lower the vehicle.
  34. Support the transmission.
  35. Attach a suitable lifting device to the engine assembly.

    36. Object Number: 205284 Size: SH
  36. Remove the bolts that secure the transmission to the engine.
  37. Remove the engine from the engine mounting brackets.
  38. Remove the engine from the vehicle.

    39. Important: It maybe necessary to remove the clutch or the flywheel from the engine assembly before the installing the engine assembly on the engine stand.

  39. Remove the clutch (if equipped) from the flywheel.
  40. Remove the flywheel from the engine assembly.
  41. Install the engine on a suitable engine stand.
  42. Remove the lifting device from the engine assembly.

Installation Procedure

    Object Number: 205284 Size: SH
  1. Remove the engine assemble from the engine stand.
  2. Install the flywheel to the engine assembly.
  3. Install the clutch (if equipped ) to the engine assembly.
  4. Align and install the engine to the transmission.
  5. Install the bolts from the transmission to the engine bolt.

    6. Object Number: 219328 Size: LH
  6. Install the front engine mounting bolts.

    7. Tighten
    Tighten the nuts to 175 N·m (129 lb ft).

  7. Remove the lifting device from the engine.
  8. Remove the support from the transmission.
  9. Raise the vehicle.

    10. Object Number: 9096 Size: SH
  10. Install the torque converter bolts to the flywheel.
  11. Install the starter assembly in the vehicle. Refer to Starter Motor Replacement in Engine Electrical.

    12. Object Number: 213161 Size: SH
  12. Connect the exhaust pipe to the turbocharger.
  13. Lower the vehicle.
  14. Connect the bypass oil filter Lubrifiner® supply and returns lines to the oil pan. Refer to Caterpillar® 3126 Unit Repair Manual.
  15. Connect the vacuum line to the modulator valve (automatic transmission only).
  16. Connect the fuel filter heater lines to the engine block. Refer to Caterpillar® 3126 Unit Repair Manual.
  17. Connect the fuel supply and the return lines to the engine. Refer to Caterpillar® 3126 Unit Repair Manual.
  18. Connect the wiring harness to the ECM (electric diesel).
  19. Connect the air lines to the air compressor. Refer to Caterpillar® 3126 Unit Repair Manual.
  20. Connect the throttle linkage.
  21. Connect the electrical wiring harness to the retainers and the brackets.
  22. Connect the electrical harness to the electrical connectors.
  23. Connect the power steering lines to the power steering pump. Refer to Caterpillar® 3126 Unit Repair Manual.
  24. Install the lower radiator mounting panel in the vehicle.
  25. Install the radiator assembly in the vehicle. Refer to Radiator Replacement in Engine Cooling.
  26. Install the radiator inlet hose on the vehicle.
  27. Install the radiator outlet hose on the vehicle.
  28. Install the surge tank inlet hose. Refer to Surge Tank Pipe Replacement - Inlet in Engine Cooling.
  29. Install the surge tank outlet hose. Refer to Surge Tank Pipe Replacement - Outlet in Engine Cooling.
  30. Install the air lines between the air compressor and the air brake reservoir. Refer to Caterpillar® 3126 Unit Repair Manual.

    31. Object Number: 198949 Size: SH
  31. Install the air cleaner assembly. Refer to Caterpillar® 3126 Unit Repair Manual.
  32. Install the turbo boost charger air cooler (turbocharger to the charger air cooler). Refer to Caterpillar® 3126 Unit Repair Manual.
  33. Connect the boost charger air cooler tube (charger air cooler to the air inlet manifold). Refer to Caterpillar® 3126 Unit Repair Manual.
  34. Connect the air inlet hose (1). Refer to Caterpillar® 3126 Unit Repair Manual.
  35. Install the hood on the vehicle. Refer to Hood Replacement in Body and Accessories.

    36. Object Number: 204729 Size: SH
  36. Connect the battery negative cables to the batteries. Refer to Battery Cable Replacement in Engine Electrical.
  37. Fill the engine crankcase with the proper grade and type of engine oil. Refer to Caterpillar® 3126 Unit Repair Manual.
  38. Fill the cooling system with the proper type and quantity of engine coolant. Refer to Cooling System Draining and Filling .
  39. Fill the power steering reservoir to the proper level. Refer to Caterpillar® 3126 Unit Repair Manual.
  40. Bleed the power steering if necessary. Refer to Caterpillar® 3126 Unit Repair Manual.
  41. Fill the air brake reservoir with air. Refer to Filling Reservoirs in Air Brakes.
  42. Prime the lubrication oil galleries if the engine has been rebuilt. Refer to Caterpillar® 3126 Unit Repair Manual.
  43. Prime the engine oil system if the engine has been rebuilt. Refer to Caterpillar® 3126 Unit Repair Manual.
  44. Prime the fuel system before starting the engine. Refer to Caterpillar® 3126 Unit Repair Manual.