GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner duct from the throttle body. Refer to Air Cleaner Outlet Rear Duct Replacement in Engine Controls.
  3. Disconnect the Camshaft Position Sensor. Refer to Camshaft Position Sensor Replacement in Engine Controls.
  4. Disconnect the ignition coil harness connectors.
  5. Disconnect the fuel supply lines from the intake manifold retaining brackets. Refer to Fuel Hose/Pipes Replacement - Chassis in Engine Controls.
  6. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  7. Remove the lower radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  8. Remove the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  9. Disconnect the coolant bypass hose and clamp from the intake manifold.
  10. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging in HVAC Systems with AC-Manual.
  11. Remove the AC discharge line from the vehicle.
  12. Remove the radiator fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  13. Disconnect the electrical connectors on the throttle body.
  14. Disconnect the engine coolant temperature sensor (ECT) connector.
  15. Disconnect the electrical leads at the generator. Refer to Generator Replacement in Engine Electrical.
  16. Remove the vacuum lines from the engine.
  17. Remove the electrical connector from the EGR valve.
  18. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  19. Remove the oil fill tube. Refer to Oil Level Indicator and Tube Replacement .
  20. Remove the hoses from the power steering pump/reservoir. Refer to Power Steering Fluid Reservoir Replacement - Off Vehicle , or Power Steering Pump Replacement in Power Steering.
  21. Remove the ground straps/wires from the engine block. Refer to Engine Ground Strap Replacement in Engine Electrical.
  22. Disconnect the engine electrical harness tie straps and position the harness clear.
  23. Raise the vehicle slightly to relieve tension on the front suspension springs and for removal of the front suspension.
  24. Remove the steering knuckle. Refer to Pitman Arm Replacement in Front Suspension.
  25. Remove the lower shock retaining bolts. Refer to Shock Absorber Replacement in Front Suspension.
  26. Disconnect and cap both front brake hose openings. Refer to Front Brake Hose Replacement in Hydraulic Brakes.
  27. Remove the front and rear front spring hanger retaining bolts. Refer to Leaf Springs Replacement in Front Suspension.
  28. Roll the front suspension assembly forward and clear of the vehicle underbody.
  29. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  30. Remove the exhaust pipes from the exhaust manifold and the catalytic converter. Refer to Exhaust Pipe Replacement in Engine Exhaust.
  31. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
  32. Remove the engine auxiliary oil cooler lines from the engine block. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
  33. Mark the position of the torque converter to the flywheel and remove the torque converter retaining bolts. Refer to Transmission Replacement in Automatic Transmission.
  34. Lower the vehicle and support the engine with a suitable moveable hydraulic dolly.
  35. Remove the front engine mount retaining nuts located below the front engine support crossmember. Refer to Engine Mount Replacement .
  36. Remove the front engine mount support crossmember retaining nuts. Refer to Crossmember Replacement in Frame and Underbody.
  37. Remove the front engine mount and support crossmember from the vehicle.
  38. Remove the bolts securing the engine to the transmission. Refer to Transmission Replacement in Automatic Transmission.
  39. Raise the vehicle to provide clearance for engine removal.
  40. Lower and remove the engine from the vehicle underbody.

Installation Procedure

Notice: Damage may result from the use of an improper bolt when attaching J36857 into the cylinder head.

  1. Position the engine in place for installation.
  2. Raise the engine or lower the vehicle to the engine for attachment.
  3. Align the engine to the transmission and install the retaining bolts. Refer to Transmission Replacement in Automatic Transmission.
  4. Install the front engine mount crossmember. Refer to Crossmember Replacement in Frame and Underbody.
  5. 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.

  6. Lower the engine assembly to allow the front engine mount bolts to pass through the mount and install the retaining nuts.
  7. Tighten
    Tighten the front engine mount bolt retaining nuts to 95 N·m (70 lb ft).

  8. Align the torque converter to flexplate and install the retaining bolts.
  9. Tighten
    Tighten the torque converter retaining bolts to 55 N·m (41 lb ft).

  10. Support the vehicle with safety stands.
  11. Install the engine auxiliary oil cooler lines. Refer to Auxiliary Engine Oil Cooler Replacement in Engine Cooling.
  12. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  13. Install the lower radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  14. Install the exhaust pipes to the exhaust manifold and catalytic converter. Refer to Exhaust Pipe Replacement in Engine Exhaust.
  15. Roll the suspension assembly under the vehicle and position into place.
  16. Install the front and rear spring hanger bolts. Refer to Leaf Springs Replacement in Front Suspension.
  17. Install the front brake hose lines. Refer to Front Brake Hose Replacement in Hydraulic Brakes.
  18. Install the lower shock retaining bolts. Refer to Shock Absorber Replacement in Front Suspension.
  19. Install the steering knuckle. Refer to Pitman Arm Replacement in Steering Linkage.
  20. Install the engine electrical harness with the appropriate tie straps.
  21. Install the ground straps to the engine block. Refer to Engine Ground Strap Replacement in Engine Electrical.
  22. Install the leads to the generator. Refer to Generator Replacement in Engine Electrical.
  23. Install the hoses to the power steering pump. Refer to Power Steering Fluid Reservoir Replacement - Off Vehicle or Power Steering Pump Replacement in Power Steering.
  24. Install the oil fill tube. Refer to Oil Level Indicator and Tube Replacement .
  25. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  26. Install the coolant bypass hose and clamp to the intake manifold.
  27. Connect the electrical connector to the EGR valve.
  28. Connect the engine coolant temperature sensor (ECT) connector.
  29. Install the vacuum hoses to the engine.
  30. Connect the electrical connectors to the throttle body.
  31. Install the radiator fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  32. Install the fuel lines to the intake manifold. Refer to Fuel Hose/Pipes Replacement - Chassis in Engine Controls.
  33. Install the AC discharge line and recharge the AC system. Refer to Refrigerant Recovery and Recharging in HVAC with AC-Manual.
  34. Install the lower radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  35. Install the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
  36. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  37. Connnect the ignition coil harness connectors.
  38. Connect the Camshaft Position Sensor. Refer to Camshaft Position Sensor Replacement in Engine Controls.
  39. Install the air intake duct to the throttle body. Refer to Air Cleaner Outlet Rear Duct Replacement in Engine Controls.
  40. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  41. Connect the negative battery cable.