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. Remove the hood.
3. Raise the vehicle.
4. Remove the exhaust pipe from the exhaust manifolds.
5. Disconnect the oil cooler pipes, if equipped.
6. Remove the bolt holding the transmission cooler lines, if equipped to the oil pan.
7. Remove the starter.
8. Remove the transmission cover.
9. Disconnect the torque convertor bolts from the flywheel, if equipped with automatic transmission.
10. Remove the transmission to engine bolts.
11. Remove the front engine mount through- bolts.
12. Lower the vehicle.
13. Drain the engine coolant.
14. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
15. Remove the air cleaner outlet duct from the throttle body.
16. Disconnect the hose to the EVAP canister purge solenoid valve and move aside.
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.
17. Remove the accelerator cable from the throttle shaft and the accelerator cable bracket.
18. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
19. Disconnect the engine wiring harness clip from the accelerator control cable bracket mounted on the power steering pump mounting bracket.
20. Remove the bolt holding the accelerator control cable bracket to the power steering pump mounting bracket.
Leave accelerator control cable and the cruise control cable on the bracket.
21. Discharge the A/C system, if equipped.
22. Remove the A/C hose from the accumulator and the compressor.
23. Move and secure the A/C hose to the right side of the vehicle.
24. Remove both the upper and lower fan shroud.
25. Remove the inlet and outlet radiator hoses from the engine.
26. Disconnect the heater hoses from the engine.
27. Disconnect the EVO pressure switch electrical connector from the power steering pump.
28. Remove the EVO wiring harness from the retainer clip at the CKP sensor bracket.
29. Disconnect the electrical connections to the generator.
30. Disconnect the CKP sensor electrical connector.
31. Remove the nut and stud holding the ground wire and the battery negative cable to the engine.
32. Remove the engine wiring harness from the front of the engine and the heater hose clip bracket on the generator bracket.
33. Remove the nut holding the ground wire to the water outlet stud.
34. Remove the nut holding the engine wiring harness to the throttle body.
35. 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 engine coolant temperature (ECT) gauge sensor
- The ignition control module (ICM)
- The Knock Sensor (KS) sensor
- The distributor
- The engine oil pressure gauge sensor
36. Remove the nut and ground wires from the stud for the engine wiring harness at the rear of the right cylinder head.
37. Remove the engine wiring harness from the engine wiring harness bracket at the right rear of the engine.
38. Remove the nut and the stud for the engine wiring harness bracket at the right rear of the engine.
39. Remove the engine wiring harness bracket.
40. Remove the engine wiring harness from the engine wiring harness bracket at the left rear of the engine.
41. Move and secure the engine wiring harness out of the way.
42. Remove the engine wiring harness bracket.
43. Remove the power steering pump from the engine.
The hoses can remain on the power steering pump.
44. Remove the three bolts and the nut holding the power steering pump mounting bracket.
45. Remove the power steering pump mounting bracket.
The A/C compressor, if equipped can remain on the power steering pump mounting bracket.
46. Remove the distributor cap.
47. Disconnect the fuel pipes at the rear of the intake manifold.
48. Disconnect the vacuum brake booster line from the intake manifold.
49. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
50. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
NOTICE: Refer to Fastener Notice in Service Precautions.
51. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:,
51.1. Remove the right rear lower intake manifold bolts.
51.2. Install the J 41427 marked RIGHT REAR.
51.3. Install the retaining bolts.
51.4. Remove the left front lower intake manifold bolts.
51.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
51.6. Install the retaining bolts.
Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
52. Attach a suitable lifting device to the engine lift brackets.
53. Support the transmission with a suitable jack or a strap.
54. 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.
2. Loosely install the top two engine to transmission bolts.
3. Remove the jack or the straps supporting the transmission.
NOTICE: Refer to Fastener Notice in Service Precautions.
4. 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 95 Nm (70 ft. lbs.)
- Tighten the nuts to 68 Nm (50 ft. lbs.)
5. Remove the J 41427 and the engine lifting device.
6. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower intake manifold bolts.
7. Install the intake manifold bolts.
7.1. Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
7.2. Tighten the bolts the first pass to 12 Nm (106 inch lbs.).
7.3. Tighten the bolts the first pass to 15 Nm (111 ft. lbs.).
8. Install the EGR valve inlet pipe to the intake and exhaust manifolds.
8.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
8.2. Tighten the EGR valve inlet pipe exhaust manifold 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 spark plug wire harness retainer on the EGR valve inlet pipe
10. Connect the fuel pipes at the rear of the engine.
Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap.
13. Install the power steering pump mounting bracket with the A/C compressor, if equipped.
Tighten the power steering pump mounting bracket bolts and nuts to 41 Nm (30 ft. lbs.).
14. Install the power steering pump to the engine.
15. Install the left side engine wiring harness bracket and the nuts on the lower intake manifold studs.
Tighten the engine wiring harness bracket nuts to 12 Nm (106 inch lbs.).
16. Install the right side engine wiring harness bracket on the EVAP canister purge solenoid valve stud.
17. Install the engine wiring harness bracket stud and nut.
- Tighten the engine wiring harness bracket stud to 25 Nm (18 ft. lbs.)
- Tighten the engine wiring harness bracket nut to 10 Nm (88 ft. lbs.)
18. Position the engine wiring harness.
19. Install the engine wiring harness to the engine wiring harness bracket at the left rear of the engine.
20. Install the engine wiring harness to the engine wiring harness bracket at the right rear of the engine.
21. Install the ground wires and nut on the stud for the engine wiring harness bracket at the rear of the right cylinder head.
Tighten the ground wires nut to 8 Nm (71 inch lbs.)
22. 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 engine coolant temperature (ECT) gauge sensor
- The ignition control module (ICM)
- The knock sensor (KS)
- The distributor
- The engine oil pressure gauge sensor
23. Install the engine wiring harness clip and nut on the stud for the throttle body.
Tighten the engine wiring harness clip nut to 10 Nm (88 inch lbs.).
24. Install the ground wire and the nut on the water outlet stud.
Tighten the ground wire nut to 8 Nm (71 inch lbs.).
25. Install the engine wiring harness to the bracket on the generator bracket and to the front of the engine.
26. Install the stud and the battery negative cable
Tighten the battery negative cable stud to 17 Nm (13 inch lbs.).
27. Install the nut and ground wire on the battery negative cable stud.
Tighten the ground wire nut to 8 Nm (71 inch lbs.).
28. Connect the CKP sensor electrical connector.
29. Connect the electrical connections to the generator.
30. Connect the electrical connector for the EVO pressure switch on the power steering pump.
31. Install the EVO wire harness to the bracket on the CKP sensor.
32. Connect the heater hoses to the engine.
33. Install the inlet and outlet radiator hoses to the engine.
34. Install both the upper and lower fan shroud.
35. Install the accelerator control cable bracket to the power steering pump mounting bracket.
Tighten the bolt to 17 Nm (13 ft. lbs.).
36. Install the A/C wiring harness to the accelerator cable bracket.
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.
37. Install a NEW accelerator control cable.
38. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket.
39. Install the A/C hose to the accumulator and the compressor.
40. Raise the vehicle.
41. Install the remaining transmission to engine bolts.
42. Install the torque converter bolts to the flywheel, if equipped.
43. Install the transmission cover.
Tighten the nut to 12 Nm (106 inch lbs.).
44. Install the starter.
45. Install the bolt holding the bracket for the transmission cooler lines, if equipped.
Tighten the bracket bolt to 12 Nm (106 inch lbs.).
46. Connect the oil cooler pipes, if equipped.
47. Install the exhaust pipe to the exhaust manifolds.
48. Install a NEW oil filter.
49. Lower the vehicle.
50. Fill the engine with oil.
51. Fill the cooling system with coolant.
52. Connect the EVAP canister purge solenoid valve hose.
53. Connect the battery negative cable.
54. Install the air cleaner outlet duct.
55. Recharge the air conditioning system, if equipped.
56. Install the hood.
57. Operate and test the engine.
- Refer to Engine Set-Up and Testing under Engine Unit Repair.