Removal and Replacement

Removal Procedure

- Tools Required
- J 41427 Engine Lift Brackets

1. Disconnect the battery negative cable. Refer to Battery Cable.
2. Remove the hood. Refer to Hood Replacement in Body and Frame.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
5. Remove the following coolant hoses:
- Remove the upper inlet radiator hose. Refer to Radiator Hose Replacement in Cooling System.
- Remove the lower outlet radiator hose. Refer to Radiator Hose Replacement in Cooling System.
- Remove both heater hoses. Refer to Heater Hoses Replacement (Inlet Hose).
6. Remove the upper radiator shroud. Refer to Fan Shroud Replacement (Upper) and Fan Shroud Replacement (Lower) in Cooling System.
7. Remove the drive belt. Refer to Drive Belt Replacement.

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.

8. Disconnect the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement.
9. Remove the engine cooling fan. Refer to Fan Clutch Replacement in Cooling System.

Important: It is not necessary to discharge the A/C refrigerant.

10. Remove the air conditioning compressor, if equipped, and set it aside. Refer to Compressor Replacement in Heating and Air Conditioning.
11. Remove AIR bypass hose assembly, if so equipped. Refer to Air Injection Check Valve/Pipe Replacement.
12. Remove the power steering pump pulley. Refer to Power Steering Pump Replacement in Steering and Suspension.





13. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (Right).
14. Set the power steering pump and the mounting bracket aside.
15. Remove the starter motor. Refer to Starter Motor Replacement.
16. Disconnect the positive battery cable at the generator. Refer to Generator Replacement.
17. Remove the torque converter to flywheel bolts.
- Refer to Transmission Replacement.
18. Disconnect the transmission cooler pipe bracket from the right side of the oil pan. Refer to Oil Cooler Line Replacement in Transmission and Drivetrain.
19. Remove the exhaust pipe from the exhaust manifolds. Refer to Exhaust Crossover Pipe Replacement in Exhaust System.
20. Support the transmission with a suitable strap.
- Refer to Transmission Replacement.
21. Remove the engine oil cooler pipes, if equipped. Refer to Oil Cooler Line Replacement.





22. Remove both engine mount through-bolts.
23. Remove seven transmission to engine bolts including the brackets.
24. Lower the vehicle.
25. Disconnect the remaining electrical connectors.
26. Remove the distributor cap. Refer to Distributor Replacement.
27. Remove the engine harness support.
28. Disconnect the fuel pipes. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
29. Remove two transmission to engine bolts at the rear top of the engine.
- Refer to Transmission Replacement.
30. Remove the EGR pipe. Refer to Secondary Air Injection Check Valve/Pipe Replacement.





Notice: Refer to Fastener Notice in Service Precautions.

31. Attach the lift brackets J 41427 to the left front and right rear intake manifold mounting bolts, using the following procedure:
31.1. Remove the right rear lower intake manifold bolts. Refer to Intake Manifold Replacement (Lower).
31.2. Install the lift bracket J 41427 marked RIGHT REAR.
31.3. Install the retaining bolts.
- Tighten the bolts to 15 Nm (11 inch lbs.).
31.4. Remove the left front lower intake manifold bolts. Refer to Intake Manifold Replacement (Lower).
31.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
31.6. Install the retaining bolts.
- Tighten the bolts to 15 Nm (11 inch lbs.).
32. Attach a suitable lifting device to the lift brackets.
33. Remove the engine.


Installation Procedure





1. Install the engine in the vehicle.
2. Install two top transmission to engine bolts, including the brackets and clips.
- Refer to Transmission Replacement.
3. Remove the J 41427 and 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. Refer to Intake Manifold Replacement (Lower).
6. Install the EGR valve inlet pipe. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
7. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the engine harness support.
- Tighten the nut to 12 Nm (106 inch lbs.).
9. Install the distributor cap. Refer to Distributor Replacement.
10. Install the AIR bypass hose assembly, if equipped. Refer to Secondary Air Injection Check Valve/Pipe Replacement.
11. Install the transmission to engine bolts.
- Refer to Transmission Replacement.





12. Install both engine mount through-bolts, if equipped. Refer to Engine Mount Replacement.
13. Install the oil cooler pipes, if equipped. Refer to Oil Cooler Line Replacement in Cooling System.
14. Remove the transmission support strap.
15. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Manifold Pipe Replacement in Exhaust System.
16. Install the transmission cooler pipe bracket to the right side of the oil pan, if equipped. Refer to Oil Cooler Line Replacement.
17. Install three torque convertor to engine flywheel bolts, if equipped.
- Refer to Transmission Replacement.
18. Install the starter motor. Refer to Starter Motor Replacement.
19. Connect the positive battery cable at the generator. Refer to Generator Replacement.





20. Install the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (Right) in Steering and Suspension System.
21. Install the Air Conditioning (A/C) compressor, if equipped. Refer to Compressor Replacement in Heating and Air Conditioning.
22. Use the J 25033-C in order to install the power steering pump pulley. Refer to Power Steering Pump Replacement in Steering and Suspension System.
23. Install the engine cooling fan. Refer to Fan Clutch Replacement in Cooling System.
24. Install the drive belt. Refer to Drive Belt Replacement.

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.

25. Connect the NEW accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Controls Cable Replacement.
26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
27. Install the upper radiator shroud. Refer to Fan Shroud Replacement (Upper) and Fan Shroud Replacement (Lower) in Cooling System.
28. Install the following coolant hoses:
- The upper inlet radiator hose. Refer to Radiator Hose Replacement in Cooling System.
- The lower outlet radiator hose. Refer to Radiator Hose Replacement in Cooling System.
- Both heater hoses. Refer to Heater Hoses Replacement (Inlet Hose) and Heater Hoses Replacement (Outlet Hose) in Heating and Air Conditioning.
29. Fill the cooling system with coolant. Refer to Draining and Filling Cooling System in Cooling System.
30. Install the hood. Refer to Hood Replacement.
31. Connect the battery negative cable. Refer to Battery Cable.
32. Before starting a new engine, or one that has been repaired. Refer to Engine Set-Up and Testing.
33. The final step is to perform the CKP System Variation Learn procedure. Refer to CKP System Variation Learn Procedure.