Engine Replacement

Engine Replacement

Removal Procedure

1. Remove the battery box and carefully set the engine control module (ECM) on top of the engine. Refer to Battery Box Replacement .




2. Remove the battery cable retainers (1) from the battery tray.




3. Remove the negative battery cable nut (2) from the inner fender body ground stud.
4. Remove the negative battery cable (1) from the inner fender body ground stud.
5. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair) .




6. Release the clamp (1) from the brake booster vacuum hose connection.
7. Disconnect the brake booster vacuum hose (2) from the intake manifold.




8. Remove the transaxle control module (TCM) (1) from the bracket (2) and set the TCM on top of the engine.
9. Remove the air cleaner assembly and air intake duct. Refer to Air Cleaner Assembly Replacement .
10. Discharge the fuel system. Refer to Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (With CH 48027) .
11. Disconnect the evaporative emission (EVAP) hose/pipe from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service .




12. Disconnect the engine fuel hose/pipe (3) from the chassis fuel hose/pipe (2). Refer to Metal Collar Quick Connect Fitting Service .
13. Discharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging .
14. Remove the A/C compressor hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to Compressor Hose Assembly Replacement (LNJ) Compressor Hose Assembly Replacement (LY7) .
15. Disconnect the transaxle shift control cable from the transaxle. Refer to Shift Control Cable Replacement .




16. Disconnect engine to body inline connector C102 (2).
17. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (Service and Repair)Cooling System Draining and Filling (LY7 Static Fill) (Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (Service and Repair) .
18. Tie the radiator, A/C condenser, and fan module assembly to the upper radiator support to keep the assembly with the vehicle when the frame and drivetrain is removed.
19. Remove the coolant surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .
20. Disconnect the heater hoses from the engine. Refer to Heater Inlet Hose Replacement (LNJ) Heater Inlet Hose Replacement (LY7) .
21. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LNJ Chevrolet) (Service and Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (Service and Repair)Radiator Inlet Hose Replacement (LY7).
22. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
23. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LNJ) (Service and Repair)Radiator Outlet Hose Replacement (LY7) (Service and Repair) .




24. Disconnect the transaxle oil cooler lines from the transaxle and remove the seals. Refer to Fluid Cooler Pipe Seal Replacement .
25. Cap the transaxle oil cooler lines and plug the transaxle oil cooler line fittings to prevent loss of transmission fluid.
26. Remove the front bumper fascia air deflector. Refer to Front Bumper Fascia Air Deflector Replacement .




27. Disconnect the heated oxygen sensor (HO2S) 2 wiring harness (2).
28. Remove the HO2S 2 wiring harness retainers (1, 3) from the vehicle underbody.
29. Remove the catalytic converter and secure the rear half of the exhaust system to the vehicle underbody. Refer to Catalytic Converter Replacement (LNJ) (Service and Repair) .




30. If equipped with all wheel drive (AWD), disconnect the transfer case vent hose from the transfer case.
31. Remove the front tires. Refer to Tire and Wheel Removal and Installation .
32. Remove the right and left engine splash shields. Refer to Engine Splash Shield Replacement .




33. Remove the steering intermediate shaft pinch bolt and discard the bolt.
34. Disconnect the steering intermediate shaft from the steering gear.




35. Remove the right and left outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .




36. Remove the right and left stabilizer shaft links from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .




37. Remove the right and left lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement .
38. Remove the right and left front wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement .
39. If equipped with AWD, remove the rear propeller shaft. Refer to Propeller Shaft Replacement .




40. Place a block of wood (1) between the frame and the engine oil pan in order to support the engine once the bolts are removed from the right engine mount.




41. Place a block of wood (1) between the frame and the transaxle in order to support the transaxle once the bolts are removed from the left transaxle mount.
42. Lower the vehicle.




43. Remove the bolts (2) that secure the right engine mount (1) to the engine (3).




44. Remove the bolts that secure the left transaxle mount to the transaxle.

Important: Insure the vehicle body is secured to the hoist.


45. Raise the vehicle.
46. Place a universal frame support fixture or jackstands under the frame.
47. Lower the vehicle until the frame contacts the frame support fixture or jackstands.




48. Remove the frame-to-body bolts. Discard the bolts.

Important: Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain.


49. Carefully raise the vehicle body up away from the powertrain.




50. Disconnect the engine electrical wiring harness from the following components:

* Exhaust gas recirculation (EGR) valve (3)
* Throttle body (4)
* EVAP purge solenoid (5)
* Remove nut (1) and generator B+ lead (2)
* Generator regulator (6)
* Fuel injector inline connector (7)
* Heated oxygen sensor (H2OS) 1 (9, 10)
* Ignition coil/control module (12)
* Remove wire harness from retainers (8, 11, 13)





51. Disconnect the engine electrical wiring harness from the following components:

* Knock sensor (KS) (1)
* Crankshaft position (CKP) sensor (2)
* Remove bolt (4) and ground lead (3)
* Remove the wire harness from retainers (5, 6)





52. If equipped with an engine coolant heater, disconnect the coolant heater cord.




53. Disconnect the engine electrical wiring harness from the following components:

* Air conditioning (AC) compressor clutch (1)
* AC refrigerant pressure sensor (2)
* Remove wire harness from retainer (3)





54. Disconnect the engine electrical wiring harness from the following components:

* Knock sensor (KS) (1)
* Oil pressure indicator switch (2)

55. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .




56. Remove the nut securing the fuel pipe to the transaxle.
57. Remove the fuel pipe retainer from the threaded stud on the transaxle.




58. If equipped with AWD, remove the transfer case mounting bracket bolts and bracket.
59. If equipped with front wheel drive (FWD), remove the intermediate shaft. Refer to Intermediate Shaft Replacement .




60. Remove the negative battery cable-to-transaxle nut from the transaxle stud
61. Remove the negative battery cable (1) from the transaxle stud.




62. Remove the engine-to-transaxle brace bolts (1, 2) and brace (3).
63. Remove the starter motor. Refer to Starter Motor Replacement (LNJ) Starter Motor Replacement (LY7) .




64. Remove the torque converter bolts.
65. Install an engine lift chain to the engine lift brackets.
66. Support the engine weight with an engine hoist.




67. Remove the automatic transaxle bolts.
68. Separate the automatic transaxle from the engine.
69. Lift the engine away from the frame and the automatic transaxle.
70. Secure the engine to an engine stand.
71. Remove any additional engine components as necessary. Refer to appropriate component sections in manual if needed.



Installation Procedure

1. Remove the engine from the engine stand.




2. Align the engine to the frame and automatic transaxle.

Notice: Refer to Fastener Notice .

3. Install the automatic transaxle bolts.

Tighten the bolts to 75 N.m (55 lb ft).

4. Place a block of wood between the frame and the engine oil pan in order to support the engine on the frame once the engine hoist is removed.
5. Remove the engine hoist and lift chain.




6. Install the torque converter bolts.

Tighten the bolts to 60 N.m (44 lb ft).

7. Install the starter motor. Refer to Starter Motor Replacement (LNJ) Starter Motor Replacement (LY7) .




8. Install the engine to transaxle brace (3) and bolts (1, 2) .

Tighten the bolts to 50 N.m (37 lb ft).





9. Install the negative battery cable (1) to the transaxle stud.
10. Install the negative battery cable-to-transaxle nut to the transaxle stud.

Tighten the nut to 45 N.m (33 lb ft).





11. If equipped with AWD, install the transfer case mounting bracket and bolts.

Tighten the bolts to 60 N.m (44 lb ft).

12. If equipped with FWD, install the intermediate shaft. Refer to Intermediate Shaft Replacement .




13. Install the fuel pipe retainer to the threaded stud on the transaxle.
14. Install the nut securing the fuel pipe to the transaxle.

Tighten the nut to 28 N.m (21 lb ft).

15. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .




16. Connect the engine electrical wiring harness to the following components:

* Oil pressure indicator switch (2)
* Knock sensor (KS) (1)





17. Connect the engine electrical wiring harness to the following components:

* Install wire harness to retainer (3)
* AC refrigerant pressure sensor (2)
* Air conditioning (AC) compressor clutch (1)





18. If equipped with an engine coolant heater, connect the coolant heater cord.




19. Connect the engine electrical wiring harness to the following components:

* Install the wire harness to retainers (5, 6).
* Install ground lead (3) and bolt (4).

Tighten the bolt to 25 N.m (18 lb ft).

* CKP sensor (2)
* KS (1)





20. Connect the engine electrical wiring harness to the following components:

* Install wire harness to retainers (8, 11, 13)
* Ignition coil/control module (12)
* H2OS 1 (9, 10)
* Fuel injector inline connector (7)
* Generator regulator (6)
* Install generator B+ lead (2) and nut (1)

Tighten the nut to 13 N.m (115 lb in).

* EVAP purge solenoid (5)
* Throttle body (4)
* EGR valve (3)


Important: Inspect for areas of body to powertrain contact or entanglement of wires and hoses while joining the vehicle body to the powertrain.


21. Carefully lower the vehicle body down to the powertrain.




22. Install NEW frame-to-body bolts.

Tighten the bolts to 155 N.m (114 lb ft).

23. Raise the vehicle up away from the frame support fixture or jackstands and remove the support fixture or jackstands from under the vehicle.
24. Lower the vehicle.




25. Install the bolts that secure the left transaxle mount to the transaxle.

Tighten the bolts to 50 N.m (37 lb ft).





26. Install the bolts (2) that secure the right engine mount (1) to the engine (3).

Tighten the bolts to 50 N.m (37 lb ft).

27. Raise the vehicle.




28. Remove the block of wood (1) between the frame and the transaxle used to support the transaxle while the bolts were removed from the left transaxle mount.




29. Remove the block of wood (1) between the frame and the engine oil pan used to support the engine while the bolts were removed from the right engine mount.
30. If equipped with AWD, install the rear propeller shaft. Refer to Propeller Shaft Replacement .
31. Install the right and left front wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement .




32. Install the right and left lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement .




33. Install the right and left stabilizer shaft links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement .




34. Install the right and left tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .




35. Connect the steering intermediate shaft to the steering gear.
36. Install a NEW pinch bolt to the steering intermediate shaft.

Tighten the bolt to 34 N.m (25 lb ft).

37. Install the right and left engine splash shields. Refer to Engine Splash Shield Replacement .
38. Install the front tires. Refer to Tire and Wheel Removal and Installation .




39. If equipped with AWD, connect the transfer case vent hose to the transfer case.
40. Install the catalytic converter. Refer to Catalytic Converter Replacement (LNJ) (Service and Repair) .




41. Install the HO2S 2 wiring harness retainers (1, 3) to the vehicle underbody.
42. Connect the HO2S 2 wiring harness.
43. Install the front bumper fascia air deflector. Refer to Front Bumper Fascia Air Deflector Replacement .




44. Install new seals and connect the transaxle oil cooler lines to the transaxle. Refer to Fluid Cooler Pipe Seal Replacement .
45. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LNJ) (Service and Repair)Radiator Outlet Hose Replacement (LY7) (Service and Repair) .
46. Lower the vehicle.
47. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LNJ Chevrolet) (Service and Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (Service and Repair)Radiator Inlet Hose Replacement (LY7).
48. Connect the heater hoses to the engine. Refer to Heater Inlet Hose Replacement (LNJ) Heater Inlet Hose Replacement (LY7) and Heater Outlet Hose Replacement (LNJ) Heater Outlet Hose Replacement (LY7) .
49. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement (Service and Repair) .
50. Untie the radiator, AC condenser, and fan module assembly from the upper radiator support.




51. Connect engine to body inline connector C102 (2).
52. Connect the transaxle shift control cable to the transaxle. Refer to Shift Control Cable Replacement .
53. Install the AC compressor hose assembly to the compressor. Refer to Compressor Hose Assembly Replacement (LNJ) Compressor Hose Assembly Replacement (LY7) .




54. Connect the engine fuel hose/pipe (3) to the chassis fuel hose/pipe (2). Refer to Metal Collar Quick Connect Fitting Service .
55. Connect the EVAP hose/pipe to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service .
56. Install the air cleaner assembly and air intake duct. Refer to Air Cleaner Assembly Replacement .




57. Install the TCM (1) to the TCM bracket (2).




58. Connect the brake booster vacuum hose (2) to the intake manifold.
59. Position the clamp (1) on the brake booster vacuum hose connection.
60. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair) .




61. Install the negative battery cable from the inner fender body ground stud.
62. Install the negative battery cable nut (2) to the inner fender body ground stud.

Tighten the nut to 12 N.m (106 lb in).





63. Install the battery cable retainers (1) to the battery tray.
64. Install the battery box, battery and ECM. Refer to Battery Box Replacement .
65. Fill the engine with engine oil. Refer to Approximate Fluid Capacities , Fluid and Lubricant Recommendations , and Maintenance Schedule (North American Emissions) .
66. Fill the engine with coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (Service and Repair)Cooling System Draining and Filling (LY7 Static Fill) (Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (Service and Repair) .
67. Check the transaxle fluid level. Refer to Sealers, Adhesives, and Lubricants , Transmission General Specifications , and Fluid Capacity Specifications .
68. Charge the AC system. Refer to Refrigerant Recovery and Recharging .
69. Prime the fuel system.

1. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.
2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
3. If the engine does not start, repeat the steps.

70. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .