Removal and Replacement

Engine Replacement

Tools Required

J 44220 Engine Lift Bracket

Removal Procedure

1. Remove the hood. Refer to Hood Replacement.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Drain engine coolant. Refer to Draining and Filling Cooling System (LL8) Draining and Filling Cooling System (LH6, LS2).
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.





Important: Keep drain plug removed during engine removal and installation.

5. Remove the oil pan drain plug and drain the oil.
6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the procedure.
7. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
8. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
9. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
10. Remove the washer solvent container. Refer to Washer Solvent Container Replacement (Envoy, TrailBlazer) Washer Solvent Container Replacement (Rainier).
11. Remove the grille. Refer to Grille Replacement (Envoy) Grille Replacement (Rainier) Grille Replacement (TrailBlazer).
12. Remove the headlamp housing. Refer to Headlamp Housing Panel Replacement (Envoy, Rainier) Headlamp Housing Panel Replacement (TrailBlazer).
13. Remove the radiator support brace. Refer to Radiator Support Diagonal Brace Replacement.
14. Remove the hood latch. Refer to Hood Latch Support Replacement.
15. Disconnect A/C lines at the condenser.
16. Disconnect the transmission cooler lines at the engine, not the radiator.
17. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud rearward for clearance. Refer to Cooling Fan and Shroud Replacement.
18. Remove the radiator with condenser and transmission cooler lines. Refer to Radiator Replacement (LH6, Ls2) Radiator Replacement (LL8).
19. Remove the drive belt. Refer to Drive Belt Replacement.
20. Remove the power steering pump bolts and lay the pump aside.




21. Ensure the heater hoses (1, 2) at the heater core are disconnected.
22. Remove the secondary air injection (AIR) reaction solenoid valve. Refer to Secondary Air Injection Solenoid Valve Replacement




23. Install the lift hook J 44220 to the AIR port on the engine head.
24. Disconnect the oxygen sensor electrical connector.
25. Disconnect the A/C line at the accumulator.
26. Disconnect the front axle actuator electrical connector.
27. Disconnect the camshaft phaser actuator valve electrical connector.




28. Unclip the transmission cooler lines from right side of the engine block.
29. Disconnect the ignition coil harness connectors.




30. Carefully disconnect harness retainer at clips (1) and remove.
31. Remove power brake hose at booster.




32. Remove the powertrain control module (PCM). Refer to Powertrain Control Module Replacement.
33. Remove all harnesses from the engine harness bracket.
34. Disconnect the front differential vent hose from the engine harness bracket.




35. Remove the engine harness bracket bolt and remove bracket.




36. Disconnect starter electrical connections (1).
37. Disconnect the A/C pressure sensor and clutch electrical connector.




38. Disconnect generator electrical connector and battery lead (1).
39. Disconnect the knock sensor electrical connector.
40. Disconnect the crankshaft sensor electrical connector.
41. Disconnect the camshaft sensor electrical connector.




42. Remove 4 grounds on the left side of the block (1).
43. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
44. Remove the wheel drive shafts, left and right. Refer to Wheel Drive Shaft Replacement.
45. Remove the propeller shaft from the front axle pinion yoke. Refer to Front Propeller Shaft Replacement.
46. Remove the engine protection shield. Refer to Engine Protection Shield Replacement.




47. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
48. Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL) Fuel Tank Shield Replacement (TrailBlazer, Envoy).




49. Disconnect the AIR pipes from the AIR pump.
50. Remove the torque converter bolt access cover.
51. Remove the torque converter bolts.
52. Place a jack on the transmission oil pan for support.
53. Remove the transmission support. Refer to Transmission Support Replacement.
54. Lower the transmission enough to reach the top bell housing bolts.




55. Remove the top 4 bell housing bolts. There may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts.
56. Raise the transmission.
57. Reinstall the transmission support using only 2 through bolts.
58. Remove the remaining bell housing bolts, for a total of 11 bolts.
59. Remove the left and right engine lower mount nuts.
60. Disconnect the oil pressure switch electrical connector.
61. Lower the vehicle.




62. Remove the left upper engine mount nut (1).




63. Remove the right upper engine mount nut (1).
64. Install the engine hoist.
65. Raise the engine out of the compartment slowly keeping the transmission supported.
66. Remove both engine mounts for clearance.
67. Remove the fasteners securing the AIR pipes to the back of the engine head.
68. Remove the AIR pipes from the vehicle.
69. Continue raising the engine out of the vehicle.
70. Install the engine to the engine stand.

Installation Procedure

1. Remove the engine from the engine stand.
2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. Install the AIR pipes to the engine.
4. Install the fasteners securing the AIR pipes to the back of the engine head.
5. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.





Notice: Refer to Fastener Notice.

6. Lower the engine onto the mounts and install the upper engine mount nuts (1).

Tighten the nuts to 70 N.m (51 lb ft).

7. Remove the engine hoist.
8. Lay the radiator into the radiator support, but do not install the radiator completely.
9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.




10. Install all of the lower bell housing bolts, excluding the top 4.
11. Remove the 2 through bolts securing the transmission support.
12. Lower the transmission.
13. Install the top 4 bell housing bolts.

Tighten all 11 bell housing bolts to 50 N.m (37 lb ft).

14. Raise the transmission.
15. Install the transmission support. Refer to Transmission Support Replacement.
16. Install the 3 torque converter bolts.

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

17. Install the torque converter bolt cover.
18. Install the fuel tank shield, if removed. Refer to Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL) Fuel Tank Shield Replacement (TrailBlazer, Envoy).




19. Connect the AIR pipes to the AIR pump.
20. Install the engine protection shield. Refer to Engine Protection Shield Replacement.
21. Install the propeller shaft to the front axle pinion yoke. Refer to Front Propeller Shaft Replacement.




22. Connect the exhaust pipe to the manifold and secure the pipe with the bolts.

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

23. Connect the oil pressure sensor electrical connector.




24. Install the oil pan drain plug.

Tighten the plug to 26 N.m (19 lb ft).




25. Install the lower radiator hose (1).
26. Install the left and right wheel drive shafts. Refer to Wheel Drive Shaft Replacement.
27. Lower the vehicle.




28. Install the 4 grounds on the left side of the block (1).
29. Install the camshaft sensor electrical connectors.
30. Install the crankshaft sensor electrical connector.
31. Install the knock sensor electrical connector.




32. Install the generator electrical connector and battery lead (1).

Tighten the generator battery lead nut to 9 N.m (80 lb in).

33. Install the A/C pressure sensor and clutch electrical connector.




34. Install starter electrical connectors and battery lead (1).

Tighten the starter battery lead to 9 N.m (80 lb in).




35. Install the engine harness bracket and bolt.

Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).

36. Install the front differential vent hose, to the engine harness bracket.
37. Install all the harnesses to the engine harness bracket.
38. Install the PCM. Refer to Powertrain Control Module Replacement.
39. Install the power brake hose at booster.




40. Install the harness retainer (1) to the original location.
41. Install the ignition coil harness electrical connectors.




42. Clip the transmission cooler lines to the right side of the engine block.
43. Connect the camshaft phaser actuator valve electrical connector.
44. Connect the front axle actuator electrical connector.
45. Connect the A/C line at the accumulator.
46. Install the oxygen sensor electrical connector.




47. Remove the lift hook J 44220.
48. Install the secondary AIR solenoid valve. Refer to Secondary Air Injection Solenoid Valve Replacement
49. Install the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement (LL8) Heater Inlet Hose Replacement (LH6) and Heater Outlet Hose Replacement (LH6) Heater Outlet Hose Replacement (LL8).
50. Install the power steering pump.




51. Install the power steering pump bolts.

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

52. Install the drive belt. Refer to Drive Belt Replacement.
53. Install cooling fan and shroud, tilting the radiator forward for clearance.
54. Finish installing the radiator. Refer to Radiator Replacement (LH6, Ls2) Radiator Replacement (LL8).
55. Install transmission cooler lines together.
56. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
57. Install the throttle body. Refer to Throttle Body Assembly Replacement.
58. Install the hood latch. Refer to Hood Latch Support Replacement.
59. Install the head lamp housing. Refer to Headlamp Housing Panel Replacement (Envoy, Rainier) Headlamp Housing Panel Replacement (TrailBlazer).
60. Install the grill. Refer to Grille Replacement (Envoy) Grille Replacement (Rainier) Grille Replacement (TrailBlazer).
61. Install the washer solvent container. Refer to Washer Solvent Container Replacement (Envoy, TrailBlazer) Washer Solvent Container Replacement (Rainier).
62. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
63. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
64. Install the hood. Refer to Hood Replacement.
65. Service the engine oil.
66. Fill the cooling system. Refer to Draining and Filling Cooling System (LL8) Draining and Filling Cooling System (LH6, LS2).
67. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging.
68. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.

Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

^ Disable the ignition system.
^ Crank the engine several times. Listen for unusual noises or evidence that parts are binding.
^ Enable the ignition system.
^ Start the engine and listen for unusual noises.
^ Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
^ Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
^ Listen for a sticking lifter and other unusual noises.
^ Inspect for fuel, oil and/or coolant leaks while the engine is running.
^ Perform a final inspection for the proper engine oil and coolant levels.

69. Install the hood. Refer to Hood Replacement.