Removal and Replacement

Removal Procedure

^ Tools Required
- J36854 Heavy Duty Automotive Engine Stand
1. Relieve the fuel pressure. Refer to Fuel Pressure Release.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Raise and support the vehicle. Refer to Vehicle Lifting.





5. Remove the front skid plate from the vehicle (if equipped).
6. Drain the engine cooling system. Refer to Draining and Filling Cooling System.
7. Drain the engine oil.





8. Remove the flywheel inspection cover (1).





9. Remove the 2 bolts and separate the front pipe assembly from the exhaust manifold on vehicles without the Three Way Warm Up (TWC) catalytic converter.
10. Lower the vehicle.
11. Remove the hood from the vehicle. Refer to Hood Replacement.





12. Remove the upper radiator hose (2) from the vehicle.





13. Remove the lower radiator hose (1) from the vehicle.
14. Remove the radiator overflow hose from the radiator.
15. Remove the 4 radiator shroud clips.
16. Remove 1 bolt from each side of the radiator upper support.





17. Lean the fan shroud toward the engine and lift the radiator up and out of the vehicle.





18. Remove the four fan mounting nuts (1). Use a second wrench to hold the fan shaft.





19. Remove the fan and the fan shroud.
20. If equipped with A/C, remove the A/C compressor upper brace.





21. Remove the A/C and power steering bracket bolts (1).
22. Remove the A/C and power steering bracket as an assembly and position aside.





23. Remove the bolt and the throttle cable bracket (1) from the intake manifold.
24. Remove the cable from the throttle body bellcrank (3) and position aside.
25. Remove the intake air tube.





26. Remove the heater hoses from the heater core. Mark the location of the inlet and outlet hoses for correct installation.





27. Disconnect the fuel feed hose (1) and the fuel return hose (2).
28. Disconnect the following electrical connectors:
^ The 2 ignition coil connectors.
^ The fuel injector wiring harness main connector.
^ The Throttle Position Sensor (TPS) connector.
^ The Manifold Absolute Pressure (MAP) sensor connector.
^ The Idle Air Control (IAC) valve connector.
^ The ground wires from the intake manifold
^ The Exhaust Gas Recirculation (EGR) valve (1).
^ The Engine Coolant Temperature (ECT) sensor connector.
^ The EVAP canister purge valve connector.
^ The Heated Oxygen Sensor 1 (HO2S1).
^ The Power Steering Pressure (PSP) switch wire.
^ The generator wires.
^ The oil pressure switch wire.
^ The Intake Air Temperature (IAT) sensor connector.
^ The Mass Air Flow (MAP) sensor connector.
^ The Camshaft Position Sensor (CMP) connector.
^ Disconnect the Crankshaft Position Sensor (CKP) connector.

29. Remove the wiring harness from the retaining clamps.
30. Remove the brake booster vacuum line from the intake manifold.
31. Disconnect the starter solenoid wires (2) and position them aside.
32. Remove the 2 bolts (1) and the starter motor. Refer to Starter Motor Replacement.





33. Remove the transmission to engine bolts.





34. Remove the 2 nuts from the top side of the engine mounts.
35. Install an engine hoist to the engine.

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

36. 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.
37. Remove the pressure plate assembly and the clutch disc on manual transmission equipped vehicles. Refer to Clutch Assembly Replacement.





38. Mark the flywheel-to-engine position.
39. Remove the 6 bolts and the flywheel (3) from the crankshaft.
40. Place the engine assembly onto the J36854.
41. Disconnect the engine hoist.

Installation Procedure





1. Install the engine hoist.
2. Remove the engine assembly from the J36854.

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

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the flywheel retaining bolts (1) to the crankshaft. Use the J35271 to lock the flywheel.
^ Cross tighten the 6 flywheel retaining bolts to 78 Nm (58 ft. lbs.).
6. Install the clutch disc and pressure plate assembly. Refer to Clutch Assembly Replacement.
7. 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.





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





10. Install the transmission to engine bolts.
^ Tighten the bolts to 85 Nm (62 ft. lbs.).





11. Install the starter motor. Refer to Starter Motor Replacement.
12. Connect the starter solenoid wires (2).





13. Install the flywheel inspection cover (1).
^ Tighten the flywheel inspection cover bolts to 10 Nm (89 inch lbs.).





14. Connect the front pipe assembly to the exhaust manifold (vehicles without PUP converter).
^ Tighten the 2 bolts to 50 Nm (37 ft. lbs.).





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





17. Install the heater hoses (1) to the heater core.





18. Connect the fuel feed and the fuel return hoses (1,2).
19. Position the harness in the vehicle and connect the wiring harness to the retaining clamps.





20. Connect the following components:
^ The manifold absolute pressure (MAP) sensor (1) connector.
^ The ground wires to the intake manifold (2).
^ The exhaust gas recirculation (EGR) valve (4).
^ The brake booster vacuum line (3).





21. Connect the following components:
^ The 2 ignition coil connectors.
^ The fuel injector wiring harness connector.
^ The throttle position sensor (TP) (4) connector.
^ The idle air control (IAC) valve (3) connector.
^ The engine coolant temperature (ECT) sensor (2) connector.
^ The EVAP canister purge valve connector.
^ The heated oxygen sensor 1 (HO2S1).
^ The power steering pressure (PSP) switch wire.
^ The generator wires.
^ The oil pressure switch wire.
^ The intake air temperature (IAT) sensor connector.
^ The mass air flow (MAP) sensor connector.
^ The camshaft position sensor (CMP) connector. Connect the crankshaft position sensor (CKP) connector.

22. Connect the main engine harness electrical connectors at the bulkhead.
23. Install the wiring harness to the retaining clamps.
24. Install the intake air pipe.





25. Install the accelerator cable (3) to the throttle body bellcrank.
26. Install the accelerator cable bracket (1) to the intake manifold.
^ Tighten the accelerator cable bracket bolt to 10 Nm (89 inch lbs.). Install the power steering pressure and return lines to the power steering pump.
28. Position the A/C and power steering bracket in place.





29. Install the A/C and power steering bracket bolts (1).
30. Install the A/C compressor upper brace.
^ Tighten the bolts to 23 Nm (17 ft. lbs.).





31. Install the fan and the fan shroud to the vehicle.





32. Install the four fan mounting nuts (1). Use a second wrench to hold the fan shaft.
^ Tighten the nuts to 11 Nm (97 inch lbs.).
33. Lean the fan shroud toward the engine and install the radiator.
34. Install 1 bolt to each side of the radiator upper support.
35. Align the shroud to the radiator and install the shroud clips.





36. Install the radiator overflow hose to the radiator.





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





38. Install the lower radiator hose (1) to the vehicle.
39. 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.).
40. Install the engine oil drain plug with a new gasket.
^ Tighten the engine oil drain plug to °35 Nm (26 ft. lbs.).
41. Fill the crankcase with oil.
42. Fill the cooling system. Refer to Draining and Filling Cooling System.
43. Install the hood to the vehicle. Refer to Hood Replacement.
44. Connect the positive battery cable.
^ Tighten the battery cable to 15 Nm (11 ft. lbs.).
45. Connect the negative battery cable.
^ Tighten the battery cable to 15 Nm (11 ft. lbs.).
46. Run the engine and inspect for the following:
^ Engine oil leaks
^ Engine exhaust leaks
^ Transmission fluid leaks
^ Engine coolant leaks
^ Fuel leaks