Removal and Replacement
^ Tools Required- J41427Engine Lift Brackets
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Evacuate and recover the A/C refrigerant, if equipped. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
4. Raise the vehicle. Refer to Vehicle Lifting.
5. Remove the oil pan skid plate (RWD shown).
6. Remove the engine shield, if equipped. Refer to Engine Protection Shield Replacement. Remove the starter. Refer to Starter Motor Replacement.
8. Remove the transmission cover.
9. Remove the bolt holding the bracket for the starter cables and transmission cooler lines, if equipped.
10. Loosen the nuts (2) at the catalytic converter pipe.
11. Remove the exhaust pipes from the exhaust manifolds. Refer to Catalytic Converter Replacement.
12. Remove the bolts holding the brackets to the oil pan for both battery cables.
13. Disconnect the crankshaft position (CKP) sensor electrical connector (2) and remove the harness from the retainer.
14. Disconnect the low oil level sensor electrical connector (3) and remove the wire harness from the retainer.
15. Remove the bolt holding the battery negative cable (1) and a ground cable (1) to the engine.
16. Remove the torque converter to flywheel bolts, if equipped, through the starter opening.
17. Remove the engine to transmission bolts.
^ Refer to Automatic Transmission Replacement
^ Refer to Manual Transmission Replacement.
18. Lower the vehicle.
19. Move the hood hinge bolts (1) to hold the hood in the service position (2).
20. Disconnect the PCV hose from the air cleaner outlet duct.
21. Remove the air cleaner outlet duct from the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement.
22. Remove the fan shroud. Refer to Fan Shroud Replacement in Cooling System.
23. Remove the drive belt. Refer to Drive Belt Replacement.
24. Remove the engine cooling fan. Refer to Fan Clutch Replacement in Cooling System.
25. Remove the radiator inlet hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
26. Remove the radiator outlet hose from the engine. Refer to Radiator Hose Replacement in Cooling System.
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.
27. Remove the accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
28. Disconnect the cruise control cable from the throttle body and the bracket on the throttle body and intake manifold, if equipped. Refer to Cruise Control Cable Replacement.
29. Remove the engine wiring harness and clip from the accelerator control cable bracket.
30. Remove the accelerator control cable bracket from the throttle body.
31. Disconnect the A/C hoses from the compressor and the accumulator, if equipped. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
32. Remove the secondary air injection (AIR) crossover pipe from the AIR pipe assemblies.
Notice: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.
33. Remove AIR pipe assemblies from the left exhaust manifold, if equipped.
34. Disconnect the AIR pipe assembly from the AIR pump.
35. Remove the AIR pipe assembly from the right exhaust manifold, if equipped.
36. Disconnect the following electrical connectors:
^ The A/C pressure switch (4), if equipped
^ The A/C compressor clutch (1), if equipped
^ The exhaust gas recirculation (EGR) valve (2)
^ The generator battery positive cable (3)
37. Disconnect the following electrical connectors:
^ The fuel meter body assembly (3)
^ The idle air control (IAC) motor (2)
^ The throttle position (TP) sensor (1)
^ The engine coolant temperature (ECT) sensor (4)
38. Disconnect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The manifold absolute pressure (MAP) sensor (2)
^ The ignition control module (ICM) (4)
^ The ignition coil (3)
39. Disconnect the following electrical connectors:
^ The engine oil pressure gauge sensor (3)
^ The distributor (2)
^ The knock sensor (KS) (1)
40. Remove the nuts holding the bracket for the engine wiring harness to the intake manifold studs.
41. Remove the bolt holding the engine wiring harness clip to the battery positive cable junction block bracket.
42. Remove the bracket for the battery positive cable junction block from the power steering pump mounting bracket.
43. Move the battery positive and negative cables aside.
44. Remove the nut holding the ground wire to the stud at the rear of the right cylinder head.
45. Remove the stud holding the engine wiring harness bracket to the rear of the right cylinder head.
46. Remove the nut holding the engine wiring harness bracket to the stud for the EVAP canister purge solenoid valve.
47. Remove the bolt holding the ground strap and the ground wire to the rear of the left cylinder head.
48. Move the engine wiring harness aside.
49. Remove both heater hoses from the engine and the cowl. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
50. Remove the distributor cap. Refer to Distributor Replacement.
51. Disconnect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
52. Disconnect the hose to the EVAP purge canister solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
53. Disconnect the power brake booster vacuum hose from the engine and the vacuum brake booster.
54. Loosen the nut holding the power steering pump rear bracket to the side of the engine.
55. Remove the nut holding the power steering pump rear bracket to the front of the engine.
56. Remove the three bolts and the nut holding the power steering pump mounting bracket to the engine.
57. With the power steering pump and the A/C compressor still attach, slide the power steering pump mount bracket off of the stud and set aside.
58. Remove the water outlet. Refer to Thermostat Replacement in Cooling System.
59. Remove the EGR valve inlet pipe from the intake and exhaust manifold.
Notice: Refer to Fastener Notice in Service Precautions.
60. Attach the J41427 to the left front and right rear intake manifold mounting bolts, using the following procedure:
60.1. Remove the right rear lower intake manifold bolts.
60.2. Install the J41427 marked RIGHT REAR.
60.3. Install the retaining bolts.
Tighten the bolts to 15 Nm (11 ft. lbs.).
60.4. Remove the left front lower intake manifold bolts.
60.5. Install the J41427marked LEFT FRONT with the arrow pointing to the front of the engine.
60.6. Install the retaining bolts.
Tighten the bolts to 15 Nm (11 ft. lbs.).
61. Attach a suitable lifting device to the engine lift brackets.
62. Remove the engine motor mount to frame bracket bolts.
63. Support the transmission with a suitable jack.
64. Remove the engine.
Installation Procedure
1. Install the engine to the vehicle.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the engine mount to frame bracket bolts.
Tighten the bolts to 65 Nm (50 ft. lbs.).
3. Remove the J41427and the 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 second pass to 12 Nm (106 inch lbs.).
5.3. Tighten the bolts the final pass to 15 Nm (11 ft. lbs.).
6. Loosely install one transmission to engine bolt.
7. Remove the support jack from under the transmission.
8. Install the EGR valve inlet pipe to the intake and the exhaust manifold.
8.1. Tighten the EGR valve inlet pipe intake nut to 25 Nm (18 ft. lbs.).
8.2. Tighten the EGR valve inlet pipe exhaust nut to 30 Nm (22 ft. lbs.).
8.3. Tighten the EGR valve inlet pipe clamp bolt to 25 Nm (18 ft. lbs.).
9. Install the water outlet. Refer to Thermostat Replacement in Cooling System.
10. Slide the power steering pump mounting bracket with the power steering pump and the A/C compressor on the stud.
11. Position the power steering pump rear bracket on the studs. Install the power steering pump mounting bracket three bolts and the nut.
13. Install the nut for the power steering pump rear bracket to the front of the engine.
Tighten the power steering pump mounting bracket and the power steering pump rear bracket bolts and the nuts to 41 Nm (30 ft. lbs.).
14. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
15. Connect the hose to the EVAP purge canister solenoid valve. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
16. Connect the vacuum brake booster hose to engine and the vacuum brake booster.
17. Install the distributor cap. Refer to Distributor Replacement.
18. Install both heater hoses to the engine and the cowl. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
19. Install the AIR pipe assembly with new gaskets to the right exhaust manifold, if equipped.
20. Install the AIR pipe nuts and bracket bolt.
20.1. Tighten the AIR nuts to 25 Nm (18 ft. lbs.).
20.2. Tighten the AIR bracket bolt to 10 Nm (88 ft. lbs.).
21. Connect the AIR pipe assembly to the AIR pump.
22. Install the AIR pipe assembly with new gaskets to the left exhaust manifold, if equipped.
23. Install the AIR pipe nuts and bracket bolt.
23.1. Tighten the AIR nuts to 25 Nm (18 ft. lbs.).
23.2. Tighten the AIR bracket bolt to 10 Nm (88 ft. lbs.).
24. Install the AIR crossover pipe to the AIR pipe assemblies.
25. Position the engine wiring harness.
26. Connect the following electrical connectors:
^ The A/C pressure switch (4), if equipped
^ The A/C compressor clutch (1), if equipped
^ The exhaust gas recirculation (EGR) valve (2)
^ The generator battery positive cable (3)
27. Connect the following electrical connectors:
^ The fuel meter body assembly (3)
^ The idle air control (IAC) motor (2)
^ The throttle position (TP) sensor (1)
^ The engine coolant temperature (ECT) sensor (4)
28. Connect the following electrical connectors:
^ The EVAP canister purge solenoid valve (1)
^ The manifold absolute pressure (MAP) sensor (2)
^ The ignition control module (ICM) (4)
^ The ignition coil (3)
29. Connect the following electrical connectors:
^ The engine oil pressure gauge sensor (3)
^ The distributor (2)
^ The Knock Sensor (KS) (1)
30. Install the bolt holding the ground strap and the ground wire to the rear of the left cylinder head.
Tighten the ground strap and ground wire bolt to 16 Nm (12 ft. lbs.).
31. Position the engine wiring harness bracket on the EVAP purge canister solenoid valve stud and install the nut.
32. Install the stud holding the wire harness bracket to the rear of the right cylinder head.
^ Tighten the nut on the EVAP solenoid to 9 Nm (80 inch lbs.).
^ Tighten the stud at rear of the cylinder head to 25 Nm (18 ft. lbs.).
33. Install the nut holding the ground wire on the stud at the rear of the right cylinder head.
Tighten the ground wire nut to 16 Nm (12 ft. lbs.).
34. Position the battery positive and negative cables.
Do not connect the negative battery cable to the battery. Refer to Battery Cable Replacement.
35. Install the battery positive cable junction block bracket and bolt to the power steering pump mounting bracket.
Tighten the junction block bracket bolt to 25 Nm (18 ft. lbs.).
36. Install the bolt holding the engine wiring harness bracket to battery positive cable junction block bracket.
37. Install the engine wiring harness bracket on the intake manifold studs and install the nuts.
^ Tighten the wiring harness bracket nuts to 12 Nm (106 inch lbs.).
^ Tighten the wiring harness bracket bolt to 9 Nm (80 ft. lbs.).
38. Connect the A/C hoses to the A/C compressor and the accumulator. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
39. Install the accelerator control cable bracket and nuts to the throttle body.
Tighten the nuts to 9 Nm (80 inch lbs.).
40. Install the engine wire harness and clip to the accelerator control cable bracket.
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.
41. Install the NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
42. Connect the cruse control cable to the throttle body and the accelerator control cable bracket, if equipped. Refer to Cruise Control Cable Replacement.
43. Install the radiator inlet hose. Refer to Radiator Hose Replacement - Inlet in Cooling System.
44. Install the radiator outlet hose. Refer to Radiator Hose Replacement in Cooling System.
45. Install the engine cooling fan. Refer to Fan Clutch Replacement in Cooling System.
46. Install the drive belt. Refer to Drive Belt Replacement.
47. Install the upper and lower radiator shroud. Refer Fan Shroud Replacement in Cooling System.
48. Install the air cleaner outlet duct to the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement.
49. Connect the PCV hose to the air inlet duct.
50. Move the hood hinge bolts from the service position (2) to the normal operating position (1).
51. Raise the vehicle.
52. Install the remaining transmission to engine bolts except for the one where the transmission cover mounts.
^ Refer to Automatic Transmission Replacement
^ Refer to Manual Transmission Replacement.
53. Install the torque convertor to flywheel bolts, if equipped. Refer to Flywheel to Torque Converter Bolts.
54. Install the transmission cover and bolts.
54.1. Tighten the transmission cover to oil pan bolt to12 Nm (106 inch lbs.).
54.2. Tighten the transmission cover to transmission bolt to 47 Nm (34 ft. lbs.).
55. Install the bolt holding the bracket for the starter cables and the transmission cooler pipes, if equipped.
Tighten the bracket bolt to 9 Nm (80 inch lbs.).
56. Install the bolts holding the positive and negative battery cable brackets to the oil pan.
Tighten the bracket bolts to 12 Nm (106 inch lbs.).
57. Install the bolt for the battery negative cable (1) and ground wire (1) to the front of the engine.
Tighten the battery negative cable and ground wire bolt to 25 Nm(18 ft. lbs.).
58. Connect the CKP sensor (2) and install the harness in the retainer.
59. Connect the low oil level sensor (3) and install the wire harness in the retainer.
60. Install the exhaust pipe to the exhaust manifolds and tighten the nuts at the catalytic converter flange. Refer to Catalytic Converter Replacement.
61. Install the starter motor. Refer to Starter Motor Replacement.
62. Install the oil pan skid plate (RWD shown).
Tighten the oil pan skid plate bolt to 20 Nm (15 ft. lbs.).
63. Install the engine shield. Refer to Engine Protection Shield Replacement.
64. Lower the vehicle.
65. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
66. Fill the engine with the proper quantity and grade of engine oil. Refer to Engine Oil and Oil Filter Replacement.
67. Fill the engine with coolant. Refer to Draining and Filling Cooling System in Cooling System.
68. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
69. Before starting a new engine, or one that has been repaired. Refer to Engine Set-Up and Testing.