2003-2010 GMC Savana 4.3L, 4.8L, 5.3L, 6.0L, 6.6L duratec engine manual

Table of Contents

1. General Information

• 1.1 Introduction
• 1.2 Vehicle Identification
• 1.3 Safety Precautions
• 1.4 Maintenance Schedule
• 1.5 Technical Specifications

2. Engine Mechanical

• 2.1 Engine Description
• 2.2 Engine Components
• 2.3 Disassembly Procedures
• 2.4 Cleaning and Inspection
• 2.5 Assembly Procedures
• 2.6 Special Tools

3. Cylinder Head and Valves

• 3.1 Cylinder Head Removal and Installation
• 3.2 Valve Removal and Installation
• 3.3 Valve Adjustment
• 3.4 Cylinder Head Gasket Replacement

4. Pistons, Connecting Rods, and Crankshaft

• 4.1 Piston Removal and Installation
• 4.2 Connecting Rod Removal and Installation
• 4.3 Crankshaft Removal and Installation
• 4.4 Inspection and Repair

5. Timing System

• 5.1 Timing Gear Removal and Installation
• 5.2 Timing Chain/Belt Inspection and Replacement
• 5.3 Timing Adjustment

6. Lubrication System

• 6.1 Oil Pump Removal and Installation
• 6.2 Oil Filter Replacement
• 6.3 Oil Cooler
• 6.4 Lubrication Circuit Diagram

7. Cooling System

• 7.1 Radiator Removal and Installation
• 7.2 Water Pump Removal and Installation
• 7.3 Thermostat Replacement
• 7.4 Cooling Fan Inspection
• 7.5 Coolant Replacement

8. Fuel System

• 8.1 Fuel Injection Pump Removal and Installation
• 8.2 Fuel Injector Removal and Installation
• 8.3 Fuel Filter Replacement
• 8.4 Fuel Tank and Lines

9. Air Intake and Exhaust System

• 9.1 Air Filter Replacement
• 9.2 Turbocharger Removal and Installation (if applicable)
• 9.3 Exhaust Manifold Removal and Installation
• 9.4 Muffler and Pipes

10. Electrical System

• 10.1 Battery Maintenance
• 10.2 Alternator Removal and Installation
• 10.3 Starter Motor Removal and Installation
• 10.4 Wiring Diagram
• 10.5 Sensors and Actuators

11. Emissions Control

• 11.1 EGR System
• 11.2 PCV System
• 11.3 Catalytic Converter
• 11.4 Emission Control Testing

12. Troubleshooting

• 12.1 Engine Performance Issues
• 12.2 Overheating Problems
• 12.3 Lubrication Problems
• 12.4 Fuel System Issues
• 12.5 Electrical System Issues

13. Maintenance and Service

• 13.1 Periodic Maintenance Tasks
• 13.2 Lubrication Points
• 13.3 Service Intervals

14. Technical Specifications

• 14.1 General Specifications
• 14.2 Torque Specifications
• 14.3 Fluid Capacities

15. Appendices

• 15.1 Maintenance Records
• 15.2 Parts List
• 15.3 Index

Contact Information

• Manufacturer Contact Information
• Service Centers

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