Installation Procedure
^ Tools Required- J 41427 Engine Lift Brackets
1. Install the engine to the vehicle.
NOTICE: Refer to Fastener Notice in Service Precautions.
2. Install the engine mount to frame bracket bolts.
^ Tighten the bolts to 50 Nm (37 ft. lbs).
3. Remove the J 41427 and the lifting device.
4. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
5. Install the intake manifold bolts.
5.1. Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
5.2. Tighten the bolts the second pass to 12 Nm (106 inch lbs).
5.3. Tighten the bolts the final pass to 15 Nm (11 ft. lbs.).
6. Loosely install one transmission to engine bolt.
7. Remove support jack from under the transmission.
8. Install the EGR valve inlet pipe to the intake and the exhaust manifold.
8.1. Tighten the EGR valve inlet pipe intake nut to 25 Nm (18 ft. lbs).
8.2. Tighten the EGR valve inlet pipe exhaust nut to 30 Nm (22 ft. lbs.).
8.3. Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs).
9. Install the water outlet. Refer to Thermostat Replacement in Cooling System.
10. Slide the power steering pump mounting bracket with the power steering pump and the A/C compressor on the stud.
11. Position the power steering pump rear bracket on the studs.
12. Install the power steering pump mounting bracket three bolts and the nut.
13. Install the nut for the power steering pump rear bracket to the front of the engine.
^ Tighten the power steering pump mounting bracket and the power steering pump rear bracket bolts and the nuts to 41 Nm (30 ft. lbs).
14. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
15. Connect the hose to the EVAP purge canister solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.
16. Connect the vacuum brake booster hose to the engine and the vacuum brake booster.
17. Install the distributor cap. Refer to Distributor Replacement in Powertrain Management.
18. Install both heater hoses to the engine and the cowl.
^ Refer to Heater Hoses Replacement in Heating and Air Conditioning.
19. Install the AIR pipe assembly with new gaskets to the right exhaust manifold, if equipped.
20. Install the AIR pipe nuts and bracket bolt.
20.1. Tighten the AIR nuts to 25 Nm (18 ft. lbs).
20.2. Tighten the AIR bracket bolt to 10 Nm (88 inch lbs).
21. Connect the AIR pipe assembly to the AIR pump.
22. Install the AIR pipe assembly with new gaskets to the left exhaust manifold, if equipped.
23. Install the AIR pipe nuts and bracket bolt.
23.1. Tighten the AIR nuts to 25 Nm (18 ft. lbs).
23.2. Tighten the AIR bracket bolt to 10 Nm (88 ft. lbs.).
24. Install the AIR crossover pipe to the AIR pipe assemblies.
25. Position the engine wiring harness.
26. Connect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The manifold absolute pressure (MAP) sensor (2)
^ The ignition control module (ICM) (4)
^ The ignition coil (3)
27. Connect the following electrical connectors:
^ The engine oil pressure gauge sensor (3)
^ The distributor (2)
^ The knock sensor (KS) (1)
28. Connect the following electrical connectors:
^ The A/C pressure switch (4), if equipped
^ The A/C compressor clutch (1), if equipped
^ The Exhaust Gas Recirculation (EGR) valve (2)
^ The generator battery positive cable (3)
29. Connect the following electrical connectors:
^ The fuel meter body assembly (3)
^ The Idle Air Control (IAC) motor (2)
^ The Throttle Position (TP) sensor (1)
^ The Engine Coolant Temperature (ECT) sensor (4)
30. Install the bolt holding the ground strap and the ground wire to the rear of the left cylinder head.
^ Tighten the ground strap and wire bolt to 16 Nm (12 ft. lbs.).
31. Position the wiring harness bracket on the EVAP purge canister solenoid valve stud and install the nut.
32. Install the stud holding the wire harness bracket to the rear of the right cylinder head.
^ Tighten the nut on the EVAP solenoid to 9 Nm (80 inch lbs.).
^ Tighten the stud at rear of the cylinder head to 25 Nm (18 ft. lbs).
33. Install the nut holding the ground wire on the stud at the rear of the right cylinder head.
^ Tighten the ground wire nut to 16 Nm (12 ft. lbs.).
34. Position the battery positive and negative cables. Refer to Battery Cable Replacement (Positive/Negative)
35. Install the battery positive cable junction block bracket and bolt to the power steering pump mounting bracket.
^ Tighten the junction block bracket bolt to 25 Nm (18 ft. lbs).
36. Install the bolt holding the engine wiring harness bracket to battery positive cable junction block bracket.
37. Install the engine wiring harness bracket on the intake manifold studs and install the nuts.
^ Tighten the wiring harness bracket nuts to 12 Nm (106 inch lbs).
^ Tighten the wiring harness bracket bolt to 9 Nm (80 ft. lbs.).
38. Connect the A/C hoses to the A/C compressor and the accumulator. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
39. Install the accelerator control cable bracket and nuts to the throttle body.
^ Tighten the nuts to 10 Nm (88 inch lbs).
CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
40. Install the NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
41. Connect the cruse control cable to the throttle body and the accelerator control cable bracket, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
42. Install the radiator inlet hose. Refer to Radiator Hose Replacement - Inlet in Cooling System.
43. Install the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet in Cooling System.
44. Install the Cooling System fan. Refer to Fan Clutch Replacement in Cooling System.
45. Install the drive belt. Refer to Drive Belt Replacement.
46. Install the upper and lower radiator shroud. Refer Fan Shroud Replacement in Cooling System.
47. Install the air cleaner outlet duct to the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement in Powertrain Management.
48. Connect the PCV hose to the air cleaner outlet duct.
49. Move the hood hinge bolts from the service position (2) to the normal operating position (1).
50. Raise the vehicle.
51. Install the remaining transmission to engine bolts except for the one where the transmission cover mounts.
^ Refer to Transmission Replacement in Transmission and Drivetrain.
52. Install three torque convertor to flywheel bolts, if equipped. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.
53. Install the transmission cover and bolts.
53.1. Tighten the transmission cover to oil pan bolt to 12 Nm (106 inch lbs).
53.2. Tighten the transmission cover to transmission bolt to 47 Nm (34 ft. lbs.).
54. Install the bolt holding the bracket for the starter cables and the transmission cooler pipes, if equipped.
^ Tighten the bracket bolt to 12 Nm (106 inch lbs).
55. Install the bolts holding the positive and negative battery cable brackets to the oil pan.
^ Tighten the bracket bolts to 12 Nm (106 inch lbs).
56. Install the bolt for the battery negative cable (1) and ground wire (1) to the front of the engine.
^ Tighten the battery negative cable and ground wire bolt to 16 Nm (12 ft. lbs.).
57. Connect the CKP sensor (2) and install the wire harness in the retainer.
58. Connect the low oil level sensor (3) and install the wire harness in the retainer.
59. Install the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement in Exhaust System.
60. Tighten the nuts at the catalytic converter flange. Refer to Catalytic Converter Replacement in Engine Exhaust.
61. Install the starter motor. Refer to Starter Motor Replacement in Starting and Charging.
62. Install the oil pan skid plate (RWD vehicle shown).
^ Tighten the oil pan skid plate bolt to 20 Nm (15 ft. lbs).
63. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Body and Frame.
64. Lower the vehicle.
65. Connect the battery negative cable. Refer to Battery Cable Replacement (Positive/Negative) in Starting and Charging.
66. Fill the engine with the proper quantity and grade of engine oil. Refer to Engine Oil and Oil Filter Replacement.
67. Fill the engine with coolant. Refer to Draining and Filling Cooling System in Cooling System.
68. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
69. Before starting a new engine, or one that has been repaired. Refer to Engine Set-Up and Testing.