Removal and Replacement

Engine Replacement

- Tools Required
- J 36854 Heavy Duty Automotive Engine Stand
- J 35271 Fly Wheel Holder

Removal Procedure





1. Relieve the fuel pressure.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the hood from the vehicle.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Remove the front skid plate (5) from the vehicle, if equipped.
6. Drain the engine oil.
7. Drain the engine cooling system.





8. Remove the automatic transmission fluid cooled lines (1) from the radiator. Cap the open lines to prevent leakage.
9. Lower the vehicle.
10. Remove the radiator.





11. Disconnect the accelerator cable (2).
12. Disconnect the A/T throttle cable (1).





Important: The vehicle should be supported on a hoist prior to removing the strut tower brace. This will facilitate removal and installation of the brace.

13. Remove the 6 bolts and the strut tower brace.





14. Reprove the 4 screws and the surge tank cover (1).
15. Disconnect the intake air temperature (IAT) sensor connector.
16. Remove the 4 nuts from the surge tank pipe (3).
17. Remove the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (3) as an assembly.





18. Remove the 1 bolt (1) and the engine oil level indicator and tube (2).
19. Remove the 1 bolt and the transmission fluid level indicator and tube.
20. Remove the ignition coil covers.





21. Disconnect the injector wire connector (1).
22. Disconnect the brake booster vacuum hose (2).





23. Disconnect the following electrical connectors:
- The camshaft position sensor (CMP)
- The 6 ignition coils
- The throttle position (TP) sensor (2)
- The mass air flow (MAP) sensor (1)
- The idle air control (IAC) valve (3)
- The ground wires (5) from the surge tank
24. Remove the clamp bracket (4)





25. Disconnect the following electrical connectors:
- The EVAP canister purge valve (4)
- The exhaust gas recirculation (EGR) valve (5)
- The oxygen sensor
- The coolant temperature sensor
- The generator wires
- The starter wires
- The oil pressure switch wire
- The power steering pressure switch wire
- The ground wire from the generator bracket
26. Remove the clamp brackets (6)





27. Disconnect the following hoses:
- The heater hose (3) from the heater water pipe
- The heater hose (5) from the water outlet cap
- The EVAP canister hose from the canister pipe





28. Remove the idle air control (IAC) valve (1).
29. Remove the EVAP canister purge valve (4).





30. Disconnect the fuel feed hose (1) from the fuel feed pipe.
31. Disconnect the fuel return hose (2) from the fuel return pipe
32. Remove the EVAP canister.





33. Remove the 3 bolts and the power steering pump from its bracket and position aside.

Important: Do not discharge the A/C system nor remove the refrigerant lines from the compressor.

34. Remove the 3 bolts (1) and the A/C compressor, if equipped, from its bracket and position aside.
35. Remove the 4 bolts and the A/C compressor bracket, if equipped.
36. Remove the lower steering shaft assembly.
37. Raise the vehicle
38. Remove the front axle housing, 4WD only.
39. Remove the front exhaust pipe.
40. Remove the exhaust manifold bracket from the transmission.
41. Remove the transmission fluid hose clamps from the engine mounting bracket.





42. Remove the flywheel cover.
43. Remove the torque converter bolts on automatic transmission equipped vehicles. Use a screwdriver in order to lock the flywheel.
44. Remove the 2 bolts and the starting motor.
45. Lower the vehicle.





46. Support the transmission.
47. Remove the 4 bolts and 2 nuts that fasten the transmission to the cylinder block.





48. Install an engine hoist to the engine.
49. Remove the 2 nuts from the top side of the engine mounts.

Important: Before lifting the engine, ensure that all of the hoses, pipes, electrical wires and cables are disconnected from the engine and positioned aside.

50. Remove the engine assembly from the vehicle by sliding the assembly toward the front side of the engine compartment. Carefully lift the engine assembly from the vehicle verifying clearance on all sides.

Installation Procedure





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

Notice: Apply the proper amount of the sealant to the fastener when assembling this component. Excessive use of the sealant can prohibit the component from being assembled properly or allow the fastener to loosen. A component or fastener that is not assembled properly can loosen or fall off leading to extensive engine damage.

3. Align the flywheel-to-engine marks and install the flywheel (3).
4. Apply GM P/N 12345493 (Canadian P/N 10953488), or the equivalent, to the flywheel retaining bolt threads.





Notice: Refer to Fastener Notice in Service Precautions.

5. Install the flywheel retaining bolts to the crankshaft. Use the J 35271 to lock the flywheel.
- Cross tighten the 8 flywheel retaining bolts to 70 Nm (51 ft. lbs.).





6. Install the engine assembly. Lower the engine into the front of the engine compartment while ensuring clearance on all sides, slide the assembly rearward.
7. Install the engine mount nuts.
- Tighten engine mount nuts to 50 Nm (37 ft. lbs.).
8. Remove the engine hoist.





9. Install the 4 bolts and 2 nuts that fasten the transmission to the cylinder block.
- Tighten the bolt and nuts to 80 Nm (58 ft. lbs.).
10. Raise the vehicle.





11. Install the torque converter bolts. Use a screwdriver in order to lock the flywheel.
- Tighten the torque converter bolts to 65 Nm (47 ft. lbs.).
12. Install the flywheel cover.
13. Install the starting motor.
14. Install the transmission fluid hose clamps to the engine mounting bracket.
15. Install the exhaust manifold bracket to the transmission.
16. Install the front exhaust pipe.
17. Install the front axle: housing, 4WD only.
18. Install the lower steering shaft assembly.





19. Install the 4 bolts and the A/C compressor bracket, if equipped.
- Tighten the compressor bracket bolts to 55 Nm (40 ft. lbs.).
20. Install the A/C compressor, if equipped. Secure with the 3 bolts (1).
- Tighten the compressor mounting bolts to 23 Nm (17 ft. lbs.).
21. Install the power steering pump to its bracket. Secure with the 3 bolts.
- Tighten the power steering pump mounting bolts to 25 Nm (19 ft. lbs.).
22. Install the power steering pump drive belt.





23. Install the EVAP canister.
24. Connect the fuel return hose (2) to the fuel return pipe
25. Connect the fuel feed hose (1) to the fuel feed pipe.





26. Install the EVAP canister purge valve (4).
27. Install the idle air control (IAC) valve (1).





28. Connect the following hoses:
- The EVAP canister hose to the canister pipe
- The heater hose (5) to the water outlet cap
- The heater hose (3) to the heater water pipe





29. Connect the following electrical connectors:
- The EVAP canister purge valve (4)
- The exhaust gas recirculation (EGR) valve (5)
- The oxygen sensor
- The coolant temperature sensor
- The generator wires
- The starter wires
- The oil pressure switch wire
- The power steering pressure switch wire
- The ground wire to the generator bracket
30. Install the clamp brackets (6)





31. Connect the following electrical connectors:
- The camshaft position sensor (CMP)
- The 6 ignition coils
- The throttle position (TP) sensor (2)
- The mass air flow (MAP) sensor (1)
- The idle air control (IAC) valve (3)
- The ground wires (5) to the surge tank
32. Install the clamp bracket (4)





33. Connect the injector wire connector (1).
34. Connect the brake booster vacuum hose (2).





35. Install the engine oil level indicator and tube (2). Secure with the bolt (1).
- Tighten the oil level indicator tube bolt to 11 Nm (8 ft. lbs.).
36. Install the transmission fluid level indicator and tube. Secure with the 1 bolt.
- Tighten the transmission fluid level indicator tube bolt to 11 Nm (8 ft. lbs.).
37. Install the ignition coil covers.





38. Install the air cleaner upper case, the intake air hose, the intake air pipe (2) and the surge tank pipe (3) as an assembly to the throttle body and intake manifold.
39. Install the 4 nuts to the surge tank pipe (3).
- Tighten the surge tank pipe nuts to 1 2 Nm (8.5 ft. lbs.).
40. Connect the intake air temperature (IAT) sensor connector.
41. Install the surge tank cover (1).





42. Install the strut tower brace. Secure with the 6 bolts.
- Tighten the strut tower brace bolts to 50 Nm (37 ft. lbs.).





43. Connect the A/T throttle cable (1).
44. Connect the accelerator cable (2).





45. Install the radiator.
46. Install the upper radiator hose.
47. Install the automatic transmission fluid cooler lines (1) to the radiator.
48. Install the lower radiator hose.





49. Install the front skid plate (5) to the vehicle, if equipped. Secure the front skid plate with the 4 bolts.
- Tighten the front skid plate bolts to 55 Nm (40 ft. lbs.).





50. Install the engine oil drain plug (3) with a new gasket.
- Tighten the engine oil drain plug to 35 Nm (26 ft. lbs.).
51. Fill the crankcase with engine oil.
52. Fill the cooling system.
53. Fill the automatic transmission fluid as necessary.
54. Connect the negative battery cable.
55. Run the engine and inspect for the following:
- Engine oil leaks
- Transmission fluid leaks
- Engine coolant leaks
- Fuel leaks