Removal and Replacement

Engine Replacement

^ Tools Required
- J 41427Engine Lift Bracket

Removal Procedure
1. Remove the coolant recovery reservoir.
2. Disconnect the negative battery cable.
3. Remove the engine cover
4. Remove air cleaner assembly.
5. Remove the front bumper.
6. Remove the grille.
7. Remove the radiator support.
8. Remove the A/C condenser.
9. Remove the radiator.

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.

10. Remove the accelerator control cable.
11. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket.





12. Remove the stud and bolt holding the ground wires to the rear of both cylinder heads.
13. Remove the nut holding the wiring harness at the transmission to engine stud.





14. Disconnect the following electrical connectors:
^ The throttle position (TP) sensor (1)
^ The idle air control (IAC) motor (2)
^ The engine coolant temperature (ECT) gage sensor (3)
^ The A/C high pressure switch (4), if equipped





15. Disconnect the following electrical connectors:
^ The fuel meter body assembly connector (1)
^ The EVAP canister purge solenoid valve (2)
^ The manifold absolute pressure (MAP) sensor (3)





16. Disconnect the following electrical connectors:
^ The distributor (2)
^ The engine oil pressure sensor (3)
^ The knock (KS) sensor (1)





17. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The engine coolant temperature (ECT) sensor (3)
18. Remove the ground wire (4) from the stud at the water outlet.





19. Disconnect the crankshaft position (CKP) sensor (3).
20. Remove the engine wiring harness clip (1) from the stud on the generator mounting bracket.
21. Remove the engine wiring harness clip (2) at the front of the engine.
22. Move the engine wiring harness aside.





23. Remove the bolt holding the battery negative cable and the ground strap to the front of the engine.
24. Remove the generator mounting bracket.
25. Remove the heater hoses from the engine.
26. Remove the radiator inlet and outlet hoses.
27. Remove the A/C compressor Discharge Hose from the vehicle.
28. Remove the A/C compressor Suction Hose from the vehicle.
29. Remove the power steering pump mounting bracket.





30. Remove the power steering pump rear mounting bracket from the engine. Set the pump aside.
31. Remove the distributor.
32. In order to allow access for the lifting device, remove the upper intake manifold.
33. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
34. Remove the clamp bolt for the EGR valve inlet pipe.





35. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.





36. Remove the transmission control cable bracket from the rear of the left cylinder head.

Notice: Remove the AIR pipes before engine removal

The AIR pipes can break or damage easily causing erratic engine operation.
37. Remove both AIR pipes from the engine.
38. Raise the vehicle. Refer to Vehicle Lifting.
39. Remove both exhaust manifolds.
40. Remove the oil pan drain plug and drain the engine oil into a suitable container.
41. Remove the engine oil filter.
42. Remove the engine oil cooler pipes from the engine.
43. Remove the starter motor.





44. Remove the transmission cover.





45. Remove the torque converter bolts from the flywheel through the transmission cover opening.





46. Remove the transmission cooler pipes from the engine.





47. Remove the bolts holding the transmission to the engine except the top 2 bolts.
48. Lower the vehicle.
49. Support the transmission with a strap between the frame rails or use a suitable transmission jack.

Notice: Refer to Fastener Notice in Service Precautions.





50. Install the J 41427 using the following procedure:
50.1. Remove the 2 right rear lower intake manifold bolts.
50.2. Install the J 41427 marked RIGHT REAR.
50.3. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
50.4. Remove the 2 left front lower intake manifold bolts.
50.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
50.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
51. Attach a suitable engine lifting device to the J 41427.
52. Remove the engine mounts from the engine mount frame brackets.
53. Remove the two remaining engine to transmission bolts.
54. Remove the engine assembly from the vehicle.

Installation Procedure
1. Install the engine assembly to the vehicle.
2. Loosely install the 2 upper transmission to engine bolts.
3. Install the engine mounts to the engine mount frame brackets.
4. Remove the engine lifting device.





5. Remove the J 41427 from the engine.
6. Apply thread lock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the lower intake manifold bolts. Tighten
7.1. Tighten the bolts to 3 Nm (27 inch lbs.).
7.2. Tighten the bolts to 12 Nm (106 inch lbs.).
7.3. Tighten the bolts to 15 Nm (11 ft. lbs.).
8. Raise the vehicle. Refer to Vehicle Lifting.
9. Install the remaining bolts from the transmission to the engine.





10. Install the bolt holding the transmission cooler pipes bracket to the oil pan.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
11. Install the torque converter bolts to the flywheel.
^ Tighten the bolts to 62 Nm (46 ft. lbs.).





12. Install the transmission cover.
^ Tighten the transmission cover bolts to 12 Nm (106 inch lbs.).
13. Install the starter motor.
14. Install the engine oil cooler pipes to the engine.
15. Install the exhaust manifolds.
16. Lower the vehicle.
17. Install the AIR pipes to the engine.
18. Install the upper intake manifold to the engine.
19. Install the EGR valve inlet pipe.
20. Install the spark plug wire harness retainer on the EGR valve inlet pipe.





21. Install the transmission control cable bracket to the rear of the left cylinder head
^ Tighten the transmission control cable bracket bolts to 40 Nm (30 ft. lbs.).
22. Install the distributor.
23. Install the power steering pump with the rear bracket to the engine.
24. Install the power steering pump mounting bracket.
25. Install the A/C compressor discharge Hose from the vehicle.
26. Install the A/C compressor Suction Hose from the vehicle.
27. Install the radiator inlet and outlet hoses to the engine.
28. Install the heater hoses to the engine.
29. Install the generator mounting bracket.





30. Install the stud and bolt holding the ground wires to the rear of both cylinder heads.
^ Tighten the bolt and the stud to 101 Nm (88 inch lbs.).
31. Install the nut holding the engine wiring harness at the transmission to engine stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).





32. Connect the crankshaft position (CKP) sensor (3).
33. Install the engine wiring harness clip (1) from the stud on the generator mounting bracket.
34. Install the engine wiring harness clip (2) at the front of the engine.





35. Connect the following electrical connectors:
^ The fuel meter body assembly connector (1)
^ The EVAP canister purge solenoid valve (2)
^ The manifold absolute pressure (MAP) sensor (3)





36. Connect the following electrical connectors:
^ The distributor (2)
^ The engine oil pressure sensor (3)
^ The knock (KS) sensor (1)





37. Connect the following electrical connectors:
^ The throttle position (TP) sensor (1)
^ The idle air control (IAC) motor (2)
^ The engine coolant temperature (ECT) gage sensor (3)
^ The A/C high pressure switch (4), if equipped





38. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The engine coolant temperature (ECT) sensor (3)
39. Install the nut holding the ground wire (4) to the water outlet stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).





40. Install the bolt holding the battery negative cable and the ground strap to the front of the engine.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).

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.

41. Install a NEW accelerator control cable.
42. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket.
43. Install the fan clutch to the water pump.
44. Install the radiator support.
45. Install the oil filter and fill the engine with engine oil.
46. Fill the cooling system with the proper quantity and type of coolant.
47. Recharge the A/C system.
48. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
49. Start the engine and listen for unusual noises.
50. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
If necessary, install an oil pressure gage and measure the engine oil pressure.
51. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
52. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
53. Inspect for oil and/or coolant leaks while the engine is operating.
54. Verify that the distributor is properly positioned.
55. Perform a final inspection for the proper engine oil and coolant levels.
56. Install the engine cover.