Part 2

Engine Replacement

Installation Procedure

1. Remove the engine from the stand.
2. Install the engine to the vehicle.





Note: The torque converter must be flush onto the flywheel and rotate freely by hand.

3. Align the engine to transmission and install the 2 outer bell housing bolts
4. Remove transmission supporting table.

Caution: Refer to Fastener Caution (Fastener Caution)

5. Install the right engine mount bracket to frame bolts and tighten to 65 Nm (48 lb ft).




6. Install the right engine mount to engine bolts and tighten to 58 Nm (43 lb ft)




7. Install the right engine mount to engine mount bracket bolts and tighten to 65 Nm (48 lb ft).
8. Install the left engine mount bracket to frame bolts and tighten to 65 Nm (48 lb ft).




9. Install the left engine mount to engine bolts and tighten to 58 Nm (43 lb ft).




10. Install the left engine mount to engine mount bracket bolts and tighten to 65 Nm (48 lb ft).
11. Lower the engine onto the engine mounts.
12. Remove the lifting device and the J-36857 - bracket.
13. Install the upper generator bracket stud from the right hand cylinder head.
14. Install the two A/C compressor bracket studs from the left hand cylinder head.
15. Install the lower radiator hose. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement
16. Install the lower transmission bell housing bolts and lines.
17. Install the fuel line bracket to the transmission.
18. Install the transmission oil cooler line bracket to the oil pan.
19. Install the PCV oil separator hose to the oil pan.





Note:
* The torque converter must be flush onto the flywheel and rotate freely by hand.
* Do not install the transmission fluid fill tube.

20. Install the bolts that secure the transmission to the engine. Tighten the studs and the bolts to 47 Nm (34 lb ft).




21. Install the bolts securing the torque converter to the engine flywheel.

1. First tighten all the bolts finger tight in order to insure proper converter seating.
2. Tighten the bolts to 63 Nm (46 lb ft).

22. If equipped with AWD, install the transfer case. Refer to Transfer Case Assembly Replacement




23. Install the wiring harness connectors to the vehicle speed sensor and the park neutral position switch.
24. Position and install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal.
25. Install the transmission vent hose and the wiring harness to the transmission.




26. Install the sight shield.
27. Install the starter motor. Refer to Starter Replacement Service and Repair
28. Install the new idler arm to relay rod retaining nut and tighten to 63 Nm (47 lb ft). Refer to Wheel Alignment Measurement (Wheel Alignment Measurement)




29. Apply a 2-3 mm wide by 0.5-1.5 high bead of GM P/N 12378521 (Canadian P/N 88901148) sealant on the right intake manifold mating surface.




30. Install the right intake manifold.
31. Install the intake manifold bolts/nuts.

Right:

32. Tighten the right intake manifold bolts/nuts in sequence to 25 Nm (18 lb ft).




33. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high bead of sealant on the intake manifold mating surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers)




34. Install the intake manifold (2).

Left:

35. Install the intake manifold bolts and nuts (1) and tighten in the sequence shown to 25 Nm (18 lb ft).





Note: The fuel pump must be correctly timed to the camshaft gear.

36. Rotate the crankshaft to align the camshaft gear timing marks with the center of the inspection hole.
37. Lubricate the O-ring on the fuel injection pump adapter with engine oil.
38. Install the fuel injection pump and adapter assembly (4) so that the timing mark on the fuel pump gear (5) is aligned with the timing marks on the camshaft gear (6).
39. Install the turbocharger cooler return pipe bracket (3).
40. Install the fuel injection pump bolts (1, 2) and tighten to 25 Nm (18 lb ft).




41. Install the camshaft gear access hole plug (1).




42. Connect the electrical connectors (1).
43. Collapse the hose clamps and install the fuel return and fuel feed hoses (2).




44. Install the fuel injection fuel rail assembly (3) and heat shield (2).
45. Install the fuel injection rail fasteners (1) and tighten to 25 Nm (18 lb ft).




46. Connect the fuel pressure sensor electrical connector (1).




47. Position the fuel injection fuel rail assembly (2) and install the fuel rail fasteners (1). Tighten to 25 Nm (18 lb ft).




48. Install the high pressure fuel pipe fitting (1) and tighten to 30 Nm (22 lb ft).




49. Install the high pressure fuel pipe fitting (2) and tighten to 30 Nm (22 lb ft).
50. Install the high pressure fuel pipe fasteners (1) and tighten to 10 Nm (89 lb in).
51. Connect any other fuel line as necessary.
52. Install ground strap as necessary.




53. Install the turbocharger lower heat shield (1) if removed.




54. Install the turbocharger assembly (2) with the oil feed pipe, oil return pipe and cooling return pipe.
55. Install the turbocharger mounting bolts (1) and tighten to 78 Nm (58 lb ft).
56. Install the turbocharger cooling return pipe bolt (3) and tighten to 25 Nm (18 lb ft).




57. Install the turbo oil return pipe fastener (1) and tighten to 25 Nm (18 lb ft).




58. Install the turbo coolant feed hose (1).





Note: Lubricate the washers with diesel fuel before installing.

59. Install the turbocharger oil feed pipe eye bolt (1) and washers (2). Tighten the eye bolt to 35 Nm (26 lb ft).




60. Install the turbocharger coolant feed hose (2) to the turbocharger coolant feed pipes (3).




61. Slide the turbocharger coolant feed hose (3) onto the thermostat housing and secure with the hose clamps (4).
62. Install the turbocharger coolant feed pipe retainer bolt (1) and tighten to 10 Nm (89 lb in).




63. Install the 2 bolts and the EGR cooler bracket (1) and tighten to 20 Nm (15 lb ft).




64. Remove the 2 rear EGR cooler valve retaining bolts (1). and tighten to 53 Nm (39 lb ft).




65. Install the intake manifold tube (2).
66. Install the intake manifold tube bolt (1) and tighten to 25 Nm (18 lb ft).
67. Install the left exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Left Side (Exhaust Manifold Outlet Pipe Replacement - Left Side)
68. Install the right exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (Exhaust Manifold Outlet Pipe Replacement - Right Side)
69. Connect the EGR valve electrical connector.




70. Install the indirect fuel injector line retainer to the fitting.
71. Install the indirect fuel injector (2) and tighten the fitting to 45 Nm (33 lb ft).




72. Install the indirect fuel injector fasteners (1, 2) to 25 Nm (18 lb ft).




73. Install the turbocharger air inlet adaptor (2).
74. Install the turbocharger air inlet clamp (1).




75. Install the crankcase depression regulator valve and bolts (1) and tighten 21 Nm (15 lb ft).




76. Install positive crankcase ventilation oil separator (2).
77. Install positive crankcase ventilation oil separator bolts (3) and tighten to 12 Nm (106 lb in).
78. Install positive crankcase ventilation oil separator hose (1).




79. Install the EGR valve bracket (2) and tighten bolts (1) to tighten to 20 Nm (15 lb ft).
80. Connect electrical connectors as necessary.
81. Position the thermostat housing crossover with NEW gaskets.




82. Install the thermostat housing crossover bolts (1) and nuts (2). Tighten to 25 Nm (18 lb ft).




83. Install the thermostat bypass bolts (2) to the water pump and tighten to 21 Nm (16 lb ft).
84. Connect the turbocharger coolant return hose (1) to the thermostat bypass pipe (3).




85. Install the oil fill tube bolt (3) and tighten to 25 Nm (18 lb ft).
86. Install the oil fill tube bracket bolt (4) and tighten to 25 Nm (18 lb ft).
87. Install the turbocharger coolant feed hose (2) and the engine coolant temperature sensor connector (1).
88. Install the fuel return line canister into the clip retainer at the top of the thermostat housing.




89. Install the fuel pressure valve bolt (1) and tighten to 25 Nm (18 lb ft).




90. Install the air conditioning compressor bracket (3).
91. Install the air conditioning compressor bracket nuts (1) and tighten to 50 Nm (37 lb ft).
92. Install the air conditioning compressor bracket bolts (2) and tighten to 50 Nm (37 lb ft).




93. Install power steering pump front mounting and tighten the bolt 22 Nm (16 lb ft).




94. Install the compressor retaining bolts (1) to the mounting bracket and tighten to 50 Nm (37 lb ft).




95. Install the auxiliary generator bracket (2) and tighten the bolt (1) to 50 Nm (37 lb ft).




96. Position the generator bracket to the engine and install the nuts (1) and bolt (2). Tighten to 50 Nm (37 lb ft).




97. Install the inlet pipe bracket bolts (1) to the generator bracket and intake manifold tube. Tighten to 25 Nm (17 lb ft).




98. Install the engine harness retainer bracket and nut (1). Tighten to 25 Nm (17 lb ft).
99. Install the engine harness ground terminal (2) and bolt (3). Tighten to 25 Nm (17 lb ft).




100. Install the drive belt tensioner bolt and tighten to 50 Nm (37 lb ft).




101. Install the oil indicator tube bracket bolt and tighten to 21 Nm (15 lb ft).




102. Install the generator (2) and the generator bolts (1) and tighten to 50 Nm (37 lb ft).
103. Install the positive battery cable to the generator, perform the following:

1. Install the positive cable.
2. Install the positive cable nut and tighten to 9 Nm (80 lb in).

104. Position the boot to cover the terminal stud.
105. Connect the generator electrical connector.
106. Install the drive belt. Refer to Drive Belt Replacement (Service and Repair)
107. Install the cooling fan. Refer to Fan Replacement (Fan Replacement)
108. Install the cooling layer. Refer to Cooling Layer Installation (Cooling Layer Installation)
109. Run the vehicle to verify correct engine operation and inspect for engine fluid leaks.
110. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair)