Engine Replacement

REMOVAL PROCEDURE

^ Tools Required
- J 36854 Heavy Duty Automotive Engine Stand

1. Relieve the fuel pressure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Drain the engine oil.
5. Remove the washer hose at the hood.
6. Remove the hood.





7. Remove the secondary spark plug wires (1) from the spark plugs.
8. Position the secondary spark plug wires aside.





9. Remove the four ignition coil bolts (1-4).
10. Remove the ignition coils with the plug wires attached from the cylinder head.





11. Remove the serpentine drive belt (1).
12. If vehicle is equipped with A/C, discharge and remove the A/C compressor.
13. If vehicle is equipped with a manual transmission, remove the following components:
- The crankshaft pulley.
- The generator.
- The drive belt tensioner.





14. Remove the accelerator cable from the throttle body (1)
15. Remove the accelerator cable from the accelerator cable bracket.
16. For vehicles equipped with automatic transmission, remove the following components:
- The transmission TV cable from the throttle body.
- The transmission TV cable from the accelerator cable bracket.

17. Disconnect the intake air temperature (IAT) sensor.
18. Remove the air cleaner hose and cap assembly.





19. Disconnect the two wire harness retaining clips from the air cleaner lower case.
20. Remove the following items from the air cleaner case:
^ The one bolt
^ The vacuum switching valve (VSV) bracket

21. Remove the air filter.





22. Remove the following items:
^ The three bolts
^ The air cleaner lower box (3)

23. Remove the upper radiator hose.
24. Remove the washer fluid tank mounting bolt.
25. Position the washer fluid tank aside.
26. Disconnect the washer pump connector.
27. Disconnect the washer pump fluid line.
28. Cap the washer pump fluid output in order to prevent the washer fluid from escaping.
29. Remove the upper generator mounting bolt.
30. Remove the following items at the engine mount bracket:
^ The one bolt
^ The ground wire

31. Disconnect all the necessary hoses in order to remove the engine.
32. Disconnect all the necessary electrical connections in order to remove the engine.
33. Disconnect the oxygen sensor connector.





34. Remove the following items:
^ The two oxygen sensor nuts
^ The oxygen sensor
^ The oxygen sensor gasket

35. Remove the following items:
^ The wiring harness bracket bolts
^ The wiring harness brackets

36. Unroute the engine harness.
37. Set the engine harness aside.
38. Remove the lower radiator hose from the thermostat housing.
39. Remove the upper starter bolt.
40. Raise and properly support the vehicle.
41. Remove the following items from the right side of the vehicle:
^ The lower engine splash shield bolts
^ The splash shield
^ The right side drive axle.

42. Remove the following items from the left side of the vehicle:
^ The lower engine splash shield bolts
^ The splash shield

43. Disconnect the starter motor electrical connectors (3).





44. Remove the following items:
^ The starter bolts (1,2)
^ The starter





45. If the vehicle is equipped with an automatic transmission, remove the six torque converter bolts.





46. Remove the following items from the power steering pump:
^ The power steering pump through bolts (1)
^ The power steering pump nuts

47. Remove the power steering pump.
48. Position the power steering pump aside.





49. Remove the following items from the front exhaust pipe to the manifold:
^ The two bolts (1, 2)
^ The springs

50. Remove the following items from the axle shaft boot heat shield:
^ The one nut
^ The two bolts

51. Remove the axle shaft heat shield.
52. Remove the four lower transmission to engine mounting bracket bolts.
53. Lower the vehicle.
54. Install the engine support fixture.
55. Remove the two upper transmission to engine mounting bolts.





56. Remove the following items from the right side engine mount:
^ The two nuts (3)
^ The four bolts (1)

57. Remove the right side engine mount.
58. Remove the following items from the vehicle:
^ The three right side engine mount bolts
^ The bracket

59. Verify that all wires and hoses are disconnected.
60. Verify that all wires and hoses are positioned aside.
61. Remove the engine assembly from the vehicle.
62. If equipped with a manual transmission, remove the clutch and pressure plate.
63. Remove the eight flywheel retaining bolts.
64. Remove the flywheel from the crankshaft.
65. Place the engine assembly onto the J 36854

INSTALLATION PROCEDURE

^ Tools Required
- J 36660 Torque Angle Meter

1. Install the engine hoist.
2. Remove the engine assembly from the J 36854

NOTICE: 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. Apply GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads (1).





4. For vehicles equipped with an Automatic Transmission, install the flywheel retaining bolts (1-8) to the crankshaft.
^ Tighten the eight flywheel retaining bolts in sequence for Automatic Transmission to 83 Nm (61 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





5. For vehicles equipped with a Manual Transmission, install the flywheel retaining bolts to the crankshaft.
^ Tighten the eight flywheel retaining bolts in sequence for Manual Transmission to 49 Nm (36 ft. lbs.). After the proper torque has been reached, use a J 36660 and tighten the flywheel bolts an additional 90 degrees.

6. For vehicles equipped with manual transmission, install the following items.
^ The pressure plate assembly
^ The clutch disc

7. Install the engine assembly. Lower the engine into the engine compartment while ensuring clearance on all sides.





8. Install the two upper transmission to engine mounting bolts.
9. Install the four lower transmission to engine mounting bolts.
^ Tighten the transmission to engine mounting bolts to 64 Nm (47 ft. lbs.).

10. Install the right side engine mounting bracket.
^ Tighten the engine mounting bracket bolts to 54 Nm (40 ft. lbs.).

11. Use the three engine mounting bracket bolts in order to secure the right side engine mounting bracket.
^ Tighten right-side engine mount-to-engine bracket bolts to 54 Nm (40 ft. lbs.).

12. Install the right side engine mount.
13. Use the two nuts and the four bolts in order to secure the right side mounting insulator.
^ Tighten the right side engine mount bolts and nuts to 54 Nm (40 ft. lbs.).

14. Remove the engine hoist.

CAUTION: Refer to Vehicle Lifting Caution in General Information.

15. Raise and support the vehicle.
16. Install the four lower transmission to engine mounting bolts.
^ Tighten the four lower transmission to engine mounting bolts to 67 Nm (49 ft. lbs.).

17. Install the axle shaft heat shield.
18. Use the one nut and two bolts in order to secure the axle shaft heat shield.
^ Tighten the axle shaft heat shield nut to 10 Nm (89 ft. lbs.).
^ Tighten the axle shaft heat shield bolts to 10 Nm (89 ft. lbs.).

19. Install the right side drive axle.
20. Install the exhaust pipe to the exhaust manifold.
21. Use the two bolts and the springs (1, 2) in order to secure the exhaust pipe to the exhaust manifold.





^ Tighten the exhaust pipe bolts to 62 Nm (46 ft. lbs.).

22. Position the power steering pump at the mounting location.





23. Use the two bolts and the nuts in order to secure the power steering.
^ Tighten the power steering pump mounting bolts to 37 Nm (27 ft. lbs.).





24. If the vehicle is equipped with an automatic transmission, install the six torque converter bolts.
^ Tighten the six torque converter bolts to 35 Nm (26 ft. lbs.).





25. Install the starter.
26. Use the starter bolts in order to secure the starter.
^ Tighten the starter bolts to 30 Nm (22 ft. lbs.).

27. Connect the starter motor electrical connections.
28. Install the left side lower engine splash shield.
29. Use the six bolts in order to secure the left side lower engine splash shield.
^ Tighten the left side engine splash shield bolts to 10 Nm (89 inch lbs.).

30. Install the right side lower engine splash shield.
31. Use the six bolts in order to secure the right side lower engine splash shield.
^ Tighten the right side engine splash shield bolts to 10 Nm (89 inch lbs.).

32. Lower the vehicle.





33. Install the upper starter bolt.
^ Tighten the upper starter bolt to 39 Nm (29 ft. lbs.).

34. Install the lower radiator hose to the thermostat housing.
35. Reroute the engine harness. Reposition the engine harness as necessary.
36. Install the engine wiring harness brackets.
37. Use the engine wiring harness bracket bolts in order to secure the engine wiring harness.
38. Install the following items:
^ The oxygen sensor
^ The oxygen sensor gasket





39. Use the two oxygen sensor nuts in order to secure the oxygen sensor.
^ Tighten the oxygen sensor nuts to 20 Nm (14 ft. lbs.).

40. Connect the oxygen sensor connector.
41. Connect all necessary electrical connectors.
42. Connect all necessary hoses.
43. Install the ground wire to the engine mount bracket.
44. Use the one ground wire bolt in order to secure the ground wire to the engine mount bracket.
^ Tighten the one ground wire bolt to 15 Nm(111bft).

45. Install the upper generator mounting bolt.
^ Tighten the upper generator mounting bolt to 23 Nm (17 ft. lbs.).

46. Remove the cap from the washer pump outlet.
47. Connect the washer pump fluid line to the washer fluid tank.
48. Connect the washer pump electrical connector.
49. Install the washer fluid tank.
50. Use the one washer fluid tank bolt in order to secure the washer fluid tank.
^ Tighten the washer fluid reservoir mounting bolt to 10 Nm (89 inch lbs.).

51. Install the upper radiator hose.





52. Install the air cleaner lower box.
53. Use the three air cleaner lower box bolts in order to secure the air cleaner lower box.
54. Install the air filter.
55. Install the vacuum switching valve (VSV) bracket to the air cleaner case.
56. Use the one VSV bracket bolt in order to secure the VSV bracket.
57. Connect the two wiring harness retainer clips to the air cleaner lower case.
58. Install the air cleaner hose and cap assembly.
59. Connect the intake air temperature (IAT) sensor.





60. For vehicles equipped with automatic transmission, install the following components:
- The transmission TV cable to the accelerator cable bracket.
- The transmission TV cable to the throttle body.

61. Install the accelerator cable to the accelerator cable bracket.
62. Install the accelerator cable to the throttle body (1)





63. Install the serpentine drive belt (1).
64. If vehicle is equipped with A/C, install the A/C compressor.
65. If vehicle is equipped with a manual transmission, install the following components:
- Crankshaft pulley.
- Generator.
- Drive belt tensioner.





66. Install the two ignition coils.
67. Use the four ignition coil bolts (1) in order to secure the ignition coils.





68. Connect the secondary spark plug wires (1).
69. Install the hood.
70. Connect the windshield washer hose at the hood.
71. Fill the engine oil.
72. Fill the cooling system.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

73. Connect the negative battery cable to the battery.