Engine Installation
Important: If you install a new engine, make sure any remaining components, brackets, or accessories are transferred to the new engine.
1. Install the engine into the frame.
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.).
6. Remove the J41427from the engine.
7. Apply thread lock GM PN 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.
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.
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. Install the air conditioning compressor, if equipped and the power steering pump mounting bracket.
17. Install the distributor cap.
18. Install the spark plug wires.
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/raised into the frame.
19. Lower the vehicle onto the engine/frame assembly.
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.
20. Install the body bolts (frame to body) (1), (2), and (3).
21. Tighten the body bolts using the following sequence.
21.1. Tighten all of the body bolts in the sequence shown to 35 Nm (26 ft. lbs.).
21.2. Tighten the right center body bolt first to 155 Nm (114 ft. lbs.).
21.3. Tighten the left center body bolt second to 155 Nm (114ft. lbs.).
21.4. Tighten the right front body bolt third to 90 Nm (66 ft. lbs.).
21.5. Tighten the left rear body bolt fourth to 90 Nm (66 ft. lbs.).
21.6. Tighten the left front body bolt fifth to 90 Nm (66 ft. lbs.).
21.7. Tighten the right rear body bolt last to 90 Nm (66 ft. lbs.).
22. Raise the vehicle.
23. Install the transfer case vent tube, if equipped.
24. Connect the wire connector to the wiring harness above the transmission.
25. Connect the shift cable to the transmission.
26. Install the torque converter bolts.
27. Install the transmission cover.
Tighten the transmission cover bolts to 12 Nm (106 inch lbs.).
28. Install the starter.
29. Install the rear propeller shaft.
30. Connect the power steering cooler.
31. Connect the inflatable restraint front end discriminating sensor electrical connector.
32. Connect the fender wheelhouse extensions from chassis to the frame.
33. Install the front bumper.
34. Install the catalytic converter assembly to the exhaust system.
35. Connect the fuel pipes at the fuel filter.
36. Connect the fuel tank electrical connector.
37. Connect the EVAP vent valve electrical connector.
38. Install the bolt and the ground wire at the chassis by the EVAP vent valve.
39. Ensure that all of the electrical connections are connected between the chassis and the frame.
40. Install the bolt and the park brake bracket to the frame.
Tighten the park brake bracket bolt to 24 Nm (17 inch lbs.).
41. Connect the rear air conditioning pipes at the rear crossmember, if equipped.
42. Connect the rear brake pipe to the BPMV.
43. Lower the vehicle.
44. Remove both of the J41602.
45. Install the front section of the running boards.
46. Install the wiring harness in the retainers.
47. Connect the fuse box and the wiring harness to the bulkhead connector.
48. Connect all related connectors including:
- The ground wires
- The accumulator
- The cruise control module
- The wiper motor
49. Connect the steering shaft to the steering gear.
50. Connect the heater hoses to the engine.
51. Connect the wire connector to the water control valve.
52. Connect the vacuum hose to the water control valve.
53. Connect the pipes to the hydro boost.
54. Install the power steering reservoir.
55. Install the master cylinder to the hydra boost.
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.
56. Install the NEW accelerator control cable.
57. Install the cruise control cable in the throttle body bracket.
58. Connect the cruise control cable to the throttle shaft.
59. Connect the air conditioning pipes at the accumulator and the condenser, if equipped.
60. Install the radiator.
61. Fill the cooling system with the proper grade of engine coolant.
62. Install the air cleaner outlet duct to the throttle body.
63. Install the air cleaner assembly.
64. Fill the crankcase with the proper grade of engine oil.
65. Fill and bleed the brake system.
66. Fill the transmission with the proper grade and quantity of transmission fluid.
67. Fill the power steering system with the proper grade and quantity of power steering fluid.
68. Connect the battery negative cable.
69. Recharge the air conditioning system and check for proper operation, if equipped.
70. Install the engine cover.
71. Operate the engine and check for proper operation.