Removal and Replacement

Engine Replacement

^ Tools Required
- J 41427 Engine Lift Bracket

Removal Procedure

Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.





1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove the hood.
5. Raise and support the vehicle. Refer to Vehicle Lifting.
6. Remove the underbody shields, if equipped.
7. Remove the exhaust pipe from the exhaust manifolds.
8. Remove the engine oil cooler pipes (2WD vehicle).
9. Remove the stud holding the starter wire harness and if equipped, transmission oil cooler lines.
10. Remove the starter.





11. Remove the transmission cover.
12. Remove the transmission.





13. Remove the front engine mount through bolts.
14. Lower the vehicle.





15. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.





16. Disconnect the breather tube at the air cleaner outlet duct.





17. Remove the air cleaner outlet duct retaining wingnut.





18. Disconnect the IAT sensor harness connector.





19. Remove the air cleaner outlet duct from the throttle body.





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.

20. Disconnect the accelerator cable from the throttle body.





21. Remove the accelerator cable from the accelerator control cable bracket.
22. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
23. Remove the radiator.
24. Remove the inlet and outlet radiator hoses from the engine.
25. Disconnect the heater hoses from the engine.





26. Disconnect the power brake booster vacuum hose from the intake manifold.
27. Disconnect the vacuum hose for the A/C system, if equipped from the intake manifold.





28. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/C compressor cutoff switch (5), if equipped
^ The TP sensor (2)
^ The IAC valve motor (3)
^ The ECT sensor (4)





29. Disconnect the following electrical connectors:
^ The fuel meter body (1)
^ The EVAP canister purge solenoid (2)
^ The MAP sensor (3)





30. Disconnect the following electrical connectors:
^ The ICM (1)
^ The ignition coil (2)
^ The EGR solenoid (3)
^ The generator (4)





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





32. Disconnect the CKP sensor (2) electrical connector.
33. Remove the bolt and the battery negative cable (1).
34. Remove the engine wiring harness bracket bolt (3).
35. Remove the engine wiring harness clips from the front of the engine.
36. Remove the engine wiring harness clips from the brackets.
37. Move the engine wiring harness aside.
38. Remove the generator.





39. Remove the bolt holding the ground wires to the left cylinder head.
40. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.





41. Remove the bolts holding the ground wires to the right cylinder head.





42. Remove the bolt holding the ground strap to the right cylinder head.





43. Remove the accelerator control cable bracket from the throttle body.
44. Remove the water pump pulley.
45. Remove the A/C compressor, if equipped.
46. Remove the nut holding the AIR reactor pipe bracket to the front of the engine, if equipped.
47. Remove the nuts holding the power steering pump rear bracket to the engine.





48. Remove the power steering pump mounting bracket.
^ The power steering pump can remain on the mounting bracket.
^ The hoses do not require removal.
^ Remove the three bolts and the nut.
^ Slide the mounting bracket off of the stud.
^ Secure the mounting bracket out of the way.

Notice: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.

49. Remove both of the Secondary Air Injection (AIR) reactor pipes from the engine.
50. Remove the AIR shut-off valve and hoses.
51. Remove the distributor cap.
52. Disconnect the fuel pipes at the rear of the intake manifold.
53. Disconnect the EVAP canister purge solenoid valve pipe.
54. Remove the water outlet.





55. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
56. Remove the clamp bolt for the EGR valve inlet pipe.
57. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.





Notice: Refer to Fastener Notice in Service Precautions.

58. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:
58.1. Remove the right rear lower intake manifold bolts.
58.2. Install the J 41427 marked RIGHT REAR.
58.3. Install the retaining bolts.
58.4. Remove the left front lower intake manifold bolts.
58.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
58.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
59. Install a engine lifting device to the engine lift brackets.
60. Remove the engine.

Installation Procedure

Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.





1. Attach the J 4 1427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:
1.1. Remove the right rear lower intake manifold bolts.
1.2. Install the J 41427 marked RIGHT REAR.
1.3. Install the retaining bolts.
1.4. Remove the left front lower intake manifold bolts.
1.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
1.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
2. Install a engine lifting device to the engine lift brackets.
3. Install the engine into the vehicle.





4. Install the engine mount through-bolts and nuts.
^ Tighten the engine mount through-bolts or the nuts to the following:
^ Tighten the through-bolts to 74 Nm (55 ft. lbs.)
^ Tighten the nuts to 63 Nm (46 ft. lbs.)
5. Remove the J 41427 and the engine lifting device.
6. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
7. Install the intake manifold bolts.
^ 7.1. Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
7.2. Tighten the bolts the second pass to 12 Nm (106 inch lbs.).
7.3. Tighten the bolts the third pass to 15 Nm (11 ft. lbs.).





8. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold. Tighten
8.1. Tighten the EGR valve inlet pipe intake manifold nut to 55 Nm (18 ft. lbs.).
8.2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
8.3. Tighten the EGR valve inlet pipe clamp bolt 55 Nm (18 ft. lbs.).
9. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
10. Install the water outlet.
11. Connect the fuel pipes at the rear of the engine.
12. Install the distributor cap.
13. Connect the EVAP canister purge solenoid valve pipe.
14. Install both of the AIR reactor pipes to the engine.
15. Install the AIR shut-off valve and hoses.





16. Install the power steering pump mounting bracket.
^ Slide the power steering pump mounting bracket on the stud.
^ Position the power steering pump rear bracket on the studs.
^ Install the power steering pump mounting bracket three bolts and the nut.
^ Install the nut for the power steering pump rear bracket to the front of the engine.
^ Tighten the power steering pump mounting bracket and the power steering pump rear bracket bolts and the nuts to 41 Nm (30 ft. lbs.).
17. Install the nut holding the AIR reactor pipe bracket, if equipped to the stud on the front of the engine.
^ Tighten the bolt to 41 Nm (30 ft. lbs.).
18. Install the A/C compressor, if equipped.
19. Install the water pump pulley.





20. Install the accelerator control cable bracket to the throttle body.
^ Tighten the bolt to 9 Nm (80 inch lbs.).





21. Install the bolt holding the ground wires to the left cylinder head.
^ Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).
22. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
^ Tighten the fuel pipe bracket bolt to 30 Nm (22 ft. lbs.).





23. Install the stud holding the ground wires to the right cylinder head.
^ Tighten the ground wire stud to 35 Nm (26 ft. lbs.).





24. Install the bolt and the ground strap to the rear of the right cylinder head.
^ Tighten the ground strap bolt to 35 Nm (26 ft. lbs.).





25. Position the engine wiring harness.
26. Install the engine wiring harness clips to the brackets.
27. Install the engine wiring harness clips to the front of the engine.
28. Connect the CKP sensor electrical connector (2).
29. Install the bolt and the battery negative cable (1).
^ Tighten the bolt to 17 Nm (113 ft. lbs.).
30. Install the engine wiring harness bracket bolt (3) to the generator mounting bracket.
^ Tighten the stud to 55 Nm (18 ft. lbs.).





31. Install the generator.
32. Connect the following electrical connectors:
^ The distributor (1)
^ The engine oil pressure sensor (2)
^ The KS sensor (3)





33. Connect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/C compressor cutoff switch (5), if equipped
^ The TP sensor (2)
^ The IAC valve motor (3)
^ The ECT sensor (4)





34. Connect the following electrical connectors:
^ The fuel meter body (1)
^ The EVAP canister purge solenoid (2)
^ The MAP sensor (3)





35. Connect the following electrical connectors:
^ The ICM (1)
^ The ignition coil (2)
^ The EGR solenoid (3)
^ The generator (4)





36. Connect the power brake booster vacuum hose to the intake manifold.
37. Connect the vacuum hose for the A/C system, if equipped.
38. Install the cruise control cable, if equipped to the throttle shaft and the accelerator 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.
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.

39. Install the NEW accelerator cable onto the throttle body.





40. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab.





41. Install the accelerator cable to the accelerator cable control bracket.
42. Install the radiator.
43. Install the inlet and outlet radiator hoses to the engine.
44. Connect the heater hoses to the engine.
45. Raise the vehicle.
46. Install the transmission.






47. Install the transmission cover.
^ Tighten the nut to 12 Nm (106 inch lbs.).
48. Install the starter.





49. Install the stud holding the bracket for the starter wiring harness and if equipped, the transmission oil cooler lines.
^ Tighten the bracket stud to 9 Nm (80 inch lbs.).
50. Install the engine oil cooler pipes (2WD vehicle).
51. Install the exhaust pipe to the exhaust manifolds,
52. Install a NEW oil filter.
53. Add engine oil supplement GM P/N 1052367 or equivalent to the engine oil.
54. Install the underbody shields, if equipped.
55. Lower the vehicle.





56. Fill the engine with oil.
57. Fill the cooling system.
58. Connect the negative battery cable.





Notice:
^ Handle the MAF sensor carefully.
^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
^ Do not damage the screen located on the air inlet end of the MAF.
^ Do not touch the sensing elements.
^ Do not allow solvents and lubricants to come in contact with the sensing elements.
^ Use a small amount of a soap based solution in order to aid in the installation.

59. Install air cleaner outlet duct to throttle body.
60. Install air cleaner outlet duct to MAF sensor.
^ Tighten the hose clamp to 4 Nm (32 inch lbs.).





61. Connect the IAT sensor harness connector.





62. Install the air cleaner outlet duct retaining wingnut.
^ Tighten the wingnut to 2 Nm (18 inch lbs.).





63. Install the breather tube to the air cleaner outlet duct.
64. Install the PCV tube to the right valve rocker arm cover and the air cleaner outlet duct.
65. Recharge the air conditioning system, if equipped.
66. Install the hood.
67. 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.
68. Start the engine and listen for unusual noises.
69. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pres3ure.
If necessary, install an oil pressure gauge and measure the engine oil pressure.
70. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
71. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
72. Inspect for oil and/or coolant leaks while the engine is operating.
73. Verify that the distributor is properly positioned.
74. Perform a final inspection for the proper engine oil and coolant levels.