GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2000 🢒 GMC C Pickup - 2WD 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Engine Replacement

Removal Procedure

    Object Number: 358421 Size: SH
  1. Remove the hood. Refer to Hood Replacement in Body Front End.
  2. Disconnect both the battery negative cables from the batteries. Refer to Battery Replacement in Engine Electrical.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Drain the engine of motor oil.
  5. Remove the upper intake manifold cover.

    6. Object Number: 317717 Size: SH
  6. Remove the air conditioning compressor from the accessory mounting bracket vehicle and secure out of the way.

    7. Object Number: 388424 Size: SH
  7. Remove the generator from the right accessory mounting bracket and secure to the side.

    8. Object Number: 388602 Size: SH
  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 Engine Cooling.
  10. Remove the power steering lines from the power steering pump. Refer to Power Steering Hoses Replacement in Power Steering.

    11. Object Number: 527102 Size: SH
  11. Disconnect the fuel lines from the fuel manager/filter.

    12. Object Number: 399420 Size: SH
  12. Disconnect the engine wiring harness assembly at the left rear of the engine block.

    13. Object Number: 345208 Size: SH
  13. Remove the ground straps from the right rear cylinder head.

    14. Object Number: 309354 Size: SH
  14. Remove the heater hoses from the heater core (non-auxiliary shown).

    15. Object Number: 72730 Size: SH
  15. Remove the radiator hoses from the engine assembly.

    16. Object Number: 222260 Size: SH
  16. Install the engine lift bracket to the rear of the right cylinder head.

    17. Notice: Damage may result from the use of an improper bolt when attaching J36857 into the cylinder head.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  17. Install J 36857 along with GM P/N 94282217 bolt and GM P/N 15650963 washer to the right rear cylinder head.

    18. Tighten
    Tighten the lift bracket bolt to 40 N·m (30 lb ft).

  18. Raise the vehicle and support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  19. Remove the front propeller shaft from the vehicle (4 wheel drive only). Refer to Front Propeller Shaft Replacement in Propeller Shaft.

    20. Object Number: 188406 Size: SH
  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 in Engine Electrical.
  22. Remove the bolts from the torque converter.

    23. Object Number: 164372 Size: SH
  23. Remove the exhaust pipe from the turbocharger.

    24. Object Number: 317722 Size: SH
  24. Disconnect the electrical connector for the block heater.

    25. Object Number: 560503 Size: SH
  25. Remove the battery ground in the front of the engine block.

    26. Object Number: 566012 Size: SH
  26. Disconnect the oil cooler lines from the engine block.
  27. Remove the engine oil cooler lines and secure out of the way.

    28. 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.
    31. • For the 4L80 E automatic transmission, refer to Transmission Replacement in Automatic Transmission -- 4L80-E.
    • For the NV 4500 manual transmission, refer to Transmission Replacement in Manual Transmission -- NV 4500.
  31. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  32. Attach a suitable lifting devise from the lifting bracket to the left accessory mounting bracket.

    33. Object Number: 551000 Size: SH
  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.

    35. Object Number: 561724 Size: SH

    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. Object Number: 561728 Size: SH
  36. Remove the right engine mount through bolt.
  37. Support the transmission assembly with a suitable support.
  38. Remove the engine from the vehicle.

    39. Object Number: 34060 Size: SH

    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. Object Number: 59794 Size: SH
  44. Remove the left accessory bracket from the engine block.

    45. Object Number: 105622 Size: SH
  45. Remove the right accessory bracket from the engine block.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 59794 Size: SH

    Notice: Damage may result from the use of an improper bolt when attaching J36857 into the cylinder head.

  1. Install J 36857 along with GM P/N 94282217 bolt and GM P/N 15650963 washer to the right rear cylinder head.

    2. Tighten
    Tighten the lift bracket bolt to 40 N·m (30 lb ft).

  2. Install the left accessory bracket to the engine block.

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 105622 Size: SH
  3. Install the right accessory bracket to the engine block.

    4. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  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 Clutch.
  8. Install the engine assembly in the vehicle.

    9. Object Number: 560499 Size: SH
  9. Install the left engine mount bracket (if removed)

    10. Tighten
    Tighten the engine mount bracket bolts to 54 N·m (40 lb ft).


    Object Number: 560501 Size: SH
  10. Install the right engine mount bracket (if removed).

    11. Tighten
    Tighten the engine mount bracket bolts to 54 N·m (40 lb ft).


    Object Number: 561724 Size: SH
  11. Install the left engine mount through bolt.

    12. Tighten
    Tighten the engine mount through bolts to 59 N·m (44 lb ft).


    Object Number: 561728 Size: SH
  12. Install the right engine mount through bolt.

    13. Tighten
    Tighten the engine mount through bolts to 59 N·m (44 lb ft).

  13. Remove the lifting device from the engine assembly.

    14. Object Number: 222260 Size: SH
  14. Remove the lifting bracket from the rear of the right cylinder head.
  15. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  16. Install the bellhousing bolts from the engine block to the transmission.
    17. • For the 4L80-E automatic transmission, refer to Transmission Replacement in Automatic Transmission -- 4L80-E.
    • For the NV 4500 NV 4500 manual transmission, refer to Transmission Replacement in Manual Transmission NV 4500.
  17. Install the starter on the engine block. Refer to Starter Motor Replacement in Engine Electrical.
  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 in Engine Exhaust.
  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 Power Steering.
  23. Install the front propeller shaft in the vehicle (4 wheel drive only). Refer to Front Propeller Shaft Replacement in Propeller Shaft.

    24. Object Number: 317722 Size: SH
  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 Hose/Pipe Replacement in Engine Cooling.

    26. Object Number: 560503 Size: SH
  26. Install the ground strap in the right front corner of the engine.
  27. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    28. Object Number: 551000 Size: SH
  28. Install the inner splash shields on the vehicle.

    29. Object Number: 345208 Size: SH
  29. Install the ground straps at the right rear cylinder head.

    30. Object Number: 399420 Size: SH
  30. Install the fuels lines to the fuel manager/filter.

    31. Object Number: 309354 Size: SH
  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 in Engine Cooling.
  33. Install the radiator in the vehicle. Refer to Radiator Replacement in Engine Cooling.
  34. Install the generator to the right accessory mounting bracket. Refer to Generator Replacement in Engine Electrical.
  35. Install the auxiliary generator on the left accessory mounting bracket (for vehicles equipped with the ambulance package only). Refer to Auxiliary Generator Replacement in Engine Electrical.
  36. Reposition the A/C compressor on the left accessory mounting bracket. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation, and Air Conditioning.

    37. Object Number: 399420 Size: SH
  37. Reconnect the engine wiring harness gray connector at the left rear of the engine.
  38. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  39. Fill the Engine crankcase with the proper motor oil. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.
  40. Connect the battery cables to the battery terminals. Refer to Battery Replacement in Engine Electrical.
  41. Install a scan tool and check fro DTC's.
  42. Check and adjust the timing for the fuel injection pump. Refer to Fuel Injection Pump Timing Adjustment in Engine Controls - 6.5L-L65.
  43. Perform the TDC offset timing procedure. Refer to Fuel Injection Pump Top Dead Center Offset Adjustment in Engine Controls - 6.5L-L65.

    44. Object Number: 358421 Size: SH
  44. Install the upper engine cover on the engine assembly.
  45. Install the hood on the vehicle. Refer to Hood Replacement in Body Front End.