Engine Removal and Installation
REMOVAL PROCEDURENOTICE: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.
^ Tool Required
- J 41427 Engine Lift Bracket
1. Disconnect the battery negative cable.
2. Raise the vehicle.
3. Remove the underbody shields.
4. Remove the braces from the engine to the transmission (manual transmission only).
5. Remove the exhaust pipe from the exhaust manifolds.
6. Disconnect the oil cooler pipes (RWD vehicle).
7. Disconnect the remote oil filter adapter inlet and outlet hoses (Four Wheel Drive vehicle).
8. Remove the bolt holding the starter wire harness and if equipped, transmission cooler lines.
9. Remove the starter.
10. Remove the transmission cover.
11. Disconnect the front propeller shaft (Four Wheel Drive only).
12. Remove the transfer case, if equipped.
13. Remove the rear engine mount to crossmember nut.
14. Remove the crossmember.
15. In order to remove the top transmission bolts lower the rear of the transmission after removing the crossmember.
16. Remove the transmission.
17. Remove the front engine mount through bolts.
18. Lower the vehicle.
19. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
20. Remove the air cleaner outlet duct from the throttle body.
21. Remove the air cleaner assembly.
22. Remove the radiator.
23. Remove the inlet and outlet radiator hoses from the engine.
24. Disconnect the heater hoses from the engine.
25. Disconnect the following electrical connectors:
^ The fuel meter body assembly.
^ The EVAP canister purge solenoid valve.
^ The idle air control (IAC) motor.
^ The throttle position (TP) sensor.
^ The A/C compressor high pressure switch, if equipped.
^ The A/C clutch switch, if equipped.
^ The exhaust gas recirculation (EGR) valve.
^ The engine coolant temperature (ECT) sensor.
^ The ignition control module (ICM).
^ The generator.
^ The crankcase position (CKP) sensor.
26. Release the engine wiring harness retainers and move the wiring harness aside.
27. Remove the battery ground cable at the engine.
28. Remove the bolts holding the ground wires to the left cylinder head.
29. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.
30. Remove the bolts holding the ground wires to the right cylinder head.
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.
31. Remove the accelerator cable from the throttle shaft and the accelerator cable bracket.
32. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
33. Remove the accelerator control cable bracket from the throttle body.
34. Remove the water pump pulley.
35. Remove the A/C compressor, if equipped.
36. Remove the nuts holding the power steering pump rear bracket to the engine.
37. Remove the power steering pump mounting bracket.
^ The power steering pump can remain on the mounting bracket.
^ The hoses do not require removal.
^ Remove the three bolts and the nut.
^ Slide the power steering pump mounting bracket off of the stud.
^ Secure the power steering pump mounting bracket out of the way.
38. Remove the distributor cap.
39. Disconnect the fuel pipes.
40. Disconnect the EVAP canister purge solenoid valve pipe.
41. Disconnect the vacuum brake booster line from the intake manifold.
42. Remove the water outlet.
43. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
NOTICE: Refer to Fastener Notice in Service Precautions.
44. Attach the J41427to the left front and the right rear intake manifold mounting bolts, using the following procedure:
44.1. Remove the right rear lower intake manifold bolts.
44.2. Install the J41427marked RIGHT REAR.
44.3. Install the retaining bolts.
44.4. Remove the left front lower intake manifold bolts.
44.5. Install the J41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
44.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (111 ft. lbs.).
45. Attach a suitable lifting device to the engine lift brackets.
46. Remove the engine.
INSTALLATION PROCEDURE
NOTICE: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.
^ Tool Required
- J 41427 Engine Lift Bracket
1. Install the engine into the vehicle.
NOTICE: Refer to Fastener Notice in Service Precautions.
2. Install the engine mount through-bolts and nuts.
^ Tighten the engine mount through-bolts or the nuts to the following:
^ Tighten the through-bolts to 74 Nm (55 ft. lbs.)
^ Tighten the nuts to 63 Nm (46 ft. lbs.)
3. Remove the J41427 and the engine lifting device.
4. Apply thread lock GM PN 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 first pass to 12 Nm (106 inch lbs.).
5.3. Tighten the bolts the first pass to 15 Nm (11 ft. lbs.).
6. Install the EGR valve inlet pipe to the intake and exhaust manifolds.
6.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
6.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
6.3. Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
7. Install the water outlet.
8. Connect the fuel pipes at the rear of the engine.
9. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
^ Tighten the fuel pipe bracket bolt to 30 Nm (22 ft. lbs.).
10. Connect the EVAP canister purge solenoid valve pipe.
11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap.
13. Install the power steering pump mounting bracket and the three bolts and the nut.
^ Tighten the power steering pump mounting bracket bolts and nuts to 41 Nm (30 ft. lbs.).
14. Install the nuts holding the power steering pump rear bracket to the engine.
^ Tighten the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).
15. Install the A/C compressor, if equipped.
16. Install the water pump pulley.
17. Install the accelerator control cable bracket to the throttle body.
^ Tighten the bolt to 9 Nm (80 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.
18. Install a NEW accelerator control cable.
19. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket.
20. Install the battery ground cable bolt.
^ Tighten the ground cable bolt to 35 Nm (26 ft. lbs.).
21. Install the bolts holding the ground wires to the left cylinder head.
^ Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).
22. Install the stud holding the ground wires to the right cylinder head.
^ Tighten Tighten the stud to 35 Nm (26 ft. lbs.).
23. Position the engine wiring harness.
24. Install the engine wiring harness in the retainers.
25. Connect the following electrical connectors:
^ The fuel meter body assembly.
^ The EVAP canister purge solenoid valve.
^ The idle air control (IAC) motor.
^ The throttle position (TP) sensor.
^ The A/C compressor high pressure switch, if equipped.
^ The A/C clutch switch, if equipped.
^ The exhaust gas recirculation (EGR) valve.
^ The engine coolant temperature (ECT) sensor.
^ The ignition control module (ICM).
^ The generator.
^ The crankcase position (CKP) sensor.
26. Install the radiator.
27. Install the inlet and outlet radiator hose to the engine.
28. Connect the heater hoses to the engine.
29 Raise the vehicle.
31. Install the transfer case, if equipped.
32. Install the front propeller shaft (Four Wheel Drive vehicle only).
33. Install the transmission cover.
^ Tighten the nut to 12 Nm (106 inch lbs.).
34. Install the starter.
35. Install the bolt holding the bracket for the starter wiring harness and if equipped, the transmission cooler lines.
^ Tighten the bracket bolt to 12 Nm (106 inch lbs.).
36. Connect the oil cooler pipes (ROOD vehicle).
37. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle).
38. Install the exhaust pipe to the exhaust manifolds.
39. Install a NEW oil filter.
40. Install the braces from the engine to the transmission.
41. Install the underbody shields.
42. Lower the vehicle.
43. Fill the engine with oil.
44. Fill the cooling system with coolant.
45. Connect the battery negative cable.
46. Recharge the air conditioning system, if equipped.
47. Operate and test the engine.