GM Service Manual Online
For 1990-2009 cars only

Special Tools

    • J 21366 Converter Holding Strap
    • J 41798 Engine Lifting Brackets

Removal Procedure


    Object Number: 1823089  Size: SH
  1. Open the hood.
  2. Remove the ground strap nut at the hood stud.
  3. Remove the ground strap from the stud.

  4. Object Number: 1711842  Size: SH
  5. Assemble 2 sets of the following: an M6 bolt, 2 each 19.05 mm (0.75 in) flat washers and an M6 nut.
  6. Release the retainer securing the hood strut rod to the hood strut bracket stud.
  7. Remove the hood strut rod (1) from the stud.
  8. Remove the air inlet grille end caps (2), lift the end cap up in order to disengage the retainers. (left side shown, right side similar).
  9. Have an assistant support the hood.
  10. Remove the hood hinge bolts (3) and set aside.

  11. Object Number: 1711844  Size: SH

    Note: There is a positive stop which limits the hood from being opened too far.

  12. Raise the hood until the service position notch (1) in the upper hinge is reached.
  13. Install the 2 sets of the M6 bolts to both the left and right side service notches and tighten finger tight.
  14. Caution: Refer to Fastener Caution in the Preface section.

  15. Lower the hood until the bolts rest against the lower hinge, tighten the bolts to secure the hood.
  16. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  17. The hood is now set in the service position.
  18. Remove the hood latch. Refer to Hood Primary and Secondary Latch Replacement.
  19. Remove the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement.
  20. Remove the intake manifold. Refer to Intake Manifold Replacement.

  21. Object Number: 1699347  Size: SH
  22. Remove the radiator vent inlet hose (2) from the radiator inlet hose clip (3).
  23. Reposition the radiator vent inlet hose clamp (1) at the air bleed pipe.
  24. Remove the radiator vent inlet hose (2) from the air bleed pipe and reposition.

  25. Object Number: 1696566  Size: SH
  26. Reposition the radiator inlet hose clamp (3) at the water pump.
  27. Remove the radiator inlet hose from the water pump.

  28. Object Number: 1699336  Size: SH
  29. Reposition the radiator outlet hose clamp at the water pump.
  30. Remove the radiator outlet hose from the water pump.
  31. Remove the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.

  32. Object Number: 1697098  Size: SH
  33. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
  34. Disconnect the engine harness electrical connector (2) from the lifter oil manifold.

  35. Object Number: 1699550  Size: SH
  36. Remove the engine ground strap bolt from the rear of the left cylinder head and cowl and reposition.

  37. Object Number: 1699543  Size: SH
  38. Remove the negative battery cable stud (1) from the right cylinder head.
  39. Remove the negative battery cable terminal (2) and the engine harness ground (3) from the right cylinder head.
  40. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

  41. Object Number: 1699536  Size: SH
  42. Remove the engine harness clip (1) from the ground stud.
  43. Remove the engine harness ground stud (2) from the engine block.
  44. Remove the engine harness grounds (3) from the engine block.
  45. Disconnect the engine harness electrical connector (4) from the knock sensor.

  46. Object Number: 1698074  Size: SH
  47. Remove the transmission oil cooler line clip bolt from the oil pan, if equipped.

  48. Object Number: 1697734  Size: SH
  49. Disconnect the engine harness electrical connector (1) from the camshaft position (CMP) sensor wire harness.
  50. Remove the battery cable channel bolt (2).
  51. Slide the channel pin (3) out of the oil pan tab.

  52. Object Number: 1699539  Size: SH
  53. Disconnect the engine harness electrical connector (1) from the A/C refrigerant pressure sensor.
  54. Remove the starter motor. Refer to Starter Motor Replacement.

  55. Object Number: 1698087  Size: SH
  56. Disconnect the engine harness electrical connector (1) from the crankshaft position (CKP) sensor.
  57. Disconnect the engine harness electrical connector (2) from the knock sensor.
  58. Disconnect the engine harness electrical connector (4) from the oil level sensor.
  59. Remove the engine harness clip (3) from the transmission oil cooler line bracket.

  60. Object Number: 1699547  Size: SH
  61. Disconnect the coolant heater cord from the coolant heater, if equipped.
  62. Lower the vehicle.

  63. Object Number: 1699607  Size: SH
  64. Remove the rear power steering pump-to-engine block bolt (1500 series shown, 2500 series similar).

  65. Object Number: 310813  Size: SH
  66. Remove the generator bracket bolts.
  67. Position the generator bracket (with power steering pump) aside.
  68. Remove the ignition coil, as required for the proper fit of the J 41798 before lifting the engine. Refer to Ignition Coil Replacement.

  69. Object Number: 1701027  Size: SH
  70. Remove the transmission oil level indicator tube nut (1).

  71. Object Number: 396798  Size: SH
  72. Remove the transmission oil level indicator tube.
  73. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 309151  Size: SH
  74. Install the J 41798 to the cylinder heads.
  75. Tighten

        • Tighten the M8 engine lift bracket bolts to 25 N·m (18 lb ft).
        • Tighten the M10 engine lift bracket bolts to 50 N·m (37 lb ft).

    Object Number: 1701016  Size: SH
  76. For 1500 series vehicles with a 4.8L engine, remove the left and right engine mount to frame bolts (1).

  77. Object Number: 1701017  Size: SH
  78. For 1500 series vehicles with a 5.3L, 6.0L, or 6.2L engines, remove the left and right engine mount to frame bolts (1).

  79. Object Number: 1701018  Size: SH
  80. For 2500 series vehicles with a 5.3L, 6.0L, or 6.2L engines, remove the left and right engine mount to engine mount bracket bolts (1).
  81. Raise the vehicle.

  82. Object Number: 1696602  Size: SH
  83. Remove the engine shield bolts and shield.

  84. Object Number: 1698082  Size: SH
  85. For 1500 series vehicles, remove the oil pan skid plate bolts and plate, if equipped.

  86. Object Number: 1698083  Size: SH
  87. For 2500 series vehicles, remove the oil pan skid plate bolts and plate, if equipped.

  88. Object Number: 1658109  Size: SH
  89. Place a suitable drain pan under the oil pan drain plug.
  90. Remove the oil pan drain plug (430).
  91. Allow the oil to drain completely.
  92. Caution: Refer to Fastener Caution in the Preface section.

  93. Reinstall and tighten the oil pan drain plug.
  94. Tighten
    Tighten the drain plug to 25 N·m (18 lb ft).

  95. Remove the catalytic converter. Refer to one of the following procedures:
  96. •  Catalytic Converter Replacement for 1500 series
    •  Catalytic Converter Replacement - Left Side for the 2500 series
    •  Exhaust Manifold Pipe Replacement for the 2500 series

    Object Number: 1701022  Size: SH
  97. Remove the flywheel to torque converter bolts.

  98. Object Number: 1701047  Size: SH
  99. Remove the fuel/evaporative emission (EVAP) pipe bracket nut from the transmission stud (typical installation shown).
  100. Remove the fuel/EVAP pipe bracket from the stud. Reposition the bracket out of the way.

  101. Object Number: 1701049  Size: SH
  102. For the 4L80-E automatic transmission, remove the transfer case vent hose bracket (1) nut from the stud, if equipped.
  103. For the 4L60-E/4L70-E/6L80-E automatic transmission, remove the transfer case vent hose bracket (2) nut from the stud, if equipped.
  104. Reposition the transfer case vent hose bracket and hose out of the way, if equipped.

  105. Object Number: 1701038  Size: SH
  106. If equipped with the 4L60-E/4L70-E automatic transmission, remove the transmission bolts/studs.

  107. Object Number: 1701039  Size: SH
  108. If equipped with the 4L80-E automatic transmission, remove the transmission bolts/studs.

  109. Object Number: 1701040  Size: SH
  110. If equipped with the 6L80-E automatic transmission, remove the transmission bolts/studs.
  111. Lower the vehicle.
  112. Position and install an engine hoist to the J 41798 .
  113. Install a floor jack under the transmission for support.
  114. Remove the engine from the vehicle.
  115. Install the J 21366 to the transmission in order to hold the torque converter.
  116. Position and install the engine onto an engine stand.
  117. Remove the engine hoist. from the J 41798 .

  118. Object Number: 309151  Size: SH
  119. Remove the J 41798 from the engine.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 309151  Size: SH
  1. Install the J 41798 to the engine.
  2. Tighten

        • Tighten the M8 engine lift bracket bolts to 25 N·m (18 lb ft).
        • Tighten the M10 engine lift bracket bolts to 50 N·m (37 lb ft).
  3. Position and install the engine hoist to the J 41798 .
  4. Remove the engine from the engine stand.
  5. Remove the J 21366 from the transmission.
  6. Install the engine to the vehicle.
  7. Align and install the engine to the transmission. Raise or lower the transmission as required using the floor jack.
  8. Once aligned and mated together completely lower and remove the engine hoist.

  9. Object Number: 1701018  Size: SH
  10. For 2500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to engine mount bracket bolts (1).
  11. Tighten
    Tighten the bolts to 65 N·m (48 lb ft) starting with the middle bolt then either side bolt.


    Object Number: 1701017  Size: SH
  12. For 1500 series vehicles with a 5.3L, 6.0L, or 6.2L engine, install the left and right engine mount to frame bolts (1).
  13. Tighten
    Tighten the bolts to 65 N·m (48 lb ft) starting with the middle bolt then either side bolt.


    Object Number: 1701016  Size: SH
  14. For 1500 series vehicles with a 4.8L engine, install the left and right engine mount to frame bolts (1).
  15. Tighten
    Tighten the bolts to 65 N·m (48 lb ft) starting with the middle bolt then either side bolt.

  16. Remove the floor jack from under the transmission.
  17. Raise the vehicle.

  18. Object Number: 1701040  Size: SH
  19. If equipped with the 6L80-E automatic transmission, install the transmission bolts/studs.
  20. Tighten
    Tighten the bolts/studs to 50 N·m (37 lb ft).


    Object Number: 1701039  Size: SH
  21. If equipped with the 4L80-E automatic transmission, install the transmission bolts/studs.
  22. Tighten
    Tighten the bolts/studs to 50 N·m (37 lb ft).


    Object Number: 1701038  Size: SH
  23. If equipped with the 4L60-E/4L70-E automatic transmission, install the transmission bolts/studs.
  24. Tighten
    Tighten the bolts/studs to 50 N·m (37 lb ft).


    Object Number: 1701049  Size: SH
  25. Position the transfer case vent hose bracket and hose and install the bracket to the stud, if equipped.
  26. For the 4L60-E/4L70-E/6L80-E automatic transmission, install the transfer case vent hose bracket (2) nut to the stud, if equipped.
  27. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  28. For the 4L80-E automatic transmission, install the transfer case vent hose bracket (1) nut to the stud, if equipped.
  29. Tighten
    Tighten the nut to 20 N·m (15 lb ft).


    Object Number: 1701047  Size: SH
  30. Position the fuel/EVAP pipe bracket and install the bracket to the stud. (typical installation shown).
  31. Install the fuel/EVAP pipe bracket nut to the transmission stud
  32. Tighten
    Tighten the nut to 20 N·m (15 lb ft).


    Object Number: 1701022  Size: SH
  33. Align the torque converter bolt holes to the flywheel bolt holes.
  34. Install the flywheel to torque converter bolts.
  35. Tighten

        • For the 4L60-E/4L70-E/6L80-E automatic transmission, tighten the bolts to 63 N·m (47 lb ft).
        • For the 4L80-E automatic transmission, tighten the bolts to 60 N·m (44 lb ft).
  36. Install the catalytic converter. Refer to one of the following procedures:
  37. •  Catalytic Converter Replacement for 1500 series
    •  Catalytic Converter Replacement - Left Side for the 2500 series
    •  Exhaust Manifold Pipe Replacement for the 2500 series
  38. Lower the vehicle.

  39. Object Number: 309151  Size: SH
  40. Remove the J 41798 from the cylinder heads.
  41. Install the ignition coil(s) and spark plug wire(s), as required. Refer to Ignition Coil Replacement.

  42. Object Number: 396798  Size: SH
  43. Install the transmission oil level indicator tube.

  44. Object Number: 1701027  Size: SH
  45. Install the transmission oil level indicator tube nut (1).
  46. Tighten
    Tighten the nut to 18 N·m (13 lb ft).


    Object Number: 310813  Size: SH
  47. Position the generator bracket (with power steering pump) to the engine.
  48. Install the generator bracket bolts.
  49. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 1699607  Size: SH
  50. Install the rear power steering pump-to-engine block bolt (1500 series shown, 2500 series similar).
  51. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).

  52. Raise the vehicle.

  53. Object Number: 1699547  Size: SH
  54. Connect the coolant heater cord to the coolant heater, if equipped.

  55. Object Number: 1698087  Size: SH
  56. Connect the engine harness electrical connector (1) to the CKP sensor.
  57. Connect the engine harness electrical connector (2) to the knock sensor.
  58. Connect the engine harness electrical connector (4) to the oil level sensor.
  59. Install the engine harness clip (3) to the transmission oil cooler line bracket.
  60. Install the starter motor. Refer to Starter Motor Replacement.

  61. Object Number: 1699539  Size: SH
  62. Connect the engine harness electrical connector (1) to the A/C refrigerant pressure sensor.

  63. Object Number: 1697734  Size: SH
  64. Slide the channel pin (3) into the oil pan tab.
  65. Install the battery cable channel bolt (2).
  66. Tighten
    Tighten the bolt to 12 N·m (106 lb in).

  67. Connect the engine harness electrical connector (1) to the CMP sensor wire harness.

  68. Object Number: 1698074  Size: SH
  69. Position the transmission oil cooler line clip to the oil pan and install the bolt, if equipped.
  70. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 1699536  Size: SH
  71. Connect the engine harness electrical connector (4) to the knock sensor.
  72. Position the engine harness grounds (3) to the engine block.
  73. Install the engine harness ground stud (2) to the engine block.
  74. Tighten
    Tighten the stud to 16 N·m (12 lb ft).

  75. Install the engine harness clip (1) to the ground stud.
  76. Lower the vehicle.

  77. Object Number: 1699543  Size: SH
  78. Position the negative battery cable terminal (2) and the engine harness ground (3) to the right cylinder head.
  79. Install the negative battery cable stud (1) to the right cylinder head.
  80. Tighten
    Tighten the stud to 25 N·m (18 lb ft).


    Object Number: 1699550  Size: SH
  81. Position the engine ground strap to the cylinder head and cowl.
  82. Install the engine ground strap bolt to the rear of the left cylinder head and cowl.
  83. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).


    Object Number: 1697098  Size: SH
  84. Connect the engine harness electrical connector (1) to the oil pressure sensor.
  85. Connect the engine harness electrical connector (2) to the lifter oil manifold.
  86. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.

  87. Object Number: 1699336  Size: SH
  88. Install the radiator outlet hose to the water pump.
  89. Position the radiator outlet hose clamp at the water pump.

  90. Object Number: 1696566  Size: SH
  91. Install the radiator inlet hose to the water pump.
  92. Position the radiator inlet hose clamp (3) at the water pump.

  93. Object Number: 1699347  Size: SH
  94. Position and install the radiator vent inlet hose (2) to the air bleed pipe.
  95. Position the radiator vent inlet hose clamp (1) at the air bleed pipe.
  96. Install the radiator vent inlet hose (2) to the radiator inlet hose clip (3).
  97. Position the generator battery jumper to the engine.
  98. Install the intake manifold. Refer to Intake Manifold Replacement.

  99. Object Number: 1698083  Size: SH
  100. For 2500 series vehicles, install the oil pan skid plate and bolts, if equipped.
  101. Tighten
    Tighten the bolts to 28 N·m (21 lb ft).


    Object Number: 1698082  Size: SH
  102. For 1500 series vehicles, install the oil pan skid plate and bolts, if equipped.
  103. Tighten
    Tighten the bolts to 28 N·m (21 lb ft).


    Object Number: 1696602  Size: SH
  104. Install the engine shield and bolts.
  105. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  106. Lower the vehicle.
  107. Install the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement.
  108. Install the hood latch. Refer to Hood Primary and Secondary Latch Replacement.

  109. Object Number: 1711844  Size: SH

    Note: There is a positive stop which limits the hood from being opened too far.

  110. With the aid of the assistant raise the hood slightly until the hood hinge bolts can be removed from the service position notch (1).

  111. Object Number: 1711842  Size: SH
  112. With the aid of an assistant lower the hood and install the hood hinge bolts (3) to the hood hinges.
  113. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  114. Install the hood strut rod (1) to the hood strut bracket stud.
  115. Install the air inlet grille end caps (2), push down the end cap in order to engage the retainers. (left side shown, right side similar).

  116. Object Number: 1823089  Size: SH
  117. Install the ground strap to the hood stud.
  118. Install the ground strap nut at the hood stud.
  119. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  120. Prelube the engine. Refer to Engine Prelubing.
  121. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
  122. Note: 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 any 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 gauge or light and confirm that the engine has acceptable oil pressure.
    • Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
    • Listen for sticking lifters or other unusual noises.
    • Inspect for fuel, oil and/or coolant leaks while the engine is running.
    • Perform a final inspection for the proper oil and coolant levels.
  123. Close the hood.