Removal and Replacement

Engine Replacement

^ Tools Required
- J 36857 Engine Lift Bracket

Removal Procedure





1. Disconnect the following electrical connectors:
^ Mass Airflow (MAF) sensor (1)
^ Intake Air Temperature (IAT) sensor (2)





2. Loosen the clamp at the air cleaner.
3. Remove the air cleaner bolts.
4. Remove the air cleaner.





5. Loosen the clamp (2) at the throttle body (1).
6. Remove the air cleaner duct (3).





7. Disconnect the negative battery cable.
8. Remove the engine cover.
9. Remove the radiator.
10. Remove the grille.
11. Recover the Air Conditioning (A/C) system.
12. Remove the front bumper.
13. Remove the intake manifold.





14. Loosen the radiator inlet hose clamp at the thermostat housing.
15. Remove the radiator inlet hose (1) from the thermostat housing.
16. Loosen the radiator outlet hose clamp at the water pump.
17. Remove the radiator outlet hose (2) from the water pump.





18. Remove the A/C condenser lines from the condenser.





19. If equipped, remove the transmission to auxiliary cooler lines from the cooler.





20. Remove the radiator support bolts (3) from the radiator support (1).
21. Disconnect the forward lamp harness electrical connector.
22. Remove the ground strap bolts from the right and left fenders.
23. Remove the radiator support (1) from the vehicle.





24. Remove the oil fill tube bolt.
25. Remove the engine oil fill tube and upper transmission fluid indicator tube.
26. Remove the engine oil level indicator tube.
27. Remove the A/C compressor.
28. Remove the power steering pump.
29. Remove the generator bracket.
30. Disconnect the fuel lines.





31. Remove the ground strap bolt.
32. Disconnect the Throttle Actuator Control (TAC) module electrical connectors.
33. Remove the vacuum lines from the engine, as required.
34. Disconnect the engine wiring harness connectors from the left side of the engine.
35. Disconnect the engine wiring harness connectors from the right side of the engine.
36. Reposition the engine wiring harness and tie out of the way.
37. Remove the starter motor.
38. Disconnect the catalytic converter from the exhaust manifolds.
39. Remove the transmission mount nut.





40. Remove the transmission cover bolts and cover.
41. Mark the flywheel and the torque converter alignment.





42. Remove the torque converter bolts.





43. Install the J136857 and a length of chain, to the right cylinder head rear corner and left cylinder head front corner.
44. Install a suitable lifting devise to the chain.





45. Remove the left engine mount bolts.





46. Remove the right engine mount bolts.
47. Remove the engine/transmission from the vehicle.





48. Remove the engine oil cooler lines from the retaining brackets.
49. Remove the transmission bolts and transmission from the engine.





50. Remove the flywheel from the crankshaft before installing the engine to the engine stand.
51. Install the engine to a suitable engine stand.
52. Remove the lifting devise from the engine.
53. Remove the J 36857 from the engine.

Installation Procedure





1. Install the J 36857 and a length of chain, to the right cylinder head rear corner and left cylinder head front corner.
2. Install a lifting devise to the engine.
3. Remove the engine from the engine stand.





Notice: Refer to Fastener Notice in Service Precautions.

4. Install the flywheel to the crankshaft.
4.1. Tighten the flywheel bolts to 80 Nm (59 ft. lbs.) a first pass.
4.2. Tighten the flywheel bolts to 100 Nm (74 ft. lbs.) a final pass.





5. Install the transmission and bolts.
^ Tighten the transmission bolts to 47 Nm (34 ft. lbs.).





6. Install the engine oil cooler lines to the retaining brackets.
7. Install the engine/transmission to the vehicle.
8. Install the right engine mount bolts.
^ Tighten the engine mount bolts to 58 Nm (40 ft. lbs.).





9. Install the left engine mount bolts.
^ Tighten the engine mount bolts to 58 Nm (40 ft. lbs.).
10. Remove the engine lifting devise.
11. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





12. Align the torque converter and flywheel marks.
13. Install the torque converter bolts.
^ Tighten the torque converter bolts to 63 Nm (46 ft. lbs.).





14. Install the transmission cover and bolts.
^ Tighten the transmission cover bolts to 33 Nm (24 ft. lbs.).
15. Install the transmission mount nut.
16. Connect the catalytic converter from the exhaust manifolds.
17. Install the starter motor.
18. Untie the engine wiring harness and position.
19. Connect the engine wiring harness connectors to the right side of the engine.
20. Connect the engine wiring harness connectors to the left side of the engine.
21. Install the vacuum lines to the engine, as required.
22. Connect the TAC module electrical connectors.
23. Position the ground straps to the engine block.





24. Install the ground strap bolt.
^ Tighten the ground strap bolt to 25 Nm (18 ft. lbs.).
25. Connect the fuel lines to the fuel rail.
26. Install the generator bracket.
27. Install the power steering pump.
28. Install the A/C compressor.
29. Install the engine oil level indicator tube.





30. Install the oil fill tube and upper transmission fluid indicator tube.
31. Install the oil fill tube bolt.
^ Tighten the oil fill tube bolt to 12 Nm (106 inch lbs.).





32. Install the radiator support (1) to the vehicle.
33. Install the ground strap bolts to the right and left fenders.
34. Connect the forward lamp harness electrical connector.
35. Install the radiator support (1) and bolts (3).





36. If equipped, install the transmission to auxiliary cooler lines to the cooler.





37. Install the A/C condenser lines to the condenser.





38. Install the radiator outlet hose (2) to the water pump.
39. Tighten the outlet hose clamp at the water pump.
40. Install the inlet hose (1) to the thermostat housing.
41. Tighten the inlet hose clamp at the thermostat housing.





42. Install the intake manifold.
43. Install the front bumper.
44. Recharge the A/C system.
45. Install the grille.
46. Install the radiator.
47. Install the engine cover.





48. Connect the negative battery cable.
49. Install the air cleaner duct (3).





50. Tighten the clamp (2) at the throttle body (1).
^ Tighten the air cleaner duct clamp to 4 Nm (35 inch lbs.).
51. Install the air cleaner.
52. Install the air cleaner bolts.
^ Tighten the air cleaner bolts to 10 Nm (89 inch lbs.).
53. Tighten the air cleaner clamp.
^ Tighten the air cleaner duct clamp to 4 Nm (35 inch lbs.).





54. Connect the following electrical connectors:
^ MAP sensor (1)
^ IAT sensor (2)
55. Before starting a new engine or one that has been repaired complete the following procedure.
^ Fill the crankcase with the proper quantity and grade of oil.
^ Add engine oil supplement GM U.S. P/N 1052367, Canada P/N 992869, or equivalent to the engine oil.
^ Remove the fuel pump fuse and disconnect the coil harness connectors, then crank until oil pressure is present.
^ Crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
^ Start the engine and listen for unusual noises.
^ Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure. If necessary, install an oil pressure gauge and measure the oil pressure,
^ Run the engine at about 1000 RPM until the engine has reached normal operating temperature.
^ Inspect for oil and or coolant leaks while the engine is running.
^ Stop engine and perform a final inspection for the proper engine oil and coolant levels.
^ The final step is to perform the Crankshaft Position (CKP) sensor variation learn procedure.