Removal and Replacement
^ Tools Required
- J 41427 Engine Lift Bracket
Removal Procedure
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.
1. Disconnect the battery negative cable. Refer to Battery Replacement.
2. Remove the hood. Refer to Hood Replacement.
3. Raise the vehicle. Refer to Vehicle Lifting.
4. Remove the underbody shields if equipped.
5. Remove the exhaust pipe from the exhaust manifolds. Refer to Catalytic Converter Replacement.
6. Disconnect the engine oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler Line Replacement in Cooling System.
7. Disconnect the remote oil filter adapter inlet and outlet hoses (Four Wheel Drive vehicle). Refer to Remote Oil Filter Adapter Pipe Replacement. Remove the stud holding the starter wire harness and if equipped, transmission oil cooler lines.
9. Remove the starter. Refer to Starter Motor Replacement.
10. Remove the transmission cover.
11. Remove the transmission.
^ Refer to Transmission Replacement in Transmission and Drivetrain.
12. Remove the front engine mount through bolts.
13. Lower the vehicle.
14. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
15. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
Caution: In order to avoid possible injury or vehicle damage, a/ways 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.
16. Remove the accelerator control cable. Refer to Accelerator Controls Cable Replacement.
17. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement (4.3L) or Cruise Control Cable Replacement (2.2L).
18. Remove the radiator. Refer to Radiator Replacement in Cooling System.
19. Remove the inlet and outlet radiator hoses from the engine. Refer to Radiator Hose Replacement in Cooling System.
20. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
21. Disconnect the power brake booster vacuum hose from the intake manifold.
22. Disconnect the vacuum hose for the A/C system, if equipped from the intake manifold.
23. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/c compressor cutoff switch (5), if equipped
^ The TP sensor (2)
^ The IAC valve motor (3)
^ The ECT sensor (4)
24. Disconnect the following electrical connectors:
^ The fuel meter body (1)
^ The EVAP canister purge solenoid (2)
^ The MAP sensor (3)
25. Disconnect the following electrical connectors:
^ The ICM (1)
^ The ignition coil (2)
^ The EGR solenoid (3)
^ The generator (4)
26. Disconnect the following electrical connectors:
^ The distributor (1)
^ The engine oil pressure sensor (2)
^ The KS sensor (3)
27. Disconnect the CKP sensor (2) electrical connector.
28. Remove the bolt and the battery negative cable (1).
29. Remove the engine wiring harness bracket bolt (3).
30. Remove the engine wiring harness clips from the front of the engine.
31. Remove the engine wiring harness clips from the brackets.
32. Move the engine wiring harness aside.
33. Remove the generator. Refer to Generator Replacement (2.2L) or Generator Replacement (4.3L).
34. Remove the bolt holding the ground wires to the left cylinder head.
35. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.
36. Remove the bolts holding the ground wires to the right cylinder head.
37. Remove the bolt holding the ground strap to the right cylinder head.
38. Remove the accelerator control cable bracket from the throttle body.
39. Remove the water pump pulley. Refer to Water Pump Replacement (2.2L) or Water Pump Replacement (4.3L) in Cooling System.
40. Remove the A/C compressor, if equipped. Refer to Compressor Replacement (2.2L) or Compressor Replacement (4.3L) in Heating and Air Conditioning.
41. Remove the nut holding the AIR reactor pipe bracket to the front of the engine, if equipped.
42. Remove the nuts holding the power steering pump rear bracket to the engine.
43. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).
^ The power steering pump can remain on the mounting bracket.
^ The hoses do not require removal.
^ Remove the three bolts and the nut.
^ Slide the mounting bracket off of the stud.
^ Secure the mounting bracket out of the way.
Notice: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.
44. Remove both of the secondary Air Injection (AIR) reactor pipes from the engine.
^ Refer to AIR Check Valve/Pipe Replacement -Bank 1.
^ Refer to AIR Check Valve/Pipe Replacement -Bank 2.
45. Remove the AIR shut-off valve and hoses. Refer to AIR Shut-Off Valve Replacement.
46. Remove the distributor cap. Refer to Distributor Replacement.
47. Disconnect the fuel pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
48. Disconnect the EVAP canister purge solenoid valve pipe. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
49. Remove the water outlet. Refer to Thermostat Replacement (2.2L) or Thermostat Replacement (4.3L) in Cooling System.
50. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
51. Remove the clamp bolt for the EGR valve inlet pipe.
52. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
Notice: Refer to Fastener Notice in Service Precautions.
53. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:
53.1. Remove the right rear lower intake manifold bolts.
53.2. Install the J 41427 marked RIGHT REAR.
53.3. Install the retaining bolts.
53.4. Remove the left front lower intake manifold bolts.
53.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
53.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
54. Attach a suitable lifting device to the engine lift brackets.
55. Remove the engine.
Installation Procedure
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.
Notice: Refer to Fastener Notice in Service Precautions.
1. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:
1.1. Remove the right rear lower intake manifold bolts.
1.2. Install the J 41427 marked RIGHT REAR.
1.3. Install the retaining bolts.
1.4. Remove the left front lower intake manifold bolts.
1.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
1.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
2. Attach a suitable lifting device to the engine lift brackets.
3. Install the engine into the vehicle.
4. 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.)
5. Remove the J 41427and the engine lifting device.
6. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
7. Install the 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 (11 ft. lbs.).
8. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.
8.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
8.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
8.3. Tighten the EGR valve inlet pipe clamp bolt 25 Nm (18 ft. lbs.).
9. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
10. Install the water outlet. Refer to Thermostat Replacement (2.2L) or Thermostat Replacement (4.3L) in Cooling System.
11. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment).
12. Install the distributor cap. Refer to Distributor Replacement.
13. Connect the EVAP canister purge solenoid valve pipe. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement.
14. Install both of the AIR reactor pipes to the engine.
^ Refer to AIR Check Valve/Pipe Replacement -Bank 1.
^ Refer to AIR Check Valve/Pipe Replacement -Bank 2.
15. Install the AIR shut-off valve and hoses. Refer to AIR Shut-Off Valve Replacement.
16. Install the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).
17. 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.).
18. Install the nut holding the AIR reactor pipe bracket, if equipped to the stud on the front of the engine.
^ Tighten the bolt to 41 Nm (30 ft. lbs.).
19. Install the A/C compressor, if equipped. Refer to Compressor Replacement (2.2L) or Compressor Replacement (4.3L) in Heating and Air Conditioning.
20. Install the water pump pulley. Refer to Water Pump Replacement (2.2L) or Water Pump Replacement (4.3L) in Cooling System.
21. Install the accelerator control cable bracket to the throttle body.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
22. Install the bolt holding the ground wires to the left cylinder head.
^ Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).
23. 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.).
24. Install the stud holding the ground wires to the right cylinder head.
^ Tighten the ground wire stud to 35 Nm (26 ft. lbs.).
25. Install the bolt and the ground strap to the rear of the right cylinder head.
^ Tighten the ground strap bolt to 35 Nm (26 ft. lbs.).
26. Position the engine wiring harness.
27. Install the engine wiring harness clips to the brackets.
28. Install the engine wiring harness clips to the front of the engine.
29. Connect the CKP sensor electrical connector (2).
30. Install the bolt and the battery negative cable (1).
^ Tighten the bolt to 17 Nm (13 ft. lbs.).
31. Install the engine wiring harness bracket bolt (3) to the generator mounting bracket.
^ Tighten the stud to 25 Nm (18 ft. lbs.).
32. Install the generator. Refer to Generator Replacement (2.2L) or Generator Replacement (4.3L).
33. Connect the following electrical connectors:
^ The distributor (1)
^ The engine oil pressure sensor (2)
^ The KS sensor (3)
34. Connect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/c compressor cutoff switch (5), if equipped
^ The TP sensor (2)
^ The IAC valve motor (3)
^ The ECT sensor (4)
35. Connect the following electrical connectors:
^ The fuel meter body (1)
^ The EVAP canister purge solenoid (2)
^ The MAP sensor (3)
36. Connect the following electrical connectors:
^ The ICM (1)
^ The ignition coil (2)
^ The EGR solenoid (3)
^ The generator (4)
37. Connect the power brake booster vacuum hose to the intake manifold.
38. Connect the vacuum hose for the A/C system, if equipped.
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.
39. Install a NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement.
40. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement (4.3L) or Cruise Control Cable Replacement (2.2L)s.
41. Install the radiator. Refer to Radiator Replacement in Cooling System.
42. Install the inlet and outlet radiator hose to the engine. Refer to Radiator Hose Replacement in Cooling System.
43. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
44. Raise the vehicle. Refer to Vehicle Lifting.
45. Install the transmission.
^ Refer to Transmission Replacement in Transmission and Drivetrain.
46. Install the transmission cover.
^ Tighten the nut to 12 Nm (106 inch lbs.).
47. Install the starter. Refer to Starter Motor Replacement.
48. Install the stud holding the bracket for the starter wiring harness and if equipped, the transmission oil cooler lines.
^ Tighten the bracket stud to 9 Nm (80 inch lbs.).
49. Connect the engine oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler Line Replacement in Cooling System.
50. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle). Refer to Remote Oil Filter Adapter Pipe Replacement.
51. Install the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement.
52. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement.
53. Install the underbody shields, if equipped.
54. Lower the vehicle.
55. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
56. Fill the cooling system with coolant. Refer to Draining and Filling Cooling System in Cooling System.
57. Connect the battery negative cable. Refer to Battery Replacement.
58. Install the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
59. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
60. Recharge the air conditioning system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
61. Install the hood. Refer to Hood Replacement.
62. Operate and test the engine. Refer to Engine Set-Up and Testing.