Powertrain Removal and Installation

Powertrain Removal and Installation

Removal Procedure




1. Open the trunk and disconnect the electronic suspension control module connectors from the module. Refer to Electronic Suspension Control Module Replacement (Service and Repair).
2. Close the trunk.
3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
4. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
5. Remove the engine sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair).
6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027)).




7. Disconnect the engine compartment evaporative emission (EVAP) purge pipe (3) quick-connect fitting from the chassis pipe.
8. Cap the open pipes in order to prevent possible contamination.
9. Disconnect the fuel inlet quick-connect fitting (1) at the fuel rail and position the line aside. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).

Note: Cap the hoses and inlets when separating the cooling system components. This prevents dirt and other contaminants from entering the cooling system.

10. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).




11. Remove the charge air cooler radiator. Refer to Charge Air Cooler Radiator Replacement (Charge Air Cooler Radiator Replacement).
12. Remove the radiator. Refer to Radiator Replacement (Service and Repair).
13. Remove the surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
14. Remove the A/C condenser. Refer to Air Conditioning Condenser Replacement (Service and Repair).




15. Remove the front portion of the supercharger front manifold (2). It is not necessary to remove the hoses from the manifold. Position the hoses with manifold aside. Refer to Charge Air Cooler Front Manifold Replacement (Charge Air Cooler Front Manifold Replacement).
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).


Note: The brake hydraulic system does not need to be opened.

16. Disconnect the vacuum brake booster hose from the brake booster.




17. Disconnect the electrical connector (1) from the brake fluid level sensor.




18. Remove the brake master cylinder nuts from the brake booster studs.
19. Pull the master cylinder forward out of contact with the brake booster studs.
20. Secure the master cylinder to the engine.




21. Remove the bolts from the intermediate steering shaft.
22. Disconnect the steering shaft from the steering gear.
23. Tie-wrap the steering shaft to the engine.
24. Remove the battery. Refer to Battery Replacement (Battery Replacement).
25. Remove the battery tray. Refer to Battery Tray Replacement (Service and Repair).




26. Remove the ground strap nut and terminals (1-3) from the stud on the frame.




27. Disconnect the A/C electrical connector from the pressure sensor.
28. Remove the underhood junction block (UHJB) from the wheelhouse.
29. Disconnect the wiring harness connector from the UHJB.
30. Secure the wiring harness to the engine.
31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
32. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
33. Remove the right front wheelhouse panel in order to gain access to the engine control module (ECM) and transmission control module (TCM) electrical connectors. Refer to Rear Wheelhouse Panel Liner Replacement (Service and Repair).
34. Disconnect and secure the following wiring harness electrical connectors to the top of engine:

* The ECM-Refer to Engine Control Module Replacement (Service and Repair).
* The engine electrical harness.

35. Disconnect A/C lines from front of dash connections. Refer to Compressor Hose Assembly Replacement (Compressor Hose Assembly Replacement).
36. Disconnect the heater hoses from the heater pipes. Refer to Heater Pipes Replacement (Heater Pipes Replacement).
37. Disconnect the front wheel speed sensor electrical connectors.




38. Disconnect the road sensing suspension position sensor links from the front lower control arms.
39. Support the lower control arm with a suitable jack.




40. Remove the shock absorber lower mounting bolts.
41. Disconnect the upper ball joint from the suspension knuckle. Refer to Steering Knuckle Replacement (Front Suspension).
42. Remove the jack from the control arm.
43. Repeat steps 40 through 42 for the other side of the vehicle.
44. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
45. Disconnect the rear park brake cables from the actuators. Refer to Parking Brake Rear Cable Replacement (Park Brake Rear Cable Replacement).




46. Disconnect the rear wheel speed sensor electrical connectors.




47. Disconnect the road sensing suspension position sensor links from the rear lower control arms.
48. Support the lower control arm with a suitable jack.




49. Remove the rear shock absorber lower mounting bolt.
50. Disconnect the upper ball joint from the suspension knuckle. Refer to Knuckle Replacement (Rear Suspension).
51. Remove the jack from the control arm.
52. Repeat steps 48 through 50 for the other side of the vehicle.
53. Remove the RH muffler assembly. Refer to Exhaust Muffler Replacement - Right Side (Service and Repair).
54. Remove the LH muffler assembly. Refer to Exhaust Muffler Replacement - Left Side (Service and Repair).
55. Remove the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement (Service and Repair).




56. Remove the bolts from the driveline tunnel closeout panel.
57. Remove the driveline tunnel closeout panel.




58. Remove the nuts (2) retaining the transmission shift cable bracket (3) to the transmission.




59. Disconnect the transmission shift control cable (1) from the transmission shift lever (2). Unsnap to release the cable.
60. Reposition the transmission shift cable and bracket.
61. Disconnect the wiring harness and ground from the rear crossmember.




62. Release the retainer (1) securing and positioning the wiring harness to the L-shaped brackets along the driveline support assembly, then slide the harness up and out of the brackets and position out of the way.




63. Disconnect the wiring harness retainer from the stud at the differential rear cover.
64. Disconnect the wiring harness retainer clip from the top of the differential.




65. Disconnect the transmission harness 20-way connector.




66. Disconnect the park/neutral position switch electrical connectors.
67. Remove the bolt retaining the transmission wiring harness to the transmission case.
68. Release the wiring harness from the harness retainer along the top of the transmission.
69. Position the powertrain table under the front frame.
70. Position the powertrain table under the rear frame.
71. With the aid of an assistant, slowly lower the vehicle onto the powertrain tables.




72. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts. Refer to Front Suspension Crossmember Replacement () and Rear Suspension Support Crossmember Replacement (Rear Suspension Support Crossmember Replacement).
73. Carefully raise the vehicle to clear the supported powertrain assembly.

Installation Procedure

1. Position the powertrain under the vehicle.
2. With the aid of an assistant, slowly lower the vehicle onto the powertrain.
3. Guide the front and rear frame into the cradle bolts.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Using HAND TOOLS ONLY, install the front and rear frame nuts and tighten to 110 Nm (81 lb ft).
5. Attach the transmission shift cable bracket to the transmission.




6. Install the nuts (2) retaining the transmission shift cable bracket (3) to the transmission and tighten to 20 Nm (15 lb ft).




7. Connect the transmission shift cable (1) to the transmission shift lever (2).




8. Install the transmission wiring harness to the left side of the transmission case retaining bolt and tighten to 2.5 Nm (22 lb in).
9. Connect the park/neutral position switch electrical connectors.




10. Connect the transmission wiring harness 20-way connector.




11. Connect the wiring harness clip to the top of the differential.
12. Connect the wiring harness retainer to the stud at the differential rear cover.




13. Carefully position the wiring harness into the L-shaped brackets along the driveline support assembly.
Align the harness retainer locator (1) to the hole in the forward bracket and secure in place.




14. Install the driveline tunnel closeout panel.
15. Install the driveline closeout panel bolts and tighten to 10 Nm (89 lb in).
16. Install the RH muffler assembly. Refer to Exhaust Muffler Replacement - Right Side (Service and Repair).
17. Install the LH muffler assembly. Refer to Exhaust Muffler Replacement - Left Side (Service and Repair).
18. Install the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement (Service and Repair).
19. Connect the upper ball joint to the right knuckle. Refer to Knuckle Replacement (Rear Suspension).




20. Install the rear shock absorber lower mounting bolts and tighten to 28 Nm (21 lb ft).




21. Connect the road sensing suspension position link to lower control arm.
22. Repeat for the other side of the vehicle.




23. Connect the rear wheel speed sensor electrical connectors.
24. Connect the rear park brake cables to the actuator. Refer to Parking Brake Rear Cable Replacement (Park Brake Rear Cable Replacement).
25. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
26. Connect the upper ball joint to the right front suspension knuckle. Refer to Steering Knuckle Replacement (Front Suspension).




27. Install the shock absorber lower mounting bolts. Refer to Shock Absorber Replacement (With F55) (Shock Absorber Replacement (With F55)).




28. Connect the road sensing suspension position sensor link to the front lower control arm.




29. Connect the front wheel speed sensor electrical connector.
30. Repeat for the other side of the vehicle.
31. Install the master cylinder to the brake booster. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
32. Install the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).
33. Connect the vacuum brake booster hose to the brake booster.
34. Connect the heater hoses to the heater pipes. Refer to Heater Pipes Replacement (Heater Pipes Replacement).
35. Connect the A/C lines to the front of dash connections. Refer to Compressor Hose Assembly Replacement (Compressor Hose Assembly Replacement).




36. Attach the engine ground cables (1-3) to the right side body frame rail and tighten to 8 Nm (71 lb in).
37. Connect the following wiring harness electrical connectors:

* The ECM-Refer to Engine Control Module Replacement (Service and Repair).
* C101 engine electrical harness.

38. Install the right front wheelhouse panel. Refer to Rear Wheelhouse Panel Liner Replacement (Service and Repair).
39. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
40. Connect the UHJB to the wheelhouse.




41. Connect the A/C electrical connector to the pressure sensor.
42. Install the battery tray. Refer to Battery Tray Replacement (Service and Repair).
43. Install the battery. Refer to Battery Replacement (Battery Replacement).
44. Install the front portion of the supercharger front manifold. Refer to Charge Air Cooler Front Manifold Replacement (Charge Air Cooler Front Manifold Replacement).
45. Install the air conditioning condenser. Refer to Air Conditioning Condenser Replacement (Service and Repair).
46. Install the radiator. Refer to Radiator Replacement (Service and Repair).
47. Install the charge air cooler radiator. Refer to Charge Air Cooler Radiator Replacement (Charge Air Cooler Radiator Replacement).
48. Install the surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair).
49. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
50. Connect the fuel inlet quick-connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
51. Connect the EVAP emission canister purge pipe to the chassis purge pipe.
52. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair).
53. Charge the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
54. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
55. Program the transmitters. Refer to Transmitter Programming (N. America and Japan, except Canada) (Programming and Relearning)Transmitter Programming (Canada and Europe) (Programming and Relearning)Transmitter Programming (New RCDLRs ONLY) (Programming and Relearning).
56. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities (Service Intervals) and Fluid and Lubricant Recommendations (Service Intervals).
57. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716) (Service and Repair).
58. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling (Static Fill) (Charge Air Cooling System Draining and Filling (Static Fill)).
59. Check the transmission fluid and add transmission fluid as necessary. Refer to Transmission Fluid Check (Transmission Fluid Check).
60. Reset the oil life monitoring system. Refer to GM Oil Life System Resetting (Service and Repair).
61. Perform the engine pre-lubrication procedures. Refer to Engine Prelubing (Overhaul).
62. Start the engine.
63. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
64. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
65. Perform a final inspection for the proper engine oil and coolant levels.