Engine Installation

Installation Procedure





1. Install the engine.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the engine mount to engine mount bracket bolts.
- Tighten the engine mount to engine mount bracket bolts to 65 Nm (48 ft. lbs.).





3. Remove the J41427 and the lifting device.
4. Apply threadlock GM U.S. P/N 12345382, Canada P/N 10953489, or equivalent to the threads of the intake manifold lower bolts.
5. Install the intake manifold bolts.
5.1. Tighten the intake manifold lower bolts a first pass to 3 Nm (27 ft. lbs.).
5.2. Tighten the intake manifold lower bolts a second pass to 12 Nm (106 inch lbs.).
5.3. Tighten the intake manifold lower bolts a final pass to 5 Nm (11 ft. lbs.).
6. Install one transmission bolt until snug.
7. Remove the support jack from under the transmission.





8. Install the EGR valve inlet pipe.
9. Install the EGR valve inlet pipe bracket bolt.
- Tighten the EGR valve inlet pipe fitting to the exhaust manifold to 25 Nm (18 ft. lbs.).
- Tighten the EGR valve inlet pipe fitting to the intake manifold to 30 Nm (22 ft. lbs.).
- Tighten the EGR valve inlet pipe bracket bolt to 25 Nm (18 ft. lbs.).





10. Install the spark plug wire harness retainer to the EGR valve inlet pipe.
11. Install the thermostat and water outlet.





12. Slide the P/S pump bracket onto the stud.
13. Install the bolts and the nut for the P/S pump bracket.
14. Install the P/S pump rear bracket front nut.
15. Tighten the P/S pump rear bracket nut.
- Tighten the P/S pump bracket bolts and nuts to 41 Nm (30 ft. lbs.).





16. Connect the power brake booster vacuum hose to the vacuum fitting (1).





17. Connect the EVAP canister harness to the purge solenoid valve.
18. Install the distributor cap.
19. Install the heater hoses.





20. Position the engine wiring harness.
21. Install the stud holding the engine wiring harness bracket.
22. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
- Tighten the engine wiring harness rear bracket nut to 9 Nm (80 inch lbs.).





23. Position the bracket and wiring harness.
24. Install the junction block bracket bolt.
- Tighten the junction block bracket bolt to 25 Nm (18 ft. lbs.).





25. Install the engine wiring harness bracket to the studs.
26. Install the engine wiring Harness bracket nuts.
- Tighten the engine wiring harness bracket nuts to 12 Nm (106 inch lbs.).





27. Position the harness ground (4) and ground strap (5).
28. Install the harness ground bolt.
- Tighten the harness ground bolt to 16 Nm (12 ft. lbs.).
29. Connect the following electrical connectors:
- The KS (1)
- The CMP sensor (2)
- The fuel pump/oil pressure sensor (3)
- The distributor (2)





30. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.
- Tighten the engine wiring harness ground nut to 16 Nm (12 ft. lbs.).
31. Connect the following electrical connectors:
- The ignition coil (1)
- The ignition coil driver (2)
- The generator (3)





32. Connect the following electrical connectors:
- The EVAP canister purge solenoid valve (1)
- The MAP sensor (2)





33. Install the engine wiring harness clip bolt (4).
- Tighten
- Tighten the engine wiring harness clip bolt to 9 Nm (80 inch lbs.).
34. Connect the following electrical connectors:
- The TP sensor (1)
- The IAC motor (2)
- The control port injector module (3)
- The ECT sensor (5)





35. Install the positive cable and nut to the generator.
- Tighten the positive cable generator nut to 18 Nm (13 ft. lbs.).
36. Connect the following electrical connectors:
- The A/C pressure switch (4), if equipped
- The A/C compressor clutch (1), if equipped
- The EGR valve (2)
37. Install the A/C compressor hose, if equipped.





38. Position the bracket and cables.
39. Install the accelerator control cable bracket with the cables attached, to the throttle body.
40. Install the accelerator control cable bracket nuts.
- Tighten the accelerator control cable bracket nuts to 9 Nm (80 inch lbs.).





41. Install the accelerator cable to the throttle body lever.





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.

42. Install the accelerator cable to the accelerator control cable bracket.





43. Install the accelerator cable to the throttle body lever.





44. Install the cruise control cable to the accelerator control cable bracket, if equipped.
45. Connect the cruise control cable to the throttle lever, if equipped.





46. Install the radiator outlet hose to the water pump.
47. Install the radiator outlet hose to the surge tank.
48. Position the radiator outlet hose clamps.





49. Install the radiator inlet hose to the thermostat housing.
50. Position the radiator inlet hose clamp.
51. Install the drive belt.
52. Install the lower fan shroud.
53. Install the fuel pipes/hoses.





54. Remove the hood hinge bolts from the service position (2).
55. Lower the hood to the normal position.
56. Install the hood hinge bolts.
- Tighten the hood hinge bolts to 25 Nm (18 ft. lbs.).
57. Raise the vehicle.





58. Install the transmission bolts.
- Tighten the transmission bolts to 50 Nm (37 ft. lbs.).
59. Install the torque converter bolts, if equipped, through the starter opening.
- Tighten the torque converter bolts to 63 Nm (47 ft. lbs.).





60. Install the transmission cover.
61. Install the starter.
62. Install the engine shield, if equipped.





63. If equipped, install the oil pan skid plate and bolts.
64. Lower the vehicle.
65. Connect the negative battery cable.
66. Fill the engine with the proper quantity and grade of oil.
67. Add engine oil supplement GM U.S. P/N 1052367, Canada P/N 992869, or equivalent to the engine oil.
68. Fill the cooling system.
69. Bleed the hydraulic clutch, if equipped.
70. Recharge the A/C system.

Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

71. Disable the ignition system.
72. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
73. Start the engine and listen for unusual noises.
74. Check the oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
75. If necessary, install an oil pressure gauge and measure the oil pressure.
76. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
77. Listen for sticking valve lifters, or other unusual noises.
78. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
79. Verify that the distributor is properly positioned.
80. Perform a final inspection for the proper oil and coolant levels.
81. Close the hood.