Engine Removal and Installation
REMOVAL PROCEDURE^ Tools Required
- J 41427 Engine Lift Bracket
1. Remove the radiator support.
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.
2. Remove the engine cover.
3. Remove the engine cooling fan.
4. Remove the stud and bolt holding the ground wires to the rear of both cylinder heads.
5. Disconnect the following electrical connections:
^ The fuel meter body assembly
^ The EVAP canister purge solenoid valve
^ The Idle Air Control (IAC) motor
^ The Throttle Position (TP) sensor
^ The Manifold Absolute Pressure (MAP)
^ 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 positive cable and connector
^ The Crankcase Position (CKP) sensor
^ The Knock (KS) Sensor
^ The engine Oil Pressure (OP) gauge sensor
^ The distributor
6. Remove the nut holding the ground wire to the water outlet stud.
7. Remove the nut holding the wiring harness at the transmission to engine stud.
8. Remove the engine wiring harness from the stud on the generator mounting bracket.
9. Move the engine wiring harness aside.
10. Remove the bolt holding the battery negative cable and the ground strap to the front of the engine.
11. Remove the generator mounting bracket.
12. Remove the heater hoses from the engine.
13. Remove the radiator inlet and outlet hoses.
14. Remove the A/C compressor pipes from the vehicle.
15. Remove the power steering pump mounting bracket.
16. Remove the power steering pump rear mounting bracket from the engine. Set the pump aside.
17. 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.
18. Remove the cruise control cable, if equipped from the throttle shaft.
19. Remove the distributor.
20. In order to allow access for the lifting device, remove the upper intake manifold. Refer to Intake Manifold Replacement (Upper).
21. Remove the EGR valve inlet pipe from the intake and exhaust manifold.
22. Remove the transmission control cable bracket from the rear of the left cylinder head.
23. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting.
24. Remove both exhaust manifolds.
25. Remove the oil pan drain plug and drain the engine oil into a suitable container.
26. Remove the engine oil filter.
27. Remove the engine oil cooler pipes from the retaining brackets.
28. Remove the engine oil cooler pipes from the engine.
29. Remove the starter motor.
30. Remove the transmission cover.
31. Remove the torque converter bolts from the flywheel through the transmission cover opening.
32. Remove the transmission cooler pipes from the engine.
33. Remove the bolts holding the transmission to the engine except the top two bolts.
34. Remove the safety stands and lower the vehicle.
35. Support the transmission with a strap between the frame rails or use a suitable transmission Jack.
36. Install the J 41427 using the following procedure:
36.1. Remove the two right rear lower intake manifold bolts.
36.2. Install the J 41427 marked RIGHT REAR.
36.3. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
36.4. Remove the two left front lower intake manifold bolts.
36.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
36.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
37. Attach a suitable engine lifting device to the J 41427
38. Remove the engine mounts from the engine mount frame brackets.
39. Remove the two remaining engine to transmission bolts.
40. Remove the engine assembly from the vehicle.
INSTALLATION PROCEDURE
^ Tools Required
- J 41427 Engine Lift Brackets
1. Install the engine assembly to the vehicle.
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.
2. Loosely install the two upper transmission to engine bolts.
3. Install the engine mounts to the engine mount frame brackets.
4. Remove the engine lifting device.
5. Remove the J 41427 from the engine.
6. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower intake manifold bolts.
7. Install the lower intake manifold bolts.
7.1. Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
7.2. Tighten the bolts the second pass to 12 Nm (106 inch lbs.).
7.3. Tighten the bolts the third pass to 15 Nm (111 ft. lbs.).
8. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting.
9. Install the remaining bolts from the transmission to the engine.
10. Install the bolt holding the transmission cooler pipes bracket to the oil pan.
^ Tighten the bolt to 12 Nm (106 inch lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
11. Install the torque converter bolts to the flywheel.
12. Install the transmission cover.
^ Tighten the transmission cover bolts to 12 Nm (106 inch lbs.).
13. Install the starter motor.
14. Install the engine oil cooler pipes to the engine.
15. Install the engine oil cooler pipes to the retaining brackets.
16. Install the exhaust manifolds.
17. Remove the safety stands and lower the vehicle.
18. Install the transmission control cable bracket to the rear of the left cylinder head.
^ Tighten the transmission control cable bracket bolts to 40 Nm (30 ft. lbs.).
19. Install the upper intake manifold to the engine.
20. Install the EGR valve inlet pipe to the intake and the exhaust manifolds.
^ Tighten the EGR valve inlet pipe intake nut to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve inlet pipe exhaust nut to 30 Nm (22 ft.).
^ Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
21. Install the distributor.
22. Install a 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.
23. Install the cruise control cable, if equipped.
24. Install the power steering pump with the rear bracket to the engine.
25. Install the power steering pump mounting bracket.
26. Install the A/C compressor pipes to the vehicle.
27. Install the radiator inlet and outlet hoses to the engine.
28. Install the heater hoses to the engine.
29. Install the generator mounting bracket.
30. Install the bolt holding the battery negative cable and the ground strap to the front of the engine.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
31. Position the engine wiring harness.
32. Install the engine wiring harness on the stud at the generator mounting bracket.
32. Connect the following electrical connections:
^ The fuel meter body assembly
^ The EVAP canister purge solenoid valve
^ The Idle Air Control (IAC) motor
^ The Throttle Position (TP) sensor
^ The Manifold Absolute Pressure (MAP)
^ 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 positive cable and connector
^ The Crankcase Position (CKP) sensor
^ The Knock (KS) Sensor
^ The engine Oil Pressure (OP) gauge sensor
^ The distributor
34. Install the stud and bolt holding the ground wires to the rear of both cylinder heads.
^ Tighten the bolt and the stud to 10 Nm (88 inch lbs.).
35. Install the nut holding the ground wire to the water outlet stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).
36. Install the nut holding the engine wiring harness at the transmission to engine stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
37. Install the fan clutch to the water pump.
38. Install the radiator support.
39. Install the oil filter and fill the engine with engine oil.
40. Fill the cooling system with the proper quantity and type of coolant.
41. Operate the engine and check for proper operation. Refer to Engine Set-Up and Testing under Engine Unit Repair.
42. Install the engine cover.