Installation

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.

^ Tools 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 J 41427 and the engine lifting device.
4. Apply thread lock GM P/N 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. Refer to Thermostat Replacement in Cooling System.
8. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
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. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.





11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap. Refer to Distributor Replacement in Powertrain Management.
13. Install both of the AIR reactor pipes to the engine.
^ Refer to AIR Check Valve/Pipe Replacement-Bank 1 in Powertrain Management.
^ Refer to AIR Check Valve/Pipe Replacement-Bank 2 in Powertrain Management.
14. Install the AIR shut-off valve and hoses. Refer to AIR Shut-Off Valve Replacement in Powertrain Management.
15. Install the power steering pump mounting bracket.





16. 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.).
17. Install the nut holding the AIR reactor pipe bracket to the stud on the front of the engine.
^ Tighten the bolt to 30 Nm (22 ft. lbs.).
18. Install the A/C compressor, if equipped. Refer to Compressor Replacement. in Heating and Air Conditioning.
19. Install the water pump pulley. Refer to Water Pump Replacement in Cooling System.





20. 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.

21. Install a NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
22. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.





23. Install the battery ground cable bolt.
^ Tighten the ground cable bolt to 35 Nm (26 ft. lbs.).





24. Install the bolts holding the ground wires to the left cylinder head.
^ Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).





25. Install the stud holding the ground wires to the right cylinder head.
^ Tighten the stud to 35 Nm (26 ft. lbs.).





26. Position the engine wiring harness.
27. Install the engine wiring harness in the retainers.
28. 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
29. Install the radiator. Refer to Radiator Replacement in Cooling System.
30. Install the inlet and outlet radiator hose to the engine. Refer to Radiator Hose Replacement in Cooling System.
31. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning





32. Raise the vehicle. Refer to Vehicle Lifting.
33. Install the transmission.
^ Refer to Transmission Replacement in Transmission and Drivetrain.
34. Install the transfer case, if equipped.
^ Refer to Transfer Case Replacement in Transmission and Drivetrain.
35. Install the front propeller shaft (Four Wheel Drive vehicle only). Refer to Propeller Shaft Replacement-Front in Transmission and Drivetrain.





36. Install the transmission cover.
^ Tighten the nut to 12 Nm (106 inch lbs.).
37. Install the starter. Refer to Starter Motor Replacement in Starting and Charging.





38. 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.).
39. Connect the oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler Line Replacement (RWD) in Cooling System.
40. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle). Refer to Remote Oil Filter Adapter Pipe Replacement.
41. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Manifold Pipe Replacement in Exhaust System.
42. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement.
43. Install the braces from the engine to the transmission. Refer to Transmission Replacement in Transmission and Drivetrain.
44. Install the underbody shields.
45. Lower the vehicle.
46. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
47. Fill the cooling system with coolant. Refer to Draining and Filling Cooling System in Cooling System.
48. Connect the battery negative cable. Refer to Battery Replacement in Starting and Charging.
49. Recharge the air conditioning system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
50. Operate and test the engine. Refer to Engine Set-Up and Testing.