Engine Replacement

REMOVAL PROCEDURE





1. Disconnect the battery negative cable from the battery.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Remove the engine cover.
3. Remove the coolant recovery reservoir.
4. Remove the air cleaner assembly.
5. Remove the air cleaner intake duct.
6. Remove the front bumper.
7. Remove the radiator grille assembly.
8. Remove the radiator support.





9. Remove the A/C condenser.
10. Remove the radiator.
11. Remove the ground straps.
12. Remove the fan clutch from the water pump.
13. Remove the heater hoses from the engine.
14. Remove the engine wiring harness.
15. Remove the accelerator control cable and the cruise control cable, if equipped.
16. Remove the generator from the mounting bracket.





17. Remove the generator mounting bracket using the following procedure:
- Remove three bolts from the front of the bracket.
- Remove one nut from the front of the bracket.
- Slide the bracket off of the stud.
- Remove the stud from the cylinder head.





18. Remove the A/C compressor from the mounting bracket.
19. Remove the power steering pump from the mounting bracket.





20. Remove the pulley from the power steering pump.





21. Remove the power steering pump mounting bracket using the following procedure:
- Remove three bolts from the front of the bracket.
- Remove one nut from the front of the bracket.
- Slide the bracket off of the stud.
- Remove the stud from the cylinder head.

22. In order to allow access for the lifting device, remove the upper intake manifold.





23. Remove the fuel pipes from the rear of the engine.
24. Remove the transmission oil level indicator and tube.
25. Remove the transmission shift cable connector.
26. Raise the vehicle and support with safety stands.
27. Drain the engine oil.
28. Remove the exhaust pipes from the exhaust manifolds.





29. Remove the engine oil cooler lines from the retaining brackets.
30. Remove the engine oil cooler lines from the engine.





31. Remove the flywheel cover.
32. Remove the torque converter bolts from the flywheel.
33. Remove the starter motor.
34. Remove the transmission cooler lines from the engine.
35. Remove the bolts holding the transmission to the engine.
36. Remove the safety stands and lower the vehicle.
37. Install a length of chain, using GM P/N 23503910 attaching bolt to the rear of the left cylinder head.
38. Support the transmission with a strap between the frame rails.
39. Attach a suitable lifting device to the chain.
40. Remove the engine mount through bolts.
41. Remove the engine mounts from the frame.
42. Remove the engine assembly from the vehicle.

INSTALLATION PROCEDURE
1. Install the engine assembly to the vehicle.
2. Install the engine mounts to the frame.
3. Install the engine mount through bolts.
4. Remove the lifting device from the chain.
5. Support the transmission with a strap between the frame rails.
6. Raise the vehicle and support with safety stands.
7. Install the bolts from the transmission to the engine.
8. Install the transmission cooler lines to the engine block.
9. Install the torque converter bolts to the flywheel.





10. Install the flywheel cover.
11. Install the starter motor.
12. Install the engine oil cooler lines to the engine.





13. Install the engine oil cooler lines to the retaining brackets.
14. Install the exhaust pipes to the exhaust manifolds.
15. Install the exhaust pipes to the exhaust manifolds.
16. Remove the safety stands and lower the vehicle.
17. Install the transmission shift cable connector.
18. Install the transmission oil level indicator and the tube.
19. Install the fuel pipes to the rear of the engine.
20. Install the upper intake manifold to the engine.





21. Install the power steering pump mounting bracket using the following procedure:
- Install the stud to the cylinder head.
- Tighten the stud to 22 Nm (16 ft. lbs.).
- Loosely assemble the bracket over the stud.
- Install a nut to the stud finger tight.
- Install three bolts finger tight.
- Install two nuts to the power steering pump finger tight.
- Tighten the nuts and bolts to 44 Nm (32 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

22. Install the power steering pump to the mounting bracket.





23. Install the A/C compressor to the mounting bracket.





24. Install the generator mounting bracket using the following procedure:
- Install the stud to the cylinder head.
- Tighten the stud to 22 Nm (16 ft. lbs.).
- Loosely assemble the bracket over the stud.
- Install a nut the stud finger tight.
- Install three bolts finger tight.
- Tighten the nuts and bolts to 44 Nm (32 ft. lbs.).

25. Install the generator to the mounting bracket.
26. Install the accelerator control cable and the cruise control cable, if equipped.
27. Install the engine wiring harness.
28. Install the heater hoses to the engine block.
29. Install the fan clutch to the water pump.
30. Install the ground straps.
31. Install the radiator.





32. Install the A/C condenser.
33. Install the radiator support.
34. Install the radiator grille assembly.
35. Install the front bumper.
36. Install the air cleaner intake duct.
37. Install the air cleaner assembly.
38. Install the coolant recovery reservoir.
39. Install the engine cover.
40. Connect the battery negative cable to the battery.
41. Fill the engine with the proper quantity and grade of engine oil.
42. Fill the cooling system with the proper quantity and type of coolant.