Engine Replacement

REMOVAL PROCEDURE

^ TOOLS REQUIRED
- J 35271 Flywheel Holder
- J 36854 Heavy Duty Automotive Engine Stand

1. Discharge and recover the refrigerant if the vehicle is equipped with A/C.
2. Relieve the fuel pressure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

3. Disconnect the negative battery cable.
4. Disconnect the positive battery cable.
5. Open the fuel filler cap to relieve pressure in the fuel tank.
6. Install the cap after relieving fuel tank pressure.
7. Raise and support the vehicle.
8. Drain the cooling system.
9. Remove the four bolts and the front skid plate from the vehicle (if equipped).
10. Drain the power steering fluid from the reservoir.
11. Disconnect the power steering fluid hoses from the power steering pump.
12. Place a drain pan or suitable container under the engine oil pan.
13. Remove the engine oil drain plug from the engine oil pan. Drain the engine oil.
14. Remove the clutch housing lower plate from manual transmission equipped vehicles.

Remove the torque converter housing lower plate from automatic transmission equipped vehicles.

15. Remove two bolts and the clutch cable from the clutch release arm and bracket on manual transmission vehicles.
16. Disconnect the automatic transmission fluid hoses from the clamps on automatic transmission equipped vehicles.
17. Remove the clutch lower plate on manual transmission vehicles.
18. Remove the torque converter lower plate on automatic transmission equipped vehicles.
19. Use the J 35271 in order to lock the drive plate. Remove the torque converter bolts on automatic transmission equipped vehicles.





20. Remove the two nuts and the front pipe/Three Way Catalytic Converter (TWC) (3) from the exhaust manifold (1).
21. Disconnect the clutch cable from the retaining straps on manual transmission vehicles.
22. Support the transmission. Remove the two bolts separating from the cylinder block.
23. Remove the starter motor.
24. Remove the engine mount lower nuts and washers.
25. Lower the vehicle.
26. Remove the upper coolant hose from the radiator.
27. Disconnect the A/C lines from the compressor, if equipped.
28. Remove the four bolts securing the shroud to the radiator and four fan clutch mounting nuts.
29. Remove the following together:
^ The shroud
^ The fan clutch
^ The cooling fan

30. Remove the radiator assembly.
31. Disconnect the air intake pipe from the engine.
32. Disconnect the accelerator cable and the automatic transmission kickdown cable from the throttle body on automatic transmission equipped vehicles.
33. Remove the following from the intake manifold:
^ The PCV valve
^ The EGR valve
^ The EGR temperature sensor

34. Remove the coolant hose from the IAC valve.
35. Remove the IAC air hose from the IAC valve.





36. Disconnect the fuel feed hose at the fuel feed hose union (1).
37. Remove the fuel return hose from the fuel return line.
38. Disconnect the (PCV) hose from the PCV valve.
39. Remove the coolant hose from the thermostat housing.
40. Remove the coolant bypass and the heater inlet hoses from the intake manifold.
41. Remove the lower coolant hose from the radiator.





42. Disconnect the following electrical connectors:
^ Main engine harness electrical connectors at the bulkhead
^ TP sensor IAC valve
^ H02S1
^ ECT sensor (4)
^ ECT sending unit
^ A/C ECT switch (A/C equipped vehicles) (3)
^ Wiring harness from retaining clamps
^ Injector wiring harness (2)
^ Generator
^ (PSP) switch
^ (EGRT) sensor
^ Exhaust gas recirculation solenoid vacuum valve (1)
^ Exhaust gas recirculation by-pass valve

43. Remove the following vacuum hoses:
^ Vacuum hose at sure tank, 3 way connector
^ EGR pressure transducer
^ EGR valve
^ Brake booster supply hose
^ Vacuum modulator supply hose (automatic equipped vehicles)
^ EVAP canister and hoses
^ MAP sensor hose from the sensor.

44. Remove the distributor from the distributor case.
45. Remove the hood from the vehicle.
46. Install the engine hoist to the engine.
47. Remove the engine mounting bracket-to-frame bolts.

IMPORTANT: Before lifting the engine, ensure that all of the hoses, pipes, electrical wires and cables are disconnected from the engine.

48. Remove the engine assembly from the vehicle by sliding the assembly toward the front side of the engine compartment. Carefully lift the engine assembly from the vehicle verifying clearance on all sides.
49. Remove the pressure plate assembly and the clutch disc on manual transmission equipped vehicles only.
50. Remove the six bolts and the flywheel from the crankshaft.
51. Place the engine assembly onto the J 36854.
52. Disconnect the engine hoist.

INSTALLATION PROCEDURE
1. Install the engine hoist.
2. Remove the engine assembly from the J 36354.

NOTICE: Do not apply an excessive amount of sealant to the flywheel retaining bolt threads. Applying too much sealant will result in the sealant overflowing the bolt seat. This could cause the bolt to break loose during vehicle operation.

3. Apply GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads.

NOTICE: Refer to Fastener Notice in Service Precautions.

4. Install the flywheel. Secure the flywheel with six retaining bolts.
^ Tighten the flywheel retaining bolts to 78 Nm (58 ft. lbs.).

5. Install the pressure plate assembly and the clutch disc on manual transmission equipped vehicles.
6. Install the engine assembly. Lower the engine into the front of the engine compartment while ensuring clearance on all sides, slide the assembly toward the rear.
7. Install the engine mounting bracket-to-frame bolts.
^ Tighten right-side engine mount-to-engine bracket bolts to 54 Nm (40 ft. lbs.).

8. Install the two left-side engine mount-to-engine bolts. Do not tighten fully.
^ Tighten left-side engine mount-to-engine bracket bolts to 54 Nm (40 ft. lbs.).

9. Remove the engine hoist.
10. Install the hood from the vehicle.
11. Install distributor into the distributor case.
12. Install the following vacuum hoses:
^ EGR pressure transducer
^ EGR valve
^ Brake booster supply hose
^ Vacuum modulator supply hose (automatic equipped vehicles)
^ EVAP canister and hoses
^ (MAP) sensor hose from the sensor





13. Connect the following electrical connectors:
^ (TP) sensor IAC valve HO2S1
^ ECT sensor (4)
^ ECT sending unit
^ A/C ECT switch (A/C equipped vehicles) (3)
^ Wiring harness from retaining clamps
^ Injector wiring harness (2)
^ Generator
^ (PSP) switch
^ (EGRT) sensor
^ Exhaust gas recirculation solenoid vacuum valve (1)
^ Exhaust gas recirculation by-pass valve

14. Install the lower coolant hose to the radiator.
15. Secure the hose with a hose clamp.
16. Install the coolant bypass and the heater inlet hoses to the intake manifold.
17. Secure the hose with a hose clamp.
18. Install the coolant hose to the thermostat housing.
19. Install the PCV hose the PCV valve.
20. Install the fuel return hose to the fuel return line.





21. Install the fuel feed hose at the fuel return hose union (1).
22. Install the IAC air hose to the IAC valve.
23. Install the coolant hose to the IAC valve.
24. Install the following to the intake manifold:
^ The positive crankcase ventilation (PCV) valve
^ The EGR valve
^ The EGR temperature sensor

25. Connect the accelerator cable and the automatic transmission kickdown cable on automatic transmission equipped vehicles to the throttle body.
26. Install the air intake pipe to the engine.
27. Install the following:
^ The fan clutch
^ The cooling fan
^ The shroud

28. Secure with four fan clutch nuts and four shroud bolts.
^ Tighten the fan clutch nuts to 11 Nm (97 inch lbs.).
^ Tighten the shroud bolts to 11 Nm (97 inch lbs.).

29. Install the A/C lines at the compressor if the vehicle is equipped.
30. Install the upper coolant hose to the radiator. Secure the hose with a hose clamp.
31. Raise and support the vehicle.
32. Install the engine mount lower nuts and washers.
^ Tighten the engine mount lower nuts to 50 Nm (37 ft. lbs.).

33. Install the starter motor.
34. Install the transmission to the cylinder block.
35. Connect the clutch cable tot he retaining straps on manual transmission equipped vehicles.





36. Install the front pipe/TWC (3) to the exhaust manifold (2).
37. Secure the front pipe/TWC with two nuts.
^ Tighten the front pipe/TWC assembly-to-exhaust manifold nuts to 50 Nm (37 ft. lbs.).

38. Use a J 35271 in order to lock the drive plate. Install the torque converter bolts on automatic transmission equipped vehicles.
^ Tighten the torque converter bolts to 54 Nm (40 ft. lbs.).

39. Install the torque converter lower plate on automatic transmission equipped vehicles.
40. Install the clutch housing lower plate on manual transmission equipped vehicles.
41. Install the automatic transmission fluid hoses to the clamps on automatic transmission equipped vehicles.
42. Install the clutch cable to the bracket and the clutch release arm on manual transmission equipped vehicles.
43. Install the engine oil drain plug with the new gasket (1).
^ Tighten the engine oil drain plug to 35 Nm (26 ft. lbs.).

44. Install the front skid plate, if vehicle equipped. Secure the front skid plate with four bolts.
^ Tighten the front skid plate bolts to 55 Nm (40 ft. lbs.).

45. Connect the power steering hoses to the power steering pump.
46. Lower the vehicle.
47. Refill the cooling system as necessary.
48. Refill the power steering fluid.
49. Connect the negative and positive battery cables.
50. Evacuate and charge the A/C system if the vehicle is equipped.