Engine Installation
Installation ProcedureImportant: 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. Refer to Transmission Replacement in Transmission and Drivetrain.
3. Remove the support from under the transmission.
4. Lower the engine and the transmission onto the engine mounts.
Notice: Refer to Fastener Notice in Service Precautions.
5. Install the engine mount through-bolts and nuts.
Tighten the engine mount through-bolt nuts to 68 Nm (50 ft. lbs.).
6. Remove the J 41427 from 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 EGR valve inlet pipe to the intake manifold and the exhaust manifold.
9.1. Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
9.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
9.3. Tighten the EGR valve inlet pipe clamp bolt 25 Nm (18 ft. lbs.).
10. Install the air conditioning compressor, if equipped, and the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).
11. Install the distributor cap. Refer to Distributor Replacement in Powertrain Management.
12. Install the spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
13. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
14. Install the exhaust pipe to the exhaust manifolds.
- Refer to Catalytic Converter Replacement (Rear Wheel Drive)
- Refer to Catalytic Converter Replacement (Automatic Four Wheel Drive) in Powertrain Management.
15. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.
16. Install the transfer case to engine block brace, if equipped. Refer to Transfer Case Replacement in Transmission and Drivetrain.
17. Install the fuel pipe bracket and stud to the rear of the left cylinder head.
Tighten the fuel pipe bracket stud to 33 Nm (24 ft. lbs.).
18. Install the A/C pipe bracket and nut, if equipped to the fuel pipe bracket stud.
Tighten the A/C pipe bracket nut to 35 Nm (26 ft. lbs.).
19. Position the engine wiring harness.
20. Install the engine wiring harness clips in the brackets.
21. Install the engine wiring harness clip bolt to the rear of the right cylinder head.
Tighten the engine wiring harness clip bolt to 36 Nm (27 ft. lbs.).
22. Install the ground wire and bolt at the rear of the left cylinder head.
Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).
23. Install the engine wiring harness bracket and bolt to the generator mounting bracket.
Tighten the engine wiring harness bolt to 35 Nm (26 ft. lbs.).
24. Install the negative battery cable and stud (2).
Tighten the negative battery cable stud to 40 Nm (30 ft. lbs.).
25. Install the CKP sensor wiring harness clip (3) in the bracket.
26. Connect the CKP sensor electrical connector (4).
27. Install the engine wiring harness clip (1) on the negative battery cable stud (2).
28. Connect the following electrical connectors:
- The knock (KS) sensor (1)
- The distributor (2)
- The engine oil pressure sensor (3)
29. Connect the following electrical connectors:
- The manifold absolute pressure (MAP) sensor(4)
- The EVAP canister purge solenoid valve
- The ignition coil (2)
- The ICM (3)
30. Connect the following electrical connectors:
- The A/C compressor clutch, if equipped (1)
- The A/C high pressure cutoff switch, if equipped (5)
- The throttle position (TP) sensor (2)
- The idle air control (IAC) motor (3)
- The fuel meter body assembly connector (4)
31. Connect the EGR valve electrical connector (1).
32. Install the ground wire (2) and the nut to the water outlet stud.
Tighten the ground wire nut to 19 Nm (14 ft. lbs.).
33. Install the generator. Refer to Generator Replacement in Starting and Charging.
34. Install the bolt for the starter wiring harness and the transmission oil cooler pipe bracket.
Tighten the starter wiring harness bracket bolt to 10 Nm (89 inch lbs.).
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 onto the engine/frame assembly.
35. Lower the vehicle onto the engine/frame assembly and the J 39580.
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.
36. Install the body bolts (frame to body) (1), (2), and (3).
37. Tighten the body bolts using the following sequence.
37.1. Tighten all of the body bolts in the sequence shown to 35 Nm (26 ft. lbs.).
37.2. Tighten the right center body bolt first to 155 Nm (114 ft. lbs.).
37.3. Tighten the left center body bolt second to 155 Nm (114 ft. lbs.).
37.4. Tighten the right front body bolt third to 90 Nm (66 ft. lbs.).
37.5. Tighten the left rear body bolt fourth to 90 Nm (66 ft. lbs.).
37.6. Tighten the left front body bolt fifth to 90 Nm (66 ft. lbs.).
37.7. Tighten the right rear body bolt last to 90 Nm (66 ft. lbs.).
38. Raise the vehicle.
39. Install the transfer case vent tube, if equipped.
40. Connect the wire connector to the wiring harness above the transmission.
41. Connect the shift cable to the transmission. Refer to Shift Cable Replacement in Transmission and Drivetrain.
42. Install the torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.
43. Install the transmission cover.
Tighten the transmission cover bolts to 12 Nm (106 inch lbs.).
44. Install the starter. Refer to Starter Motor Replacement in Starting and Charging.
45. Install the oil cooler pipes to the oil filter adapter. Refer to Engine Oil Cooler Line Replacement in Cooling System.
46. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Transmission and Drivetrain.
47. Connect the power steering cooler. Refer to Power Steering Cooler Pipe/Hose Replacement in Steering and Suspension.
48. Connect the inflatable restraint front end discriminating sensor electrical connector. Refer to Inflatable Restraint Front End Discriminating Sensor Replacement in Restraint System.
49. Connect the fender wheelhouse extensions from chassis to the frame.
50. Install the front bumper.
51. Install the muffler and the tailpipe section to the hangers and install it to the converter assembly.
- Refer to Catalytic Converter Replacement (Rear Wheel Drive) -
- Refer to Catalytic Converter Replacement (Automatic Four Wheel Drive) in Powertrain Management.
52. Connect the fuel pipes at the fuel filter. Refer to Fuel Hose/Pipes Assembly Replacement (Fuel Tank) in Powertrain Management.
53. Position the engine wiring harness in the clips on the frame and the cross sills. Refer to Undercarriage Wiring in Diagrams/Diagnostic Aids.
54. Connect the fuel tank electrical connector.
55. Connect the EVAP vent valve electrical connector.
56. Install the bolt and the ground wire at the chassis by the EVAP vent valve.
Tighten the ground wire bolt to 9 Nm (80 inch lbs.).
57. Ensure that all of the electrical connections are connected between the chassis and the frame.
58. Install the bolt and the park brake bracket to the frame.
Tighten the park brake bracket bolt to 24 Nm (17 ft. lbs.).
59. Connect the rear air conditioning pipes at the rear crossmember by the fuel tank fill hoses, if equipped.
- Refer to Accumulator Tube Replacement -Auxiliary Side in Heating and Air Conditioning.
- Refer to Evaporator Tube Replacement -Auxiliary Side in Heating and Air Conditioning.
60. Connect the rear brake pipe to the BPMV. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Brakes and Traction Control.
61. Remove the bell housing to transmission bolt.
62. Lower the vehicle.
63. Remove both of the J 41602.
64. Install the front section of the running boards.
65. Install the battery cable assembly to the fender and the radiator support. Refer to Battery Cable Replacement in Starting and Charging.
66. Install the battery positive cable but do not install the battery negative cable.
67. Install the wiring harness in the retainers clips along the bulkhead.
68. Connect the fuse box and the wiring harness to the bulkhead connector.
69. Connect all related connectors including:
- The ground wires
- The A/C module
- The cruise control module
- The wiper motor
- differential pressure input switch
70. Connect the steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering and Suspensions.
71. Connect the heater hoses to the engine. Refer to Hot Water Bypass Valve Replacement (Standard) or Hot Water Bypass Valve Replacement (RPO C60) in Heating and Air Conditioning.
72. Connect the vacuum hose for the vacuum tank to the intake manifold.
73. Connect the pipes to the hydro boost. Refer to Hydraulic Brake Booster Replacement in Brakes and Traction Control.
74. Install the power steering reservoir. Refer to Remote Power Steering Fluid Reservoir Replacement in Steering and Suspension.
75. Install the master cylinder to the hydro boost. Refer to Master Cylinder Replacement in Brakes and Traction Control.
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.
76. Install the NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
77. Connect the cruise control cable to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Controls.
78. Connect the air conditioning pipes at the accumulator and the condenser, if equipped.
- Refer to Compressor/Condenser Hose Replacement - Auxiliary (RPO C60)
- Refer to Compressor/Condenser Hose Replacement - Auxiliary (RPO C69)
- Refer to Compressor/Condenser Hose Replacement - Auxiliary (RPO YF7) in Heating and Air Conditioning.
79. Install the radiator. Refer to Radiator Replacement in Cooling System.
80. Fill the cooling system with the proper grade of engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
81. Install the air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Powertrain Management.
82. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
83. Fill the crankcase with the proper grade of engine oil. Refer to Engine Oil and Oil Filter Replacement
84. Fill and bleed the brake system. Refer to Hydraulic Brake System Bleeding in Brakes and Traction Control.
85. Fill the transmission with the proper grade and quantity of transmission fluid. Refer to Automatic Transmission Fluid/Filter Changing in Transmission and Drivetrain.
86. Fill the power steering system with the proper grade and quantity of power steering fluid. Refer to Checking and Adding Power Steering Fluid in Steering and Suspension.
87. Connect the battery negative cable. Refer to Battery Replacement in Starting and Charging.
88. Recharge the air conditioning system and check for proper operation, if equipped. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
89. Install the engine cover. Refer to Engine Cover Replacement.
90. Perform a crankshaft variation relearn procedure. Refer to CKP System Variation Learn Procedure in Powertrain Management.
91. Operate the engine and check for proper operation. Refer to Engine Set-Up and Testing.