Engine Installation

1. Engine hoist and remove engine assembly from heavy duty automotive engine stand.
2. Apply GM P/N 12345493, or equivalent, to the flywheel retaining bolt threads.

CAUTION: Do not apply an excessive amount of sealant to the flywheel retaining bolt threads. Applying too much sealant will result in the sealant overflowing the bolt seat. This could cause the bolt to break loose during vehicle operation.

3. Flywheel; secure with six flywheel retaining bolts.
^ Tighten the flywheel retaining bolts to 78 Nm (58 ft. lbs.).
4. Pressure plate assembly and clutch disc (manual transmission equipped vehicles only).
5. Engine assembly, lowering into front of engine compartment while ensuring clearance on all sides, then slide assembly toward rear.
6. Engine mounting bracket-to-frame bolts.
A. Three right-side engine mount-to-engine bracket bolts.
^ Tighten the Right-side engine mount-to-engine bracket bolts to 54 Nm (40 ft. lbs.).
B. Two left-side engine mount-to-engine bolts. Do not tighten fully.
^ Tighten the Left-side engine mount-to-engine bolts to 54 Nm (40 ft. lbs.).
7. Remove engine hoist.
8. Hood to vehicle.
9. Distributor into distributor case.
10. The following vacuum hoses:
^ EGR pressure transducer.
^ EGR valve.
^ Brake booster supply hose.
^ Vacuum modulator supply hose (automatic transmission equipped vehicles).
^ EVAP canister purge valve.
^ MAP sensor hose to sensor.





11. The following electrical connectors:
^ TP sensor.
^ IAC valve.
^ H02S1.
^ ECT sensor.
^ ECT sensor sending unit.
^ A/C ECT switch (A/C equipped vehicles).
^ Wiring harness into retaining clamps.
^ Injector wiring harness.
^ Generator.
^ PSP switch.
^ EGRT sensor.
^ Exhaust gas recirculation solenoid vacuum valve.
^ Exhaust gas recirculation by-pass valve.
12. Lower coolant hose to radiator; secure with hose clamp.
13. Coolant bypass and heater inlet hoses to intake manifold; secure with hose clamps.
14. Coolant hose to thermostat housing.
15. PCV hose to PCV valve.
16. Fuel return hose to fuel return line.





17. Fuel feed hose at fuel feed hose union.
18. IAC air hose to IAC valve.
19. Coolant hose to the IAC valve.
20. Positive crankcase ventilation (PCV) valve, EGR valve, and EGR temperature sensor to intake manifold.
21. Accelerator cable and automatic transmission kickdown cable (automatic transmission equipped vehicles) to throttle body.
22. Air intake pipe to engine.
23. Fan clutch, cooling fan and shroud; secure with four fan clutch nuts and four shroud bolts.
^ Tighten
- Fan clutch nuts to 11 Nm (97 inch lbs.).
- Shroud bolts to 11 Nm (97 inch lbs.).
24. A/C lines at compressor (if equipped).
25. Upper coolant hose to radiator; secure with hose clamp.
26. Raise and suitably support vehicle.
27. Engine mount lower nuts and washers.
^ Tighten the engine mount lower nuts to 50 Nm (37 ft. lbs.).
28. Starter motor.
29. Transmission to cylinder block.
30. Clutch cable to retaining straps (manual transmission equipped vehicles).





31. Front pipe/TWC to exhaust manifold; secure with two nut.
^ Tighten the front pipe/TWC assembly-to-exhaust manifold nuts to 50 Nm (37 ft. lbs.).
32. Torque converter bolts (automatic transmission equipped vehicles) using a flywheel holder to lock drive plate.
^ Tighten the torque converter bolts to 54 Nm (40 ft. lbs.).
33. Torque converter lower plate (automatic transmission equipped vehicles).
34. Clutch housing lower plate (manual transmission equipped vehicles).
35. Automatic transmission fluid hoses to clamps (automatic transmission equipped vehicles).
36. Clutch cable to bracket and clutch release arm (manual transmission equipped vehicles). Refer to Transmission and Drivetrain.
37. Engine oil drain plug with new gasket.
^ Tighten the engine oil drain plug to 35 Nm (26 ft. lbs.).
38. Front skid plate (if equipped); secure with four bolts.
^ Tighten the front skid plate bolts to 55 Nm (40 ft. lbs.).
39. Power steering hoses to power steering pump. Refer to Steering and Suspension.
40. Lower vehicle.
41. Refill cooling system as necessary.
42. Refill power steering fluid.
43. Negative (-) and positive (+) battery cables.
44. Evacuate and charge A/C system (if equipped).