Engine Mechanical - 4.8L, 5.3L & 6.0L: Removal & Installation GMC Yukon Denali

REMOVAL & INSTALLATION

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

1. Disconnect negative battery cable. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(ref-97542-S20014687912001050800000) . Drain cooling system. Discharge A/C system (if equipped), using approved refrigerant recovery/recycling equipment. Remove hood, grille, and front bumper. Remove air cleaner duct. Remove upper and lower radiator hose and both heater hoses. Remove upper and lower fan shrouds.
2. Remove A/C condenser. Remove radiator upper support, and remove radiator. Remove serpentine belt and fan. Remove accelerator and cruise control cables. Remove A/C pressure hose from A/C compressor, and remove compressor.
3. Disconnect necessary electrical connectors and vacuum lines. Remove generator and generator mounting bracket. Disconnect fuel pipes from engine. Raise and support vehicle. Remove body shield (if equipped). Drain crankcase. Remove steering linkage. Remove starter. Remove torque converter to flexplate bolts (A/T). Disconnect transmission cooler pipe bracket from right side of oil pan (if equipped). Remove exhaust pipe from exhaust manifolds. Remove lower bell housing studs from engine.
4. Lower vehicle. Remove remaining bell housing bolts. Support transmission with floor jack or stands. Remove engine mount through-bolts. Remove ignition coil(s) as required to ensure proper installation of engine lift brackets to cylinder heads. Attach engine Lift Brackets (J-41798) to cylinder heads. Attach engine hoist. Remove engine from vehicle.

Installation

Use NEW "O" rings when reconnecting fuel lines. To install, reverse removal procedure. Fill crankcase and cooling system. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-97542-S20014687912001050800000) . Drain cooling system. Remove sight shield (intake manifold cover) and sight shield mounting bracket. Remove air cleaner duct. Disconnect accelerator cable, cruise control cable, and coolant hose from throttle body. Disconnect necessary electrical connectors, and vacuum lines.
2. Remove EGR pipe. Remove fuel injector electrical connectors. Disconnect fuel pipes from fuel rail. Remove intake manifold bolts, and remove intake manifold.

1. Use NEW "O" rings when reconnecting fuel lines. Apply light coating of engine oil to NEW "O" ring and install onto EGR pipe. Tighten EGR valve bolts in 2 steps to specification. See «TORQUE SPECIFICATIONS»(ref-97542-S25419399842001050800000).
2. Install NEW gaskets and intake manifold. Apply Threadlock (12345382) or equivalent to intake manifold bolts. Tighten intake manifold bolts in sequence and to specification. (Scheme 1) See «TORQUE SPECIFICATIONS»(ref-97542-S25419399842001050800000). To complete installation, reverse removal procedure.

Scheme 1

Raise and support vehicle. Remove EGR pipe. Remove AIR pipe and valve. Remove AIR studs from manifold if necessary. Disconnect O2 sensors. Disconnect exhaust pipes from exhaust manifolds. Lower vehicle. Remove exhaust manifold bolts and studs. Remove exhaust manifold heat shield. Remove exhaust manifold and gaskets.

To install, reverse removal procedure. Install NEW gaskets. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Remove intake manifold. See INTAKE MANIFOLD . Remove exhaust manifold. See EXHAUST MANIFOLD . Remove generator, and generator mounting bracket. Remove valve cover. Remove rocker arms, rocker arm pivot support and pushrods. Remove cylinder head bolts. Discard M11 head bolts. Remove cylinder head and gasket.

Note. Engine displacement may be stamped on cylinder head gasket tab. (Scheme 2) Some 4.8L and 5.3L head gaskets have "53" stamped on tab. Some 6.0L head gaskets have "60" stamped on tab. Ensure tab on head gasket is toward front of engine.

Clean gasket surfaces, bolt threads and bolt holes. Position NEW head gasket onto cylinder block. DO NOT use sealant on head gasket. Ensure tab on gasket is toward front of engine, and all holes align. (Scheme 2) Install cylinder head. Apply Threadlock (12345382) or equivalent onto head bolts. Install (finger tighten) NEW M11 head bolts and original M8 bolts (if undamaged). Tighten head bolts in sequence and to specification. (Scheme 3) See TORQUE SPECIFICATIONS. To complete cylinder head installation, reverse removal procedure. Adjust valves. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Scheme 2

Scheme 3

Disconnect negative battery cable. Remove ignition coil and bracket assembly from valve covers (if necessary). Disconnect oil fill tube (if necessary). Remove valve covers, and rocker arm nuts. If only replacing pushrods, loosen rocker arm bolt until rocker arm can be turned away from pushrod, and remove pushrod.

Valve cover gaskets are reusable. Replace gaskets only if damaged. Tighten to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Remove starter. Remove upper and lower fan shroud. Remove serpentine belt. Using Fan Clutch Wrench (J-41240), remove fan clutch and fan.
2. To remove crankshaft damper, install Flywheel Holder (J-42386), and ensure holder teeth mesh with flywheel teeth. (Scheme 4) Remove crankshaft damper bolt. Using Damper Puller (J-41816) and Crankshaft End Protector (J41816-2), remove crankshaft damper.

1. Using Damper/Sprocket Installer (J-41665), install crankshaft damper. Install original damper bolt, and tighten to 240 ft. lbs. (330 N.m). Ensure nose of crankshaft is recessed.094-.176" (2.39-4.47 mm) into damper bore. (Scheme 5)
2. Remove and discard original damper bolt, and install NEW damper bolt. Tighten NEW bolt in 2 steps to specification. See «TORQUE SPECIFICATIONS»(ref-97542-S25419399842001050800000). To complete installation, reverse removal procedure.

Scheme 4

Scheme 5

Disconnect negative battery cable. Remove crankshaft damper. See CRANKSHAFT DAMPER . Remove oil seal from front cover.

Coat front cover oil seal with clean engine oil. Using Seal Installer (J-41478), install NEW seal into front cover. (Scheme 6) To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 6

1. Remove negative battery cable. Drain cooling system. Remove upper and lower fan shrouds. Remove crankshaft damper. See «CRANKSHAFT DAMPER»(ref-97542-S19678270352001050800000) .
2. Remove water pump. See «WATER PUMP»(ref-97542-S20419305522001050800000) . Remove front cover bolts and front cover. Inspect front cover for distortion and damage. Replace cover if necessary.

1. Using NEW gasket, install front cover, and finger tighten cover bolts. Install Front Cover Aligner (J-41480) onto cylinder block. DO NOT tighten bolts. (Scheme 7) Install Front Cover Aligner (J-41476) onto crankshaft, and finger tighten crankshaft damper bolt. (Scheme 7)
2. Tighten Front Cover Aligner (J-41480) bolts. Tighten front cover bolts to 18 ft. lbs. (24 N.m). Measure front cover-to-cylinder block surface alignment. (Scheme 8) If not within specification, repeat alignment procedure.
3. Coat NEW front cover oil seal with engine oil. Using Seal Installer (J-41478), install NEW oil seal. (Scheme 6) To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97542-S25419399842001050800000).

Scheme 7

Scheme 8

1. Disconnect battery. Drain coolant. Remove front cover. See «FRONT COVER»(ref-97542-S02181954012001050800000). Remove oil pan, and oil pump. See «OIL PAN»(ref-97542-S41226295322001050800000) and «OIL PUMP»(ref-97542-S05762472362001050800000) under ENGINE OILING. CAUTION: To prevent damage to pistons and valves, Do not rotate engine after timing chain is removed.
2. Rotate crankshaft until timing marks on camshaft and crankshaft sprockets are aligned. (Scheme 9) Remove camshaft sprocket and timing chain. Using Sprocket Puller (J-41558), Crankshaft Pilot (J-41816-2), and Pulley Puller (J-8433-1), remove crankshaft sprocket.

1. Install Woodruff key into crankshaft (if removed). Using Crankshaft Sprocket Installer (J-41665), install crankshaft sprocket until fully seated against flange. Rotate crankshaft sprocket until alignment mark is at 12 o'clock. Install camshaft sprocket and timing chain. Make sure timing marks on sprockets are aligned. (Scheme 9) Install and tighten camshaft sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97542-S25419399842001050800000).
2. Install NEW front cover gasket, and NEW front cover seal. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97542-S25419399842001050800000).

Scheme 9

Disconnect negative battery cable. Remove cylinder head and gasket. See CYLINDER HEAD . Remove valve lifter guide bolts, lifters and guide. Remove stuck valve lifter(s) using Valve Lifter Remover (J-3049-A).

Lubricate valve lifters and cylinder block valve lifter bores with engine oil. Install lifters into original locations in lifter guide when reusing lifters. Push lifter completely into guide. Install lifter and valve guide assembly into original location in cylinder block, and install lifter guide bolt. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(ref-97542-S20014687912001050800000). Disconnect negative battery cable. Remove hood. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Drain cooling system. Remove radiator hoses. Remove front grille. Remove radiator support, radiator and A/C condenser. Remove A/C compressor. Remove air cleaner duct. Remove generator, and generator mounting bracket.
2. Raise vehicle. Remove starter. Remove crankshaft damper. See «CRANKSHAFT DAMPER»(ref-97542-S19678270352001050800000). Remove oil pan. See «OIL PAN»(ref-97542-S41226295322001050800000). Remove front cover. See «FRONT COVER»(ref-97542-S02181954012001050800000). Remove cylinder head. See «CYLINDER HEAD»(ref-97542-S16877869882001050800000). Remove valve lifters. See «VALVE LIFTERS»(ref-97542-S34089759102001050800000).
3. Align timing chain timing marks. (Scheme 9) Remove camshaft sprocket, timing chain and crankshaft sprocket. See «TIMING CHAIN & SPROCKETS»(ref-97542-S21651997252001050800000). Remove camshaft sensor bolt, "O" ring and sensor. (Scheme 10) Remove camshaft retainer bolts, retainer and gasket. Install 3 M8 bolts in camshaft front holes. Using bolts as handle, carefully rotate and pull camshaft out of engine block. Remove M8 bolts from camshaft.

Note. If replacing camshaft, install NEW valve lifters.

Coat camshaft lobes and bearing journals with engine oil. Install 3 M8 bolts into camshaft front holes. Using bolts as handle, carefully install camshaft into cylinder block. Remove M8 bolts. Tighten camshaft retainer bolts to specification. Coat camshaft sensor bolt "O" ring with engine oil. Tighten sensor bolt to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Scheme 10

Release fuel system pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Remove transmission, clutch (M/T) and flywheel. On A/T see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. On M/T see appropriate article in CLUTCHES. Remove rear crankshaft oil seal.

Coat oil seal O.D. only with engine oil. DO NOT lubricate oil seal I.D. Install oil seal using Seal Installer (J-41479). (Scheme 11) Remove seal installer. Apply Threadlock (12345382) or equivalent onto flywheel-to-crankshaft bolts, and install flywheel. Tighten flywheel-to-crankshaft bolts in 3 steps, in sequence and to specification. (Scheme 12) See TORQUE SPECIFICATIONS. Install clutch (M/T) and transmission. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 11

Scheme 12

Disconnect battery. Drain cooling system. Remove upper fan shroud. Remove serpentine belt, fan, fan clutch, and water pump pulley from water pump. Disconnect all coolant hoses from water pump. Remove water pump mounting bolts. Remove water pump and gaskets.

Install water pump with NEW gaskets. Tighten water pump bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Disconnect negative battery cable. Raise vehicle. Remove skid plate (if equipped). Remove oil pan shield and cross brace. On 4WD models, remove front differential carrier assembly. See appropriate DIFFERENTIALS article in DRIVE AXLES. On all models, drain engine oil and remove filter. Remove bellhousing-to-oil pan bolts. Disconnect oil level sensor electrical connector. Remove left and right oil pan close-out covers. Remove oil pan bolts and oil pan. Drill out oil pan gasket retaining rivets (if necessary), and remove gasket. Remove oil pan baffle (if necessary).

1. Apply bead of Sealant (12378190) or equivalent,.20" (5 mm) wide and.08" (20 mm) long, onto tabs of front and rear cover gasket that protrude into oil pan surface. (Scheme 14) Install NEW oil pan gasket onto oil pan, and install oil pan onto engine block. Finger tighten bolts.
2. Place straightedge across rear of cylinder block and rear of oil pan at bellhousing mounting surfaces. Align oil pan until rear of pan is flush or even with block. Tighten oil pan-to-block and oil-pan-to-front cover bolts to 18 ft. lbs. (24 N.m). Tighten oil pan-to-rear cover bolts to 106 INCH lbs. (12 N.m). Ensure rear of oil pan does not protrude beyond cylinder block and transmission mounting surfaces.
3. Using straightedge and feeler gauge, measure gap at oil pan/bellhousing mounting surface. (Scheme 13) Ensure gap does not exceed.010" (.25 mm). If necessary, remove oil pan, and repeat installation procedure.

Tighten oil pan nuts and bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Always use new oil filter. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Scheme 13

Scheme 14

Removal Procedure

The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable.

Scheme 15

Scheme 16

Scheme 17

1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe.
2. Hold one leg of the retaining clip.
3. Using a small pick-type tool or bent screwdriver, gently pry the other end of the retaining clip from the quick connect fitting.
4. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely.
5. Discard the OLD retaining clip.
6. Perform the following: 6.1. Open the oil cooler hose clip located on the lower fan shroud. 6.2. Remove the oil cooler hoses from the clip. 6.3. Gently, pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 6.4. Raise and suitably support the vehicle.
7. If equipped, remove the engine shield bolts.
8. Remove the engine shield.
9. If equipped with the a 6.0L engine, perform the following: 10.1. Remove the oil cooler hose bracket bolt (1). 10.2. Remove the oil cooler hose adapter bolts (2). 10.3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 10.4. Inspect the fittings, connectors and cooler hoses for damage or distortion.

Installation Procedure

Important: A distinct snap should be heard when assembling tube ends of the hose assembly to quick connectors. To ensure tube is fully inserted into the connector, check by giving tube a forceful pull.

Scheme 18

Scheme 19

1. Perform the following: 2.1. Install the oil cooler hose assembly and a new gasket. 2.2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 N.m (106 lb in). 2.3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 N.m (18 lb ft).
2. If equipped, install the engine shield.
3. Install the engine shield bolts. Tighten the bolts to 20 N.m (15 lb ft).
4. Do not install the new retaining clip onto the fitting by pushing on the clip. Important: Failure to properly install the retaining clip could cause the cooler line to come loose and cause damage to the engine.
5. Install the NEW retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the new retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in all 3 slots.
6. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place.
7. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots.
8. Install a new retaining clip into the remaining quick connect fitting.
9. Perform the following: 10.1. Install the oil cooler hoses to the hose clip on the fan shroud. 10.2. Snap the oil cooler hose clip shut. Important: Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap on to the cooler line prior to cooler line installation. Do not use the plastic cap in order to install the cooler line into the fitting.
10. Snap the plastic cap onto the quick connect fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating.
14. Run the engine. Inspect the engine oil cooling system for leaks.
15. Inspect the engine oil level. Add oil if necessary.

Removal & Disassembly

Note. Oil pump internal parts are not serviced separately (excluding spring). Replace pump if internal components are worn or damaged.

Remove front cover, and remove oil pan. See FRONT COVER and OIL PAN under REMOVAL & INSTALLATION. Remove oil pump pick-up tube and discard "O" ring. Remove remaining crankshaft oil deflector nuts and remove deflector. Remove oil pump-to-block bolts, and oil pump. Remove pump cover. Mark relationship between gears at a meshing point for reassembly. Remove gears. Remove pressure regulator valve and spring.

Reassembly & Installation

Note. Original oil pan gasket is retained and aligned with rivets. It is not necessary to install new rivets when replacing pan gasket.

Coat all wear or internal surfaces with clean engine oil. Install pump gears into pump body with marked gear teeth indexed. Install pump cover. Install pick-up tube NEW "O" ring. Tap tube end into pump using plastic hammer. Reassemble remaining components in reverse order of disassembly. Tighten bolts to specification. See TORQUE SPECIFICATIONS .