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Engine External Components R&R Instructions

Draining and Filling Cooling System

Drain and Fill Procedure

4.8, 5.3, 6.0 & 8.1

Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

Notice: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

  1. Park the vehicle on a level surface.
  2. Follow the steps below in order to remove the surge tank fill cap:
        1. Slowly rotate the cap counterclockwise.
        2. Stop rotating and allow the hissing to stop.
        3. After all hissing stops, continue turning counterclockwise in order to remove the cap.
  3. Open the radiator drain cock.
  4. Allow the system to drain completely.
  5. Inspect the engine coolant for the following:
        - Discolored - follow the flush procedure below.
        - Normal in appearance - continue with the next step.

     Notice: When adding coolant, use DEX-COOL? coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

     Notice: DO NOT use cooling system seal tabs, or similar compounds, unless otherwise instructed. The use of cooling system seal tabs, or similar compounds, may restrict coolant flow through the passages of the cooling system or the engine components. Restricted coolant flow may cause engine overheating and/or damage to the cooling system or the engine components/assembly.

  6. Close the radiator drain cock.
  7. Fill the system through the surge tank opening.
  8. Pre-mix a 50 to 60 percent solution of DEX-COOL? and clean, drinkable water.
  9. Slowly add the pre-mixed solution to the surge tank until the level is slightly above the COLD FILL mark.
 10. Start the engine.
 11. Idle the engine for 1 minute.
 12. Loosely install the surge tank cap. DO NOT allow the system to build up pressure.
 13. Cycle the engine from idle to 3,000 RPM in 30 second intervals until the engine coolant reaches 99?C (210?F) and the thermostat opens.
 14. Shut off the engine.
 15. Refer to step 2 in order to remove the surge tank cap.
 16. Start the engine.
 17. Idle the engine for 1 minute. Fill the surge tank to 12.7 mm (1/2 in) above the COLD FILL mark on the surge tank.
 18. Install the radiator surge tank cap.
 19. Cycle the engine from idle to 3,000 RPM in 30 second intervals until the engine coolant reaches 99?C (210?F) and the thermostat opens.
 20. Shut off the engine.
 21. Top off the coolant, as necessary, to 12.7 mm (1/2 in) above the COLD FILL mark on the surge tank.
 22. Rinse away any excess coolant from the engine and the engine compartment.
 23. Inspect the concentration of the coolant.

Engine Block Draining



  1. Drain the cooling system, refer to the above procedure.
  2. If equipped with the 4.8L, 5.3L or 6.0L engine, remove the left and right engine block coolant drain plugs.



  3. If equipped with the 8.1L engine, remove the left and right engine block coolant drain plugs.
  4. Remove the engine block coolant heater, if equipped. Refer to (5.3, 6.0) Coolant Heater Replacement . or (8.1) Coolant Heater Replacement.
  5. Allow the engine block to drain completely.
  6. Apply sealant GM P/N 12346004 (Canadian  P/N 10953480) or equivalent to the drain plugs.

     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.

  7. Re-install the engine block coolant drain plugs.

     Tighten

        ? Tighten the 4.8L, 5.3L or 6.0L engine block coolant drain plug to 60 N?m (44 lb ft).
        ? Tighten the 8.1L engine block coolant drain plug to 60 N?m (44 lb ft).
  8. Install the engine block coolant heater, if equipped. Refer to (5.3-6.0) Coolant Heater Replacement or (8.1) Coolant Heater Replacement.
  9. Fill the cooling system, refer to the above procedure.
 
Coolant Heater Replacement (4.8L, 5.3L, and 6.0L Engines)

Removal Procedure



  1. Drain the cooling system/engine block. Refer to Draining and Filling Cooling System .
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.

  3. Remove the oil pan skid plate bolts and plate.



  4. Remove the oil cooler hose bracket bolt.
  5. Remove the oil cooler hose adapter bolts.
  6. Remove and discard the oil cooler hose adapter gasket.
  7. Position the oil cooler hose adapter end out of the way.



  8. Disconnect the coolant heater electrical connector (2).



     Important: Do not score the surface of the engine block hole when removing the coolant heater.
  9. Remove the coolant heater from the engine block.
 10. Remove any burrs, sealer, or other rough spots.

Installation Procedure


  1. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads.

     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.

  2. Install the coolant heater to the engine block.

     Tighten

     Tighten the coolant heater to 50 N?m (37 lb ft).


  3. Connect the coolant heater electrical connector (2).



  4. Position the oil cooler hose adapter end.
  5. Install a NEW oil cooler hose adapter gasket.
  6. Install the oil cooler hose adapter bolts.

     Tighten

     Tighten the bolts to 12 N?m (106 lb in).
  7. Install the oil cooler hose bracket bolt.

     Tighten

     Tighten the bolt to 25 N?m (18 lb ft).




  8. Install the oil pan skid plate and bolts.

     Tighten

     Tighten the bolts to 20 N?m (15 lb ft).
  9. Lower the vehicle.
 10. Fill the cooling system/engine block. Refer to Draining and Filling Cooling System .
 
Coolant Heater Replacement (8.1L Engine)

Removal Procedure



  1. Drain the cooling system/engine block. Refer to Draining and Filling Cooling System .
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
  3. Remove the oil pan skid plate bolts and plate.



  4. Disconnect the coolant heater electrical connector.



  5. Remove the coolant heater from the engine block.

Installation Procedure



  1. If reusing the old coolant heater, apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads.

     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.

  2. Install the coolant heater into the engine block.

     Tighten

     Tighten the coolant heater to 60 N?m (40 lb ft).



    Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage.

  3. Connect the coolant heater electrical connector.
  4. Fill the cooling system/engine block. Refer to Draining and Filling Cooling System .
 
Air Cleaner Resonator Outlet Duct Replacement

Removal Procedure



  1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor.
  2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body.
  3. Remove the radiator inlet hose clamp from the outlet duct.
  4. Remove the air cleaner outlet duct.

Installation Procedure



  1. Install the air cleaner outlet duct.
  2. Install the air cleaner outlet duct to the throttle body.
  3. Install the air cleaner outlet duct to MAF/IAT sensor.
  4. Install the radiator inlet hose clamp to the outlet duct.

     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.

  5. Tighten the air cleaner outlet duct clamps.

     Tighten

     Tighten the clamps to 4 N?m (35 lb in).
 
Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L (RPO LQ4))

Removal Procedure



  1. Loosen the intake manifold sight shield bolt.
  2. Remove the sight shield from the sight shield retainer.



  3. Remove the sight shield retainer bolts and the retainer, if required.

Installation Procedure



     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.

  1. Install the sight shield retainer and the bolts, if required.

     Tighten

     Tighten the bolts to 5 N?m (44 lb in).



     Notice: Use care when installing the engine sight shield to avoid contacting the manifold absolute pressure (MAP) sensor wire harness connector. Loss of engine performance or engine damage may result.

  2. Install the intake manifold sight shield to the retainer.

     Tighten

     Tighten the bolt to 10 N?m (89 lb in).
 
Engine Sight Shield Replacement (6.0L (RPO LQ9))

Removal Procedure



  1. Loosen the intake manifold sight shield bolt.
  2. Remove the sight shield from the sight shield retainer.
  3. Loosen the left fuel rail cover bolts.
  4. Remove the left fuel rail cover.
  5. Remove the surge tank/heater hoses from the clip on the right fuel rail cover.
  6. Loosen the right fuel rail cover bolts.
  7. Remove the right fuel rail cover.



  8. Remove the sight shield retainer bolts and retainer, if required.

Installation Procedure




     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.

  1. Install the sight shield retainer and bolts, if required.

     Tighten

     Tighten the bolts to 5 N?m (44 lb in).



  2. Install the right fuel rail cover.
  3. Tighten the right fuel rail cover bolts.

     Tighten

     Tighten the bolts to 9 N?m (80 lb in).

  4. Install the surge tank/heater hoses to the clip on the right fuel rail cover.
  5. Install the left fuel rail cover.
  6. Tighten the left fuel rail cover bolts.

     Tighten

     Tighten the bolts to 9 N?m (80 lb in).

     Notice: Use care when installing the engine sight shield to avoid contacting the manifold absolute pressure (MAP) sensor wire harness connector. Loss of engine performance or engine damage may result.

  7. Install the sight shield to the sight shield retainer.
  8. Tighten the intake manifold sight shield bolt.

     Tighten

     Tighten the bolt to 10 N?m (89 lb in).
 
Throttle Control Assembly Replacement

Removal Procedure

Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

Important:
  ? DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged.
  ? An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required.




  1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to Draining and Filling Cooling System.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical - 4.8L, 5.3L, 6.0(LQ4), and 6.0L.
  4. Disconnect the throttle actuator motor electrical connector (3).



  5. Reposition the coolant air bleed hose clamp at the throttle body.
  6. Remove the coolant air bleed hose from the throttle body.



  7. Remove the throttle body nuts.
  8. Remove the throttle body and the gasket.

     Important: Do not reuse the throttle body gasket. Install a new gasket during assembly.
  9. Discard the throttle body gasket.

Installation Procedure



  1. Install a NEW throttle body gasket.
  2. Install the throttle body.

     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.

  3. Install the throttle body nuts.

     Tighten

     Tighten the nuts to 10 N?m (89 lb in).



  4. Install the coolant air bleed hose to the throttle body.
  5. Position the coolant air bleed hose clamp at the throttle body.



     Important: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged.

  6. Connect the throttle actuator motor electrical connector (3).
  7. Install the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  9. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
 10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
 11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
 12. Verify that the vehicle meets the following conditions:
        - The vehicle is not in a reduced engine power mode.
        - The ignition is ON.
        - The engine is OFF.
 13. Start the engine.
 14. Inspect for coolant leaks.
 
Fuel Pressure Relief Procedure

Tools Required

J 34730-1A Fuel Pressure Gage

Caution: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.



  1. Disconnect the negative battery cable.
  2. Install the J 34730-1A . Refer to Fuel Pressure Gage Installation and Removal .
  3. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure.
  4. Open the valve on J 34730-1A in order to bleed the system pressure. The fuel connections are now safe for servicing.
  5. Drain any fuel remaining in the gage into an approved container.
  6. Once the system pressure is completely relieved, remove the J 34730-1A .
 
Quick Connect Fitting(s) Service (Metal Collar)

Tool Required

J 41769 Fuel Line Quick Disconnect Tool

Removal Procedure



  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the retainers from the fuel line quick-connect fittings.



     Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.

  3. Using compressed air, blow any dirt or debris from around the fittings.



  4. Using the correct tool from J 41769 , insert the tool into the female connector, then push inward in order to release the quick connect locking tabs.



  5. Pull the fuel line connection apart.

     Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

  6. Use a clean shop towel in order to wipe off the male connection end.
  7. Inspect both ends of the fittings for dirt and burrs. Clean or replace the components as required.

Installation Procedure



     Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends.This will ensure proper reconnection and prevent a possible fuel leak.During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

  1. Apply a few drops of clean engine oil to the male connection end.



  2. Push both sides of the fittings together in order to snap the retaining tabs into place.



  3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.



  4. Install the retainers to the fuel line quick-connect fittings.
  5. Install the fuel fill cap.
  6. Connect the negative battery cable.
 
Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)

Removal Procedure

Important:  An 8-digit identification number (1) is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required.



  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .



  2. Remove the wire harness bracket nut (2).
  3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
  4. Disconnect the generator electrical connector (3).



  5. Disconnect the following electrical connectors:
        - Manifold absolute pressure (MAP) sensor (1)
        - Knock sensor (2)
  6. Remove the knock sensor harness connector from the intake manifold.



  7. Remove the connector position assurance (CPA) lock.
  8. Disconnect the following electrical connectors from both sides of the engine:
        - Main coil (2)
        - Fuel injectors
  9. Remove the harness clips from the fuel rail (1).
 10. Reposition the engine wire harness aside.



 11. Perform the following steps in order to disconnect the fuel injector electrical connectors.
        1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
        2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
        3. Push the tab (1) on the connector in.
        4. Disconnect the fuel injector electrical connector.
        5. Repeat the steps for each injector electrical connector.



 12. Remove the positive crankcase ventilation (PCV) hose.



 13. Disconnect the fuel feed and return pipes (1) from the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
 14. Remove the fuel pressure regulator vacuum hose.



 15. Remove the fuel rail bolts.

    Notice:
        ? Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
        ? Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.


     Important: Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.

 16. Remove the fuel rail.



 17. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
 18. Discard the O-ring seal.

Installation Procedure



  1. Lubricate NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto each injector, if necessary.



  3. Install the fuel rail.
  4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian 10953489), or equivalent to the threads of the fuel rail bolts.

     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.

  5. Install the fuel rail bolts.

     Tighten

     Tighten the bolts to 10 N?m (89 lb in).



  6. Install the fuel pressure regulator vacuum hose.
  7. Connect the fuel feed and return pipes (1) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .



  8. Install the PCV hose.



  9. Perform the following steps in order to connect the fuel injector electrical connectors.
        1. Install the connectors to their corresponding injectors to ensure correct reassembly.
        2. Connect the fuel injector electrical connector.
        3. Push the CPA retainer (2) on the connector in 1 click.
        4. Repeat the steps for each injector electrical connector.



 10. Position the engine wire harness.
 11. Connect the following electrical connectors to both sides of the engine:
        - Main coil (2)
        - Fuel injectors
 12. Install the harness clips to the fuel rail (1).
 13. Install the CPA retainers.



 14. Connect the following electrical connectors:
        - MAP sensor (1)
        - Knock sensor (2)
 15. Install the knock sensor harness connector to the intake manifold.



 16. Connect the EVAP purge solenoid electrical connector (1).
 17. Connect the generator electrical connector (3).
 18. Install the wire harness bracket nut (2).

    Tighten

     Tighten the nut to 5 N?m (44 lb in).

 19. Tighten the fuel fill cap.
 20. Connect the negative battery cable.

 21. Use the following procedure in order to inspect for leaks:
        1. Turn the ignition ON, with the engine OFF, for 2 seconds.
        2. Turn the ignition OFF for 10 seconds.
        3. Turn the ignition ON, with the engine OFF.
        4. Inspect for fuel leaks.
 
Fuel Rail Assembly Replacement (5.3L (L59) Dual-Fuel Engine)

Removal Procedure

     Important: The L59 E85 fuel rail is comprised of a material that is compatible with fuel that has a concentration of up to 85 percent ethanol. The E85 fuel rail also uses an E85 Denso fuel injectors. Because of this, special procedures will be used in servicing the fuel rail and associated components. The screws that fasten the retaining clips for the crossover pipe to the fuel rails are thread cutting and therefore should NOT be removed from the fuel rail. The fuel rail will be serviced as an entire component.

     Important:  An 8-digit identification number (1) is located on the fuel rail. Refer to this model identification number if service or part replacement is required.



  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .



  2. Remove the wire harness bracket nut (2).
  3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
  4. Disconnect the generator electrical connector (3).



  5. Disconnect the following electrical connectors:
        - Manifold absolute pressure (MAP) sensor (1)
        - Knock sensor (2)
  6. Remove the knock sensor harness connector from the intake manifold.



  7. Remove the connector position assurance (CPA) retainer.
  8. Disconnect the following electrical connectors from both sides of the engine:
        - Main coil (2)
        - Fuel injectors
  9. Remove the harness clips from the fuel rail (1).
 10. Reposition the upper engine wire harness aside.



 11. Perform the following steps in order to disconnect the fuel injector electrical connectors:

     Important: When disconnecting the Multec? 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable.

        1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
        2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
        3. Push the tab (1) on the connector in.
        4. Disconnect the fuel injector connector electrical connector.
        5. Repeat the steps for each injector connector.



 12. Remove the positive crankcase ventilation (PCV) hose.



 13. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
 14. Disconnect the fuel pressure regulator vacuum line.



 15. Remove the fuel rail bolts.

     Notice:
        ? Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
        ? Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.


     Important: Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvents.

 16. Remove the fuel rail.



 17. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
 18. Discard the O-ring seal.

Installation Procedure



  1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto each injector, if necessary.



  3. Install the fuel rail.
  4. Apply a 5 mm (0.020 in) band of threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts.

     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.

  5. Install the fuel rail bolts.

    Tighten

     Tighten the bolts to 10 N?m (89 lb in).



  6. Connect the fuel pressure regulator vacuum line.
  7. Connect the fuel feed and return pipes (1, 2) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .



  8. Install the PCV hose.



  9. Perform the following steps in order to connect the fuel injector electrical connectors.
        1. Install the connectors to their corresponding injectors to ensure correct reassembly.
        2. Connect the fuel injector electrical connector.
        3. Push the CPA retainer (2) in the connector in 1 click.
        4. Repeat the steps for each injector electrical connector.



 10. Position the engine wire harness.
 11. Connect the following electrical connectors to both sides of the engine:
        - Main coil (2)
        - Fuel injectors
 12. Install the harness clips to the fuel rail (1).
 13. Install the CPA retainers.



 14. Connect the following electrical connectors:
        - MAP sensor (1)
        - Knock sensor (2)
 15. Install the knock sensor harness connector to the intake manifold.



 16. Connect the EVAP purge solenoid electrical connector (1).
 17. Connect the generator electrical connector (3).
 18. Install the wire harness bracket nut (2).

     Tighten

     Tighten the nut to 5 N?m (44 lb in).

 19. Tighten the fuel fill cap.
 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
 21. Use the following procedure in order to inspect for leaks:
        1. Turn the ignition ON, with the engine OFF, for 2 seconds.
        2. Turn the ignition OFF for 10 seconds.
        3. Turn the ignition ON, with the engine OFF.
        4. Inspect for fuel leaks.
 
Fuel Injector Replacement

Removal Procedure

Notice: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

Important

The engine oil may be contaminated with fuel if the fuel injectors are leaking.




  1. Remove the fuel rail. Refer to Fuel Rail Assembly Replacement .
  2. Remove and discard the fuel injector retainer clip (19).
  3. Remove the fuel injector (17).



  4. Remove and discard the fuel injector retainer clip (1).
  5. Remove and discard the fuel injector O-ring seals (2, 4).

Installation Procedure



Important

When ordering new fuel injectors, you must order the correct injector for the application being serviced.


The fuel injector (1) is stamped with a identification part number (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector.




  1. Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil.
  2. Install the NEW injector O-ring seals onto the fuel injector.
  3. Install a NEW retainer clip (1) onto the fuel injector.



  4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket.
  5. Install the fuel rail. Refer to Fuel Rail Assembly Replacement .

 
 
Fuel Rail and Injectors Removal

     Caution
     Refer to Fuel Rail Stop Bracket Installation Caution.




     Notice:
        ? Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
        ? Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.


     Important

     The intake manifold, throttle body, fuel injection rail and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the intake manifold as a complete assembly.


  1. Remove the fuel rail stop bracket and bolt, if required.
  2. Remove the vacuum hose from the fuel pressure regulator for the L59 engine.



  3. Loosen the crossover tube-to-right fuel rail retaining bolt.
  4. Remove the fuel rail bolts.

    Important
         * Do not separate the fuel injectors from the fuel rail unless component service is required.
         * Use cleanliness and care when handling the fuel system components.
         * Do not allow dirt or debris to enter the fuel injectors or fuel rail components, cap ends as necessary.


  5. Remove the fuel rail, with injectors, lifting evenly from both sides of the fuel rail until all the injectors have left their bores.
 
Fuel Rail Stop Bracket Installation Caution

Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.
 
Throttle Body Removal



     Important: The intake manifold, throttle body, fuel injection rail, and fuel injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove the electrical wire harness connectors from the throttle body.
  2. Remove the engine coolant air bleed hose and clamp, if applicable.
  3. Remove the throttle body nuts.
  4. Remove the throttle body.



  5. Remove the throttle body gasket (509).
  6. Discard the gasket.
  7. Remove the throttle body studs, if required.
 
Intake Manifold Cleaning and Inspection

Cleaning Procedure



    Important: Do not use the intake manifold-to-cylinder head sealing gaskets again.

  1. Remove the manifold absolute pressure (MAP) sensor (714) from the rear of the intake. The MAP sensor is to be reinstalled upon completion of the cleaning and inspection procedures.
  2. Inspect the sealing grommet on the MAP sensor. The grommet should not be torn or damaged.



  3. Remove and discard the intake manifold-to-cylinder head gaskets (514).



  4. Remove the fuel rail with injectors. Refer to Fuel Rail and Injectors Removal .



  5. Remove the throttle body and gasket. Refer to Throttle Body Removal .



  6. Remove the evaporative emission (EVAP) canister purge solenoid valve (70:cool:, bolt (710), and isolator (709).
  7. Clean the intake manifold in solvent.
        - Clean the intake manifold gasket surfaces.
        - Clean the intake manifold internal passages.

Safety Glasses Caution

Caution: Wear safety glasses in order to avoid eye damage.

  8. Dry the intake manifold with compressed air.

Inspection Procedure



  1. Inspect the throttle body studs and threaded inserts for looseness or damaged threads.
  2. Inspect the wire harness stud and threaded insert for looseness or damaged threads.



  3. Inspect the fuel rail bolt inserts for looseness or damaged threads.
  4. Inspect the intake manifold vacuum passages for debris or restrictions.



  5. Inspect for damaged or broken vacuum fittings, damaged MAP sensor (714) mounting bore, or broken MAP sensor retaining tabs.
  6. Inspect the composite intake manifold assembly for cracks or other damage.
  7. Inspect the areas between the intake runners. Inspect all the gasket sealing surfaces for damage.



  8. Inspect the fuel injector bores for excessive scoring or damage.
  9. Inspect the intake manifold cylinder head deck for warpage.
        1. Locate a straight edge across the intake manifold cylinder head deck surface.
        2. Position the straight edge across a minimum of 2 runner port openings. Insert a feeler gage between the intake manifold and the straight edge.
           A intake manifold with warpage in excess of 3 mm (0.118 in) over a 200 mm (7.87 in) area is warped and should be replaced.



 10. Install the MAP sensor (714).

    Notice: Refer to Fastener Notice.

 11. Install the EVAP canister purge solenoid valve, bolt, and isolator.

     Tighten

     Tighten the EVAP valve bolt to 10 N?m (89 lb in).
 
Intake Manifold Replacement

Removal Procedure

      Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  1. Remove the throttle body. Refer to Throttle Body Assembly Removal - 4.8L, 5.3L, and 6.0L.
  2. Remove the fuel injectors. Refer to Fuel Injector Remove & Replace - 4.8L, 5.3L, and 6.0L.



  3. Disconnect the following electrical connectors:
        - Manifold absolute pressure (MAP) sensor (1)
        - Knock sensor (2)
  4. Remove the knock sensor harness electrical connector from the intake manifold.
  5. Set the electrical harness aside.



  6. If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.



  7. Remove the positive crankcase ventilation (PCV) hose.



  8. Remove the MAP sensor (1) from the intake manifold.



  9. Remove the evaporative emission (EVAP) purge solenoid vent tube by performing the following:
        1. Remove the EVAP tube end from the solenoid (1).
        2. Remove the EVAP tube end from the vapor pipe (2).



  10. Remove the EVAP purge solenoid bolt (2), solenoid (3), and isolator (1) from the intake manifold.



  11. Loosen the intake manifold bolts.
  12. Remove the intake manifold.

492770.gif


  13. Remove the intake manifold gaskets (1) from the intake manifold.
  14. Discard the old intake manifold gaskets.
  15. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection .

Installation Procedure

492770.gif


  1. Install NEW intake manifold gaskets (1) to the intake manifold.



  2. Install the intake manifold.
  3. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the intake manifold bolts.



    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.

  4. Tighten the intake manifold bolts.

      Tighten

        1. Tighten the bolts a first pass in sequence to 5 N?m (44 lb in).
        2. Tighten the bolts a final pass in sequence to 10 N?m (89 lb in).



  5. Install the EVAP purge solenoid (3), isolator (1), and bolt (2) to the intake manifold.

      Tighten

      Tighten the bolt to 10 N?m (89 lb in).


  6. Install the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).



      Important: Lightly coat the MAP sensor seal with clean engine oil before installing.

  7. Install the MAP sensor (1) to the intake manifold.



  8. Install the PCV hose.



  9. If equipped with vacuum assisted brakes, install the vacuum brake booster hose to the rear of the intake manifold.
  10. Route the electrical harness into position over the engine.



  11. Connect the knock sensor harness electrical connector to the intake manifold.
  12. Connect the following electrical connectors.
        - MAP sensor (1)
        - Knock sensor (2)
  13. Install the fuel injectors. Refer to Fuel Injector Remove & Replace - 4.8L, 5.3L, and 6.0L.
  14. Install the throttle body. Refer to Throttle Body Assembly Replacement - 4.8L, 5.3L, and 6.0L.
 
Throttle Body Assembly Replacement

Removal Procedure

Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

Important:
  ? DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged.
  ? An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required.




  1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to Draining and Filling Cooling System in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  4. Disconnect the throttle actuator motor electrical connector (2).



  5. Reposition the coolant air bleed hose clamp at the throttle body.
  6. Remove the coolant air bleed hose from the throttle body.



  7. Remove the throttle body nuts.
  8. Remove the throttle body.



  9. Remove and discard the throttle body gasket (1).

Installation Procedure



  1. Install the NEW throttle body gasket (1).



  2. Install the throttle body.

      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.

  3. Install the throttle body nuts.

      Tighten

      Tighten the nuts to 10 N?m (89 lb in).



  4. Install the coolant air bleed hose to the throttle body.
  5. Position the coolant air bleed hose clamp at the throttle body.



    Important: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged.

  6. Connect the throttle actuator motor electrical connector (2).
  7. Install the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  9. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  12. Verify that the vehicle meets the following conditions:
        - The vehicle is not in a reduced engine power mode.
        - The ignition is ON.
        - The engine is OFF.
  13. Start the engine.
  14. Inspect for coolant leaks.
 
Knock Sensor (KS) Replacement

Removal Procedure



  1. Remove the intake manifold. Refer to Intake Manifold Replacement - 4.8L, 5.3L, and 6.0L.
  2. Gently pry up the rubber covers.
  3. Disconnect the knock sensor electrical connectors.



  4. Remove the knock sensors.

Installation Procedure



     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.

  1. Install the knock sensors.

     Tighten

     Tighten the sensor to 20 N?m (15 lb ft).



  2. Connect the knock sensor electrical connectors.
  3. Push down on the rubber covers.
  4. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical-4.8L, 5.3L, and 6.0L.
 
Throttle Position (TP) Sensor Replacement (02 referenced)

Removal Procedure

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. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

     Notice: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent as damage may result.

Important: If the vehicle is equipped with electronic throttle control (ETC) the throttle position (TP) sensor is NOT serviceable. The throttle body and TP sensor MUST be serviced as a complete assembly.

normal_309169.gif



  1. Disconnect the negative battery cable.
  2. Remove the generator. Refer to Generator Replacement in Engine Electrical.

normal_389028.gif


  3. Disconnect the throttle position TP sensor electrical connector.

normal_356448.gif


  4. Remove the TP sensor attaching screws (5).
  5. Remove the TP sensor (6).
  6. Remove the TP sensor O-ring seal (7).

Installation Procedure

normal_356448.gif


  1. Install the TP sensor O-ring seal (7) on the TP sensor (6).
  2. Install the TP sensor on the throttle body with the throttle valve in the closed position. Verify the TP sensor lever lines up with the TP sensor drive lever on the throttle shaft.

     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.

  3. Install the TP sensor attaching screws (5).

     Tighten

     Tighten the screws to 2 N?m (18 lb in).

normal_389028.gif


  4. Connect the TP sensor electrical connector.

normal_309169.gif


  5. Install the generator. Refer to Generator Replacement in Engine Electrical.
  6. Connect the negative battery cable.
 
5.3 6.0 Full Engine View Left Side (c)

(1) Idle Air Control (IAC) Motor
(2) Evaporative Emissions (EVAP) Canister Purge Solenoid
(3) Fuel Injector 1
(4) Fuel Injector 3
(5) Fuel Injector 5
(6) Manifold Absolute Pressure (MAP) Sensor
(7) Fuel Injector 7
(8} Positive Crankcase Ventilation (PCV) Valve
(9) Ignition Coil 7
(10) Ignition Coil 5
(11) Ignition Coil 3
(12) Ignition Coil 1
(13) Engine Coolant Temperature (ECT) Sensor
(14) Throttle Position (TP) Sensor
(15) Throttle Body

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5.3 6.0 Right Side of the Engine (c)

(1) Throttle Body
(2) Fuel Injector 2
(3) Ignition Coil 2
(4) Fuel Injector 4
(5) Ignition Coil 4
(6) C149
(7) Fuel Injector 6
(8} Ignition Coil 6
(9) Ignition Coil 8
(10) Fuel Injector 8

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Engine Oil Pressure (EOP) Sensor and CMP Sensor Locations

(1) Engine Oil Pressure (EOP) Sensor
(2) Camshaft Position (CMP) Sensor
(3) Camshaft Position (CMP) Sensor Connector

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Attachments

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5.3 6.0 Crankshaft Position (CKP) Sensor Location

(1) CKP Mounting Bolt
(2) CKP Mounting Location
(3) Crankshaft Position (CKP) Sensor

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Attachments

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