GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Tahoe 4WD - RHD 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Engine Replacement

Removal Procedure

    Object Number: 399420 Size: SH
  1. Remove the hood assembly from the vehicle. Refer to Hood Replacement in Body Front End.
  2. Disconnect the battery negative cables from the batteries. Refer to Battery Replacement in Engine Electrical.
  3. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C--Manual.
  4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
  6. Remove the air inlet duct from the turbocharger.
  7. Remove the upper fan shroud from the radiator. Refer to Fan Shroud Replacement in Engine Cooling.
  8. Remove the radiator from the vehicle. Refer to Radiator Replacement in Engine Cooling.
  9. Remove the fan clutch assembly from the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
  10. Remove the drive belt from the pulleys. Refer to Drive Belt Replacement .
  11. Remove the air conditioning lines from the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C--Manual.
  12. Remove the A/C lines from the A/C condenser. Refer to Condenser Replacement in HVAC Systems with A/C--Manual.
  13. Remove the accumulator from the evaporator housing. Refer to Air Conditioning Accumulator Replacement in HVAC Systems with A/C--Manual.
  14. Disconnect the fuel lines at the left rear corner of the engine assembly.
  15. Remove the heater hoses from the heater core. Refer to Heater Hoses Replacement .
  16. Remove the battery feed wire from the generator. Refer to Generator Replacement in Engine Electrical.
  17. Disconnect the engine wiring harness at the 60 way connector (black) at the left rear of the engine.
  18. Remove the ground wire at the right front of the engine.

    19. Object Number: 293494 Size: SH
  19. Remove the ground wire at right rear of the lower intake manifold.
  20. Remove the ground wire at the left rear of the engine assembly.
  21. Raise the vehicle.

    22. Object Number: 317722 Size: SH
  22. Disconnect the electrical connection from the block heater.
  23. Remove the lower radiator fan shroud from the vehicle. Refer to Fan Shroud Replacement in Engine Cooling.
  24. Remove the exhaust pipe from the turbocharger. Refer to Front Pipe Replacement in Engine Exhaust.
  25. Remove the engine protection shield from the vehicle. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  26. Drain the engine of oil.
  27. Remove the oil filter adapter from the engine block. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  28. Remove the engine oil cooler lines from the engine block fittings. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.

    29. Object Number: 106952 Size: SH
  29. Remove the transmission cooler lines from the retainers and secure out of the way.
  30. Remove the brace from the transmission to the engine block (right side).
  31. Remove the torque convertor inspection shield.
  32. Remove the starter assembly from the engine block. Refer to Starter Motor Replacement in Engine Electrical.

    33. Important: Mark a torque convertor bolt to ensure proper installation sequence.

  33. Remove the torque convertor bolts.

    34. Object Number: 177057 Size: SH
  34. Remove the bolts from the transmission to the engine block.
  35. Remove the engine mount through bolts.
  36. Lower the vehicle.

    37. Object Number: 293495 Size: SH
  37. Remove the three hoses from the power steering pump.
  38. Support the transmission with a suitable engine stand.

    39. Object Number: 222260 Size: SH
  39. Install the engine lift bracket to the right corner of the cylinder head.
  40. Install a suitable lifting device the right rear and left front lifting (left accessory bracket).
  41. Remove the engine assembly from the vehicle.

    42. Important: It may be necessary to remove the flywheel from the crankshaft before installing the engine assembly on a suitable engine stand.

  42. Install the engine on a suitable engine stand.
  43. Remove the lifting bracket from the cylinder head.
  44. Transfer all necessary items if install a new engine assembly.

Installation Procedure

    Object Number: 222260 Size: SH
  1. Install the lifting bracket to the right rear cylinder head.
  2. Remove the engine from the engine stand.
  3. Install the flywheel on the crankshaft. Refer to Engine Flywheel Replacement .
  4. Install the engine assembly in the vehicle.
  5. Remove the lifting device from the engine assembly.
  6. Raise the vehicle
  7. Install the engine mount through bolts. Refer to Engine Mount Replacement .

    8. Object Number: 177057 Size: SH
  8. Install the bolts from the transmission to the engine block.

    9. Object Number: 317722 Size: SH
  9. Reconnect the electrical connector for the engine block heater.
  10. Install the starter in the engine block. Refer to Starter Motor Replacement in Engine Electrical.
  11. Install the bolts from the flywheel to the torque convertor.
  12. Install the torque convertor inspection cover on the vehicle.
  13. Install the engine oil cooler lines to the fittings on the engine block. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.

    14. Object Number: 106952 Size: SH
  14. Install the transmission oil cooler lines in the retainers.
  15. Install the engine oil filter adapter to the engine block. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  16. Install the brace from the transmission to the engine block.
  17. Install the exhaust pipe from the turbocharger to the catalytic convertor. Refer to Front Pipe Replacement in Engine Exhaust.
  18. Install the lower radiator fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  19. Lower the vehicle.
  20. Install the ground wire at the left rear of the engine.

    21. Object Number: 293494 Size: SH
  21. Install the ground wire right rear of the lower intake manifold.
  22. Install the ground wire right front of the engine.
  23. Install the battery feed wire to the generator. Refer to Generator Replacement in Engine Electrical.
  24. Install the radiator in the vehicle. Refer to Radiator Replacement in Engine Cooling.
  25. Install the heater hose to the heater core. Refer to Heater Hoses Replacement .

    26. Object Number: 399420 Size: SH
  26. Connect the engine wiring harness at the 60 way connector (black) at the left rear of the engine.
  27. Install the accumulator to the evaporator housing. Refer to Air Conditioning Accumulator Replacement in HVAC Systems with A/C--Manual.
  28. Install the A/C lines to the A/C condenser. Refer to Condenser Replacement in HVAC Systems with A/C--Manual.
  29. Install the A/C lines on the A/C compressor Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C--Manual.
  30. Install the fuel lines at the left rear of the engine assembly.

    31. Object Number: 293495 Size: SH
  31. Install the three hoses to the power steering pump.
  32. Install the drive belt on the pulleys. Refer to Drive Belt Replacement .
  33. Install the fan clutch on the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
  34. Install the radiator in the vehicle. Refer to Radiator Replacement in Engine Cooling.
  35. Install the upper fan shroud on the radiator. Refer to Fan Shroud Replacement in Engine Cooling.
  36. Install the air intake duct to the turbocharger.
  37. install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
  38. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  39. Recharge to A/C system. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C--Manual.
  40. Install the hood assembly on the vehicle. Refer to Hood Replacement in Body Front End.
  41. Connect the battery negative cables to the batteries. Refer to Battery Replacement in Engine Electrical.
  42. Check the injection timing. Refer to Fuel Injection Pump Timing Adjustment in Engine Controls-6.5L.
  43. Perform the TDC offset timing procedure. Refer to Fuel Injection Pump Top Dead Center Offset Adjustment in Engine Controls-6.5L.