Removal and Replacement

Engine Replacement

^ Tools Required
- J 41427 Engine Lift Brackets
Removal Procedure





1. Raise the hood to the service position, perform the following:
1. Remove the hood hinge bolts (1).
2. Raise the hood until vertical.
3. Install the hood hinge bolts until snug in the service position (2).
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove the fuel pipes/hoses.
5. Remove the lower fan shroud.
6. Remove the drive belt.
7. Raise and suitably support the vehicle.





8. If equipped, remove the oil pan skid plate bolts and plate.
9. If equipped, remove the engine shield.
10. Remove the starter.





11. Remove the transmission cover.





12. Remove the positive battery cable clip bolt (2).
13. Remove the catalytic converter.





14. Remove the battery cable bracket bolts.





15. Disconnect the crankshaft position (CKP) sensor electrical connector (5) and remove the harness from the retainer clip.
16. Remove the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.





17. If equipped, remove the torque converter bolts.
18. Remove the transmission bolts.
19. Lower the vehicle.





20. Reposition the radiator inlet hose clamp.
21. Remove the radiator inlet hose from the thermostat housing.





22. Reposition the radiator outlet hose clamps.
23. Remove the radiator outlet hose from the surge tank.
24. Remove the radiator outlet hose from the water pump.





25. If equipped, disconnect the cruise control cable from the throttle lever.
26. If equipped, remove the cruise control cable from the accelerator control cable bracket.





27. Remove the accelerator cable from the throttle body lever.






28. 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.

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.

Remove the accelerator cable from the accelerator control cable bracket.





29. Remove the accelerator cable from the throttle body lever.





30. Remove the accelerator control cable bracket nuts.
31. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
32. Reposition and secure the bracket and cable out of the way.
33. If equipped, remove the air conditioning (A/C) hoses.





34. Disconnect the following electrical connectors:
^ A/C pressure switch (4), if equipped
^ A/C compressor clutch (1), if equipped
35. Remove the positive cable nut and cable from the generator.





36. Disconnect the following electrical connectors:
^ Throttle position (TP) sensor (1)
^ Idle air control (IAC) motor (2)
^ Control port injector module (3)
^ Engine coolant temperature (ECT) sensor (5)
37. Remove the engine wiring harness clip bolt (4).





38. Disconnect the following electrical connectors:
^ Evaporative emission (EVAP) canister purge solenoid valve (1)
^ Manifold absolute pressure (MAP) sensor (2)





39. Disconnect the following electrical connectors:
^ Ignition coil (1)
^ Ignition coil driver (2)
^ Generator (3)
40. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.





41. Disconnect the following electrical connectors:
^ Knock sensor (1)
^ Camshaft position (CMP) sensor (2)
^ Fuel pump/oil pressure sensor (3)
^ Distributor (2)
42. Remove the harness ground bolt.
43. Reposition the harness ground (4) and ground strap (5).





44. Remove the engine wiring harness bracket nuts.
45. Remove the engine wiring harness bracket from the studs.





46. Remove the junction block bracket bolt.
47. Reposition the bracket and wiring harness aside.





48. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
49. Remove the stud holding the engine wiring harness bracket.
50. Reposition the engine wiring harness with the bracket aside.
51. Remove the heater hoses.
52. Remove the distributor cap.





53. Disconnect the EVAP canister harness from the purge solenoid valve.





54. Disconnect the power brake booster vacuum hose from the vacuum fitting.





55. Loosen the power steering (P/S) pump rear bracket nut.
56. Remove the P/S pump rear bracket front nut.
57. Remove the bolts and the nut for the P/S pump bracket.
58. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
59. Slide the P/S pump bracket forward off the stud and set aside.
60. Remove the thermostat and water outlet.





61. Remove the left front and right rear intake manifold lower bolts.
62. Install J 41427 to the left front and right rear intake manifold bolts, using the following procedure:
0. Install the J 41427 marked RIGHT REAR.

Notice: Refer to Fastener Notice in Service Precautions.

1. Install the lift bracket bolts.
^ Tighten the bolts to 15 Nm (11 ft. lbs.).
2. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
3. Install the lift bracket bolts.
^ Tighten the bolts to 15 Nm (11 ft. lbs.).
63. Install a suitable lifting devise to the engine lift brackets.





64. Remove the engine mount to engine mount bracket nuts.
65. Support the transmission with a suitable floor jack.
66. Remove the engine.

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 bolts to 65 Nm (48 ft. lbs.).





3. Remove the lifting devise and the J 41427
4. Apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold lower bolts.
5. Install the intake manifold bolts.
1. Tighten the bolts a first pass to 3 Nm (27 inch lbs.).
2. Tighten the bolts a second pass to 12 Nm (106 inch lbs.).
3. Tighten the bolts a final pass to 15 Nm (11 ft. lbs.).
6. Install one transmission bolt until snug.
7. Remove the support jack from under the transmission.
8. Install the thermostat and water outlet.





9. Slide the P/S pump bracket onto the stud.
10. Install the bolts and the nut for the P/S pump bracket.
11. Install the P/S pump rear bracket front nut.
12. Tighten the P/S pump rear bracket nut.
^ Tighten the bolts and nuts to 41 Nm (30 ft. lbs.).





13. Connect the power brake booster vacuum hose to the vacuum fitting.





14. Connect the EVAP canister harness to the purge solenoid valve.
15. Install the distributor cap.
16. Install the heater hoses.





17. Position the engine wiring harness.
18. Install the stud holding the engine wiring harness bracket.
19. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
^ Tighten the nut to 9 Nm (80 inch lbs.).





20. Position the bracket and wiring harness.
21. Install the junction block bracket bolt.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).





22. Install the engine wiring harness bracket to the studs.
23. Install the engine wiring harness bracket nuts.
^ Tighten the nuts to 12 Nm (106 inch lbs.).





24. Position the harness ground (4) and ground strap (5).
25. Install the harness ground bolt.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
26. Connect the following electrical connectors:
^ Knock sensor (1)
^ CMP sensor (2)
^ Fuel pump/oil pressure sensor (3)
^ Distributor (2)





27. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.
^ Tighten the nut to 16 Nm (12 ft. lbs.).
28. Connect the following electrical connectors:
^ Ignition coil (1)
^ Ignition coil driver (2)
^ Generator (3)



29. Connect the following electrical connectors:
^ EVAP canister purge solenoid valve (1)
^ MAP sensor (2)





30. Install the engine wiring harness clip bolt (4).
^ Tighten the bolt to 9 Nm (80 inch lbs.).
31. Connect the following electrical connectors:
^ TP sensor (1)
^ IAC motor (2)
^ Control port injector module (3)
^ ECT sensor (5)



32. Install the positive cable and nut to the generator.
^ Tighten the nut to 18 Nm (13 ft. lbs.).
33. Connect the following electrical connectors:
^ A/C pressure switch (4), if equipped
^ A/C compressor clutch (1), if equipped
34. If equipped, install the A/C hoses.





35. Position the bracket and cables.
36. Install the accelerator control cable bracket with the cables attached, to the throttle body.
37. Install the accelerator control cable bracket nuts.
^ Tighten the nuts to 9 Nm (80 inch lbs.).





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






39. 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.

Install the accelerator cable to the accelerator control cable bracket.

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.





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





41. If equipped, install the cruise control cable to the accelerator control cable bracket.
42. If equipped, connect the cruise control cable to the throttle body lever.





43. Install the radiator outlet hose to the water pump.
44. Install the radiator outlet hose to the surge tank.
45. Position the radiator outlet hose clamps.





46. Install the radiator inlet hose to the thermostat housing.
47. Position the radiator inlet hose clamp.
48. Install the drive belt.
49. Install the lower fan shroud.
50. Install the fuel pipes/hoses.





51. Remove the hood hinge bolt from the service position (2).
52. Lower the hood to the normal position.
53. Install the hood hinge bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
54. Raise the vehicle.





55. Install the transmission bolts
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
56. If equipped, Install the torque converter bolts.
^ Tighten the bolts to 63 Nm (47 ft. lbs.).





57. Install the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
58. Connect the CKP sensor electrical connector (5) and install the harness to the retainer clip.





59. Install the battery cable bracket bolts.
^ Tighten the bolts to 12 Nm (106 inch lbs.).
60. Install the catalytic converter.





61. Install the positive battery cable clip bolt (2).





62. Install the transmission cover.
^ Tighten the bolts to 12 Nm (106 inch lbs.).
63. Install the starter.
64. If equipped, install the engine shield.





65. If equipped, install the oil pan skid plate and bolts.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
66. Lower the vehicle.
67. Connect the negative battery cable.
68. Perform the engine prelube procedure.
69. Add engine oil supplement GM P/N 1052367 (Canadian P/N 992869), or equivalent to the engine oil.
70. Fill the cooling system.
71. If equipped, bleed the hydraulic clutch.
72. 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.

73. Disable the ignition system.
74. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
75. Start the engine and listen for unusual noises.
76. Check the oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
77. If necessary, install an oil pressure gauge and measure the oil pressure.
78. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
79. Listen for sticking valve lifters, or other unusual noises.
80. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
81. Verify that the distributor is properly positioned.
82. Perform a final inspection for the proper oil and coolant levels.
83. Close the hood.