Engine Removal and Installation
REMOVAL PROCEDURE^ Tools Required
- J 41427 Engine Lift Bracket
- J 41602 Body Protection Hoist Adapter Set
- J 39580 Universal Engine Support Table
If the engine is damaged internally and a new engine is installed, make sure that all foreign material is completely flushed out of the cooling system.
NOTICE: Failure to flush out the oil cooling system or the engine cooling system may result in premature failure of the replacement engine.
The oil cooler system should be also be flushed out, if equipped.
1. Disconnect the battery negative cable.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
2. Remove the engine cover.
IMPORTANT: This procedure must be performed on a side lift hoist. The engine and front frame assembly will be removed out of the bottom of the vehicle, therefore, a single post hoist or a twin post hoist cannot be used to perform this procedure.
3. Remove the air cleaner assembly.
4. Remove the air cleaner outlet retaining nut (1).
5. Remove the air cleaner outlet duct (2) from the throttle body assembly.
6. Disconnect the Intake Air Temperature (IAT) sensor harness connector.
7. Loosen the air cleaner outlet duct from the Mass Air Flow (MAF) sensor.
8. Remove the air cleaner outlet duct.
9. Remove the radiator.
10. Disconnect the air conditioning pipes at the accumulator and the condenser, if equipped.
^ Refer to Compressor/Condenser Hose Replacement - Auxiliary (C60) in Heating and Air Conditioning with A/C - Manual.
^ Refer to compressor/condenser Hose Replacement - Auxiliary (C69) in Heating and Air Conditioning with A/C - Manual.
^ Refer to Compressor/Condenser Hose Replacement - Auxiliary (YF7) in Heating and Air Conditioning with A/C - Manual.
11. Remove the accelerator control cable from the throttle shaft.
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.
12. Remove the cruise control cable, if equipped from the throttle shaft.
13. Remove the accelerator control cable and the cruise control cable from the accelerator control cable bracket.
14. Remove the power steering reservoir and drain the fluid.
15. Disconnect the pipes from the hydro boost unit.
16. Disconnect the master cylinder from the hydro boost unit.
17. Tie the master cylinder to the oil fill tube.
18. Disconnect the steering shaft from the steering gear.
^ Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column -Standard.
^ Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
19. Disconnect the heater hoses from the engine.
^ Refer to Hot Water Bypass Valve Replacement (Standard) in Heating and Air Conditioning (Non-A/C).
^ Refer to Hot Water Bypass Valve Replacement (C36) in Heating and Air Conditioning (Non-A/C).
20. Disconnect the vacuum hose from the water control valve.
21. Disconnect the wire connector from the water control valve.
22. Disconnect the fuse box and the wiring harness from the bulkhead connector.
23. Disconnect all related electrical connectors that connect the wiring harness to the body under the hood including the following: Refer to Engine/Center of Front of Dash Wiring (Components) in Diagrams.
^ The ground wires
^ The accumulator
^ The cruise control module
^ The wiper motor
24. Remove the wiring harness from the retainers and lay the harness on the engine.
25. Install the J 41602 to the pinch weld area on both sides of the vehicle.
26. Position the front hoist arms under the J 41602.
27. Make sure the rear of the vehicle is slightly higher than the front.
28. Raise the vehicle.
29. Remove the oil pan drain plug and drain the engine oil into a suitable container.
30. Remove the rear propeller shaft.
31. Remove the starter.
32. Remove the transmission cover.
33. Remove the torque converter bolts through the starter opening.
34. Disconnect the shift cable from the transmission.
35. Disconnect the wire connector from the wiring harness above the transmission.
36. Disconnect the exhaust system at the main flange behind the catalytic converter.
^ Refer to Catalytic Converter Replacement (Rear Wheel Drive) in Exhaust System.
^ Refer to Catalytic Converter Replacement (Full-Time Four-Wheel Drive) in Exhaust System.
37. Remove the park brake bracket from the frame.
38. Disconnect the rear brake pipe from the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement in Anti Lock Brakes.
39. Remove the front bumper.
40. Disconnect the power steering cooler from the front air deflector.
41. Disconnect the inflatable restraint front end discriminating sensor electrical connector.
42. Disconnect the fender wheelhouse extensions from the chassis to the frame.
43. Disconnect the rear air conditioning pipes at the rear crossmember, if equipped.
Leave the air conditioning pipes attached to the powertrain assembly.
^ Refer to Accumulator Tube Replacement -Auxiliary Side in Heating and Air Conditioning, with A/C - Manual.
^ Refer to Evaporator Tube Replacement -Auxiliary Side in Heating and Air Conditioning, with A/C - Manual.
44. Disconnect the fuel pipes at the fuel filter.
45. Pull the fuel pipes through the crossmember (forward). Lay the fuel pipes on the transmission.
46. Disconnect the fuel tank electrical connector.
47. Disconnect the EVAP vent valve electrical connector.
48. Remove the bolt and the ground wire at the chassis by the EVAP vent valve.
49. Make sure all the connections are disconnected between the chassis and the frame.
50. Disconnect the transfer case vent hose, if equipped.
51. Position the J 39580 under the frame assembly.
52. Lower the vehicle.
53. Adjust J 39580 to properly support the frame assembly with the engine, transmission, front suspension components, and front differential carrier assembly, if equipped.
54. Remove the body mount bolts (1), (2) and (3).
55. Place a jack stand under the transmission crossmember to prevent the frame assembly from tipping off of the J 39580.
56. Raise the hoist in order to separate the body from the frame assembly.
57. Install support stands under the rear axle.
58. Remove the EGR valve inlet pipe from the intake manifold and the exhaust manifold.
59. Disconnect the spark plug wires from the spark plugs.
60. Remove the distributor cap with the spark plug wire harness.
61. Remove the drive belt.
62. Remove the air conditioning compressor.
63. Remove the oil filler tube bolt.
64. Remove the oil filler tube from the valve rocker arm cover.
65. Remove the power steering pump pulley.
66. Remove the three bolts holding the power steering pump to the power steering pump mounting bracket.
67. Remove the three bolts and nut holding the power steering pump mounting bracket to the engine.
68. Slide the power steering pump mounting bracket off the stud and the power steering pump.
69. Install the J 41427 using the following procedure:
69.1. Remove the two right rear lower intake manifold bolts.
69.2. Install the J 41427 marked RIGHT REAR.
69.3. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
69.4. Remove the two left front lower intake manifold bolts.
69.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
69.6. Install the retaining bolts
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
70. Remove the engine mount through bolts.
71. Remove the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
72. Disconnect the fuel pipes at the rear of the engine.
73. Disconnect the electrical harness at the transmission.
74. Disconnect all the wire harness connections and the ground wires from the engine and move the harness aside.
^ Refer to Engine Wiring RH Side in Diagrams.
^ Refer to Engine Wiring, LH Side (Components) in Diagrams.
75. Remove the transfer case to engine block brace, if equipped.
76. Raise the engine slightly. Support the front of the transmission with suitable floor stand and a block of wood. Do not support the transmission under the oil pan.
77. Remove the exhaust pipe from the exhaust manifolds.
^ Refer to Catalytic Converter Replacement (Rear Wheel Drive) in Exhaust System.
^ Refer to Catalytic Converter Replacement (Full-Time Four-Wheel Drive) in Exhaust System.
78. Remove the transmission to engine bolts.
79. Disconnect the engine from the transmission.
80. Remove the engine from the frame.
INSTALLATION PROCEDURE
1. Install the engine into the frame.
IMPORTANT: If you install a new engine, make sure any remaining components, brackets, or accessories are transferred to the new engine.
2. Connect the engine to the transmission.
3. Remove the support from under the transmission.
4. Lower the engine and the transmission onto the engine mounts.
5. Install the engine mount through-bolts.
^ Tighten the engine mount through-bolts to 68 Nm (50 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
6. Remove the J 41427 from the engine.
7. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
8. Install the intake manifold bolts.
8.1. Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
8.2. Tighten the bolts the second pass to 12 Nm (106 inch lbs.).
8.3. Tighten the bolts the first pass to 15 Nm (11 ft. lbs.).
9. Install the exhaust pipe to the exhaust manifolds.
^ Refer to Catalytic Converter Replacement (Rear Wheel Drive) in Engine Exhaust.
^ Refer to Catalytic Converter Replacement (Full-Time Four-Wheel Drive) in Engine Exhaust.
10. Connect the fuel pipes at the rear of the engine.
11. Connect the fuel pipe bracket to the rear of the left cylinder head.
^ Tighten the fuel pipe bracket bolt to 30 Nm (22 ft. lbs.).
12. Connect all of the wiring harness connections and the ground wires to the engine.
^ Refer to Engine Wiring RH Side in Diagnostic Aids.
^ Refer to Engine Wiring, LH Side (Components) in Diagnostic Aids.
13. Connect the electrical harness at the transmission,
14. Install the transfer case to engine block brace, if equipped.
15. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.
^ Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
^ Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
16. Slide the power steering pump mounting bracket on the stud and the power steering pump.
17. Install the power steering pump mounting bracket three bolts and the nut.
^ Tighten the power steering pump mounting bracket bolts and nut to 41 Nm (30 ft. lbs.).
18. Install the power steering pump mounting bracket to the power steering pump.
^ Tighten the power steering pump bolts to 50 Nm (37 ft. lbs.).
19. Install the power steering pump pulley.
20. Install the oil filler tube in the valve rocker arm cover.
21. Install the oil filler tube bolt.
^ Tighten the oil filler tube bolt to 25 Nm (18 ft. lbs.).
22. Install the drive belt.
23. Install the air conditioning compressor, if equipped.
24. Install the distributor cap.
25. Install the spark plug wires.
26. Lower the vehicle onto the engine/frame assembly.
IMPORTANT: Align the frame using the two alignment holes in the frame and the body. Use a pry bar or dowel pin in order to align the holes as the vehicle is being lowered onto the frame assembly..
27. Install the body bolts (frame to body) (1), (2), and (3).
IMPORTANT: The six body bolts (frame to body) must be tightened in sequence in order to ensure proper alignment of the frame to the chassis.
28. Tighten the body bolts using the following sequence.
28.1. Tighten all of the body bolts in the sequence shown to 35 Nm (26 ft. lbs.).
28.2. Tighten the right center body bolt first to 155 Nm (114 ft. lbs.).
28.3. Tighten the left center body bolt second to 155 Nm (114 ft. lbs.).
28.4. Tighten the right front body bolt third to 90 Nm (66 ft. lbs.).
28.5. Tighten the left rear body bolt fourth to 90 Nm (66 ft. lbs.).
28.6. Tighten the left front body bolt fifth to 90 Nm (66 ft. lbs.).
28.7. Tighten the right rear body bolt last to 90 Nm (66 ft. lbs.).
29. Raise the vehicle.
30. Install the transfer case vent tube, if equipped.
31. Connect the wire connector to the wiring harness above the transmission.
32. Connect the shift cable to the transmission.
33. Install the torque converter bolts.
34. Install the transmission cover.
^ Tighten the transmission cover bolts to 12 Nm (106 inch lbs.).
35. Install the starter.
36. Install the rear propeller shaft.
37. Connect the power steering cooler.
38. Connect the inflatable restraint front end discriminating sensor electrical connector.
39. Connect the fender wheelhouse extensions from chassis to the frame.
40. Install the front bumper.
41. Install the catalytic converter assembly to the exhaust system.
^ Refer to Catalytic Converter Replacement (Rear Wheel Drive) in Exhaust System.
^ Refer to Catalytic Converter Replacement (Full-Time Four-Wheel Drive) in Exhaust System.
42. Connect the fuel pipes at the fuel filter.
43. Connect the fuel tank electrical connector.
44. Connect the EVAP vent valve electrical connector.
45. Install the bolt and the ground wire at the chassis by the EVAP vent valve.
46. Ensure that all of the electrical connections are connected between the chassis and the frame.
47. Install the bolt and the park brake bracket to the frame.
^ Tighten the park brake bracket bolt to 24 Nm (17 inch lbs.).
48. Connect the rear air conditioning pipes at the rear crossmember, if equipped.
^ Refer to Accumulator Tube Replacement -Auxiliary Side in Heating and Air Conditioning, with A/C - Manual.
^ Refer to Evaporator Tube Replacement -Auxiliary Side in Heating and Air Conditioning, with A/C - Manual.
49. Connect the rear brake pipe to the BPMV.
50. Lower the vehicle.
51. Remove both of the J 41602.
52. Install the wiring harness in the retainers.
53. Connect the fuse box and the wiring harness to the bulkhead connector.
54. Connect all related connectors including: Refer to Engine/Center of Front of Dash Wiring (Components) in Diagrams.
^ The ground wires
^ The accumulator
^ The cruise control module
^ The wiper motor
55. Connect the steering shaft to the steering gear.
^ Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Columns -Standard.
^ Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Columns - Tilt.
56. Connect the heater hoses to the engine.
^ Refer to Hot Water Bypass Valve Replacement (Standard) in Heating and Air Conditioning, - (Non A/C)
^ Refer to Hot Water Bypass Valve Replacement (C36) in Heating and Air Conditioning, - (Non A/C)
57. Connect the wire connector to the water control valve.
58. Connect the vacuum hose to the water control valve.
59. Connect the pipes to the hydro, boost.
60. Install the power steering reservoir.
61. Install the master cylinder to the hydro boost.
62. Install the NEW accelerator control cable.
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.
63. Install the cruise control cable in the throttle body bracket.
64. Connect the cruise control cable to the throttle shaft.
65. Connect the air conditioning pipes at the accumulator and the condenser, if equipped.
^ Refer to Compressor/Condenser Hose Replacement - Auxiliary (C60) in Heating and Air Conditioning, with A/C - Manual.
^ Refer to Compressor/Condenser Hose Replacement - Auxiliary (C69) in Heating and Air Conditioning, with A/C - Manual.
^ Refer to Compressor/Condenser Hose Replacement - Auxiliary (YF7) in Heating and Air Conditioning, with A/C - Manual.
66. Install the radiator.
67. Fill the cooling system with the proper grade of engine coolant.
68. Install the air cleaner outlet duct to the Mass Air Flow (MAF) sensor.
69. Connect the Intake Air Temperature (IAT) sensor harness connector.
70. Install the air cleaner outlet duct (2) on the throttle body assembly.
71. Tighten the retaining nut (1).
^ Tighten the retaining nut to 2 Nm (18 inch lbs.).
72. Install the air cleaner assembly.
73. Fill the crankcase with the proper grade of engine oil.
74. Fill and bleed the brake system.
75. Fill the transmission with the proper grade and quantity of transmission fluid.
76. Fill the power steering system with the proper grade and quantity of power steering fluid.
77. Connect the battery negative cable.
78. Recharge the air conditioning system and check for proper operation, if equipped.
79. Install the engine cover.
80. Operate the engine and check for proper operation.