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.

Tool Required

J 41427 Engine Lift Bracket

1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the exhaust pipe from the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
5. Disconnect the oil cooler pipes, if equipped. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.



6. Remove the bolt holding the transmission cooler lines, if equipped to the oil pan.
7. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.



8. Remove the transmission cover.
9. Disconnect the torque convertor bolts from the flywheel, if equipped with automatic transmission. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transmission - 4L60-E.
10. Remove the transmission to engine bolts.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - NV 3500.




11. Remove the front engine mount through- bolts.
12. Lower the vehicle.
13. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
14. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
15. Remove the air cleaner outlet duct from the throttle body. Refer to Intake Air Resonator Replacement in Engine Controls.
16. Disconnect the hose to the EVAP canister purge solenoid valve and move aside.




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.
17. Remove the accelerator cable from the throttle shaft and the accelerator cable bracket. Refer to Accelerator Controls Cable Replacement in Engine Controls.
18. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
19. Disconnect the engine wiring harness clip from the accelerator control cable bracket mounted on the power steering pump mounting bracket.
20. Remove the bolt holding the accelerator control cable bracket to the power steering pump mounting bracket.

Leave accelerator control cable and the cruise control cable on the bracket.

21. Discharge the A/C system, if equipped. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C - Manual.
22. Remove the A/C hose from the accumulator and the compressor. Refer to Compressor Hose Assembly Replacement in HVAC Systems with A/C - Manual.
23. Move and secure the A/C hose to the right side of the vehicle.
24. Remove both the upper and lower fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
25. Remove the inlet and outlet radiator hoses from the engine. Refer to Radiator Hose Replacement in Engine Cooling.
26. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating and Ventilation (Non A/C).



27. Disconnect the EVO pressure switch electrical connector from the power steering pump.
28. Remove the EVO wiring harness from the retainer clip at the CKP sensor bracket.



29. Disconnect the electrical connections to the generator.
30. Disconnect the CKP sensor electrical connector.
31. Remove the nut and stud holding the ground wire and the battery negative cable to the engine.
32. Remove the engine wiring harness from the front of the engine and the heater hose clip bracket on the generator bracket.



33. Remove the nut holding the ground wire to the water outlet stud.
34. Remove the nut holding the engine wiring harness to the throttle body.



35. Disconnect the following electrical connectors:

•	The fuel meter body assembly

•	The EVAP canister purge solenoid valve

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The A/C compressor high pressure switch, if equipped

•	The A/C clutch switch, if equipped

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT ) sensor

•	The engine coolant temperature (ECT ) gauge sensor

•	The ignition control module (ICM)

•	The knock sensor (KS) sensor

•	The distributor

•	The engine oil pressure gauge sensor




36. Remove the nut and ground wires from the stud for the engine wiring harness at the rear of the right cylinder head.



37. Remove the engine wiring harness from the engine wiring harness bracket at the right rear of the engine.



38. Remove the nut and the stud for the engine wiring harness bracket at the right rear of the engine.
39. Remove the engine wiring harness bracket.



40. Remove the engine wiring harness from the engine wiring harness bracket at the left rear of the engine.
41. Move and secure the engine wiring harness out of the way.



42. Remove the engine wiring harness bracket.



43. Remove the power steering pump from the engine. Refer to Power Steering Pump Replacement in Power Steering Systems.

The hoses can remain on the power steering pump.

44. Remove the three bolts and the nut holding the power steering pump mounting bracket.
45. Remove the power steering pump mounting bracket.

The A/C compressor, if equipped can remain on the power steering pump mounting bracket.

46. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.
47. Disconnect the fuel pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.



48. Disconnect the vacuum brake booster line from the intake manifold.



49. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
50. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

51. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:

51.1.

Remove the right rear lower intake manifold bolts.

51.2.

Install the J 41427 marked RIGHT REAR.

51.3.

Install the retaining bolts.

51.4.

Remove the left front lower intake manifold bolts.

51.5.

Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.

51.6.

Install the retaining bolts.

Tighten
Tighten the retaining bolts to 15 N·m (11 lb ft).

52. Attach a suitable lifting device to the engine lift brackets.
53. Support the transmission with a suitable jack or a strap.
54. Remove the engine.

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.

Tool Required

J 41427 Engine Lift Bracket

1. Install the engine into the vehicle.
2. Loosely install the top two engine to transmission bolts.
3. Remove the jack or the straps supporting the transmission.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the engine mount through-bolts and nuts.

Tighten
Tighten the engine mount through-bolts or the nuts to the following:

•	Tighten the through-bolts to 95 N·m (70 lb ft)

•	Tighten the nuts to 68 N·m (50 lb ft)

5. Remove the J 41427 and the engine lifting device.
6. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower intake manifold bolts.
7. Install the intake manifold bolts.

Tighten

1. Tighten the bolts the first pass to 3 N·m (27 lb in).
2. Tighten the bolts the first pass to 12 N·m (106 lb in).
3. Tighten the bolts the first pass to 15 N·m (11 lb ft).



8. Install the EGR valve inlet pipe to the intake and exhaust manifolds.

Tighten

1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N·m (18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N·m (18 lb ft).
9. Install the spark plug wire harness retainer on the EGR valve inlet pipe
10. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.



11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.



13. Install the power steering pump mounting bracket with the A/C compressor, if equipped.

Tighten
Tighten the power steering pump mounting bracket bolts and nuts to 41 N·m (30 lb ft).

14. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement in Power Steering Systems.



15. Install the left side engine wiring harness bracket and the nuts on the lower intake manifold studs.

Tighten
Tighten the engine wiring harness bracket nuts to 12 N·m (106 lb in).




16. Install the right side engine wiring harness bracket on the EVAP canister purge solenoid valve stud.
17. Install the engine wiring harness bracket stud and nut.

Tighten

•	Tighten the engine wiring harness bracket stud to 25 N·m (18 lb ft)

•	Tighten the engine wiring harness bracket nut to 10 N·m (88 lb ft)




18. Position the engine wiring harness.
19. Install the engine wiring harness to the engine wiring harness bracket at the left rear of the engine.



20. Install the engine wiring harness to the engine wiring harness bracket at the right rear of the engine.



21. Install the ground wires and nut on the stud for the engine wiring harness bracket at the rear of the right cylinder head.

Tighten
Tighten the ground wires nut to 8 N·m (71 lb in)




22. Connect the following electrical connectors:

•	The fuel meter body assembly

•	The EVAP canister purge solenoid valve

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The A/C compressor high pressure switch, if equipped

•	The A/C clutch switch, if equipped

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT ) sensor

•	The engine coolant temperature (ECT ) gauge sensor

•	The ignition control module (ICM)

•	The knock sensor (KS)

•	The distributor

•	The engine oil pressure gauge sensor




23. Install the engine wiring harness clip and nut on the stud for the throttle body.

Tighten
Tighten the engine wiring harness clip nut to 10 N·m (88 lb in).

24. Install the ground wire and the nut on the water outlet stud.

Tighten
Tighten the ground wire nut to 8 N·m (71 lb in).




25. Install the engine wiring harness to the bracket on the generator bracket and to the front of the engine.
26. Install the stud and the battery negative cable

Tighten
Tighten the battery negative cable stud to 17 N·m (13 lb in).

27. Install the nut and ground wire on the battery negative cable stud.

Tighten
Tighten the ground wire nut to 8 N·m (71 lb in).

28. Connect the CKP sensor electrical connector.
29. Connect the electrical connections to the generator.



30. Connect the electrical connector for the EVO pressure switch on the power steering pump.
31. Install the EVO wire harness to the bracket on the CKP sensor.
32. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Ventilation (Non A/C).
33. Install the inlet and outlet radiator hoses to the engine. Refer to Radiator Hose Replacement in Engine Cooling.
34. Instal both the upper and lower fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.



35. Install the accelerator control cable bracket to the power steering pump mounting bracket.

Tighten
Tighten the bolt to 17 N·m (13 lb ft).

36. Install the A/C wiring harness to 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.
37. Install a NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls.
38. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise Controls.
39. Install the A/C hose to the accumulator and the compressor. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C - Manual.
40. Raise the vehicle.
41. Install the remaining transmission to engine bolts.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - NV 3500.

42. Install the torque converter bolts to the flywheel, if equipped. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transmission - 4L60-E.



43. Install the transmission cover.

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

44. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.



45. Install the bolt holding the bracket for the transmission cooler lines, if equipped.

Tighten
Tighten the bracket bolt to 12 N·m (106 lb in).

46. Connect the oil cooler pipes, if equipped. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
47. Install the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
48. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement .
49. Lower the vehicle.
50. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
51. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
52. Connect the EVAP canister purge solenoid valve hose. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.
53. Connect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
54. Install the air cleaner outlet duct. Refer to Intake Air Resonator Replacement in Engine Controls.
55. Recharge the air conditioning system, if equipped. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C - Manual.
56. Install the hood. Refer to Hood Replacement in Body Front End.
57. Operate and test the engine. Refer to Engine Set-Up and Testing .