Installation Procedure

1. Install the engine hoist.
2. Remove the engine assembly from the J 36854.

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. Install the Crankshaft Position (CKP) sensor.





4. Align the flywheel-to-engine marks and install the flywheel (3).
5. Apply GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads.





Notice: Refer to Fastener Notice in Service Precautions.

6. Install the flywheel retaining bolts to the crankshaft. Use the J 35271 to lock the flywheel.
Cross tighten the 8 flywheel retaining bolts to 70 Nm (51 ft. lbs.).
7. Install the pressure plate assembly and the clutch disc on manual transmission equipped vehicles.
8. Install the engine assembly. Lower the engine into the front of the engine compartment while ensuring clearance on all sides, slide the assembly rearward.





9. Install the engine mount nuts.
Tighten engine mount nuts to 50 Nm (37 ft. lbs.).
10. Remove the engine hoist.





11. Install the cylinder block-to-transmission bolt and nuts.
Tighten the bolt and nuts to 85 Nm (62 ft. lbs.).
12. Install the starter motor.





13. Install the battery positive cable (3) to the starter solenoid.
14. Connect the starter solenoid electrical connector.
15. Connect the CKP sensor (2) connector.
16. Raise the vehicle.





17. Install the torque converter bolts on automatic transmission equipped vehicles. Use the J 35271 in order to lock the flywheel (1).
Tighten the bolts to 65 Nm (47 ft. lbs.).





18. Install the right side engine block-to-transmission support bracket (3).
Tighten the bolts to 50 Nm (37 ft. lbs.).
19. Install the flywheel cover.





20. Connect the front pipe assembly to the exhaust manifold on vehicles not equipped with the PUP catalytic converter.
Tighten the 2 bolts to 50 Nm (37 ft. lbs.).
21. Lower the vehicle.





22. Connect the front pipe assembly to the exhaust manifold on vehicles with the PUP catalytic converter.
23. Install the engine block-to-catalytic converter support bracket on vehicles with the PUP catalytic converter.
Tighten the 3 nuts to 50 Nm (37 ft. lbs.).





24. Install the A/C compressor to its bracket, if equipped. Secure with 3 bolts.
Tighten the bolts to 23 Nm (17 ft. lbs.).





25. Install the heater hoses (1) to the heater core.
26. Position the harness in the vehicle and connect the wiring harness to the retaining clamps.





27. Connect the fuel feed and return hoses (9).
28. Connect the following electrical connectors:
^ The 4 ignition coils
^ The fuel injector wiring harness (3)
^ The Throttle Position (TP) sensor (8)
^ The Manifold Absolute Pressure (MAP) sensor (11)
^ The Idle Air Control (IAC) valve (6)
^ The Exhaust Gas Recirculation (EGR) valve (1)
^ The Engine Coolant Temperature (ECT) sensor (2)
^ The EVAP canister purge valve (7)
^ The Heated Oxygen Sensor 1 (HO2S1)
^ The Power Steering Pressure (PSP) switch wire
^ The generator wires
^ The oil pressure switch wire
^ The Camshaft Position (CMP) sensor
29. Connect the ground wires to the intake manifold (10).
30. Install the EVAP canister purge hose to the intake manifold.
31. Install the wiring harness to the retaining clamps.
32. Install the brake booster vacuum line to the intake manifold.
33. Install the air cleaner assembly.
34. Connect the Intake Air Temperature (IAT) sensor connector.
35. Connect the Mass Air Flow (MAF) sensor connector.
36. Install the cables to the throttle body bellcrank.





37. Install the throttle cable bracket (2) to the intake manifold. Secure with the bolt.
38. Install the power steering pressure and return lines to the power steering pump.





39. Rotate the belt tensioner clockwise and install the accessory drive belt.
40. Install the fan belt tensioner.





41. Install the 2 tensioner mounting bolts (1, 3).
42. Install the fan belt.
43. Adjust the tension on the fan belt to specification by rotating the tension bolt (2) clockwise.
New Belt Deflection: 4-5 mm (0.16-0.20 inch) at 10 kg (22 lbs.) of force.
Used Belt Deflection: 5-7 mm (0.20-0.27 inch) at 10 kg (22 lbs.) of force.
44. Tighten the adjusting bolt (1) and the pivot bolt (3) while holding the correct tension on the fan belt.
Tighten the bolts to 45 Nm (33 ft. lbs.).





45. Install the fan and the fan shroud to the vehicle.
46. Install the fan to the hub.





47. Install the four fan mounting nuts. Use a second wrench to hold the fan shaft.
Tighten the nuts to 11 Nm (97 inch lbs.).





48. Lean the fan shroud toward the engine and install the radiator.
49. Install 1 bolt to each side of the radiator upper support.
50. Align the shroud to the radiator and install the shroud clips.
51. Install the radiator overflow hose to the radiator.





52. Install the upper radiator hose (2) to the vehicle.





53. Install the lower radiator hose (1) to the vehicle.





54. Install the strut tower brace.
Tighten the 6 bolts to 50 Nm (37 ft. lbs.).
55. Install the hood to the vehicle.
56. Raise the vehicle.





57. Install the automatic transmission fluid cooler lines (1) to the radiator on automatic transmission equipped vehicles.
58. Install the front skid plate, if equipped. Secure the front skid plate with four bolts.
Tighten the front skid plate bolts to 55 Nm (40 ft. lbs.).
59. Install the engine oil drain plug with a new gasket.
Tighten the engine oil drain plug to 35 Nm (26 ft. lbs.).
60. Lower the vehicle.
61. Fill the crankcase with engine oil.
62. Fill the cooling system.
63. Fill the automatic transmission fluid as necessary.
64. Fill and bleed the power steering system as necessary.
65. Connect the negative battery cable.
66. Run the engine and inspect for the following:
^ Engine oil leaks
^ Transmission fluid leaks
^ Engine coolant leaks
^ Fuel leaks