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.

Tools Required

J 41427 Engine Lift Bracket

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.
2. Remove the PCV tube from the air cleaner outlet duct .
3. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
4. Drain the engine coolant into a suitable container. Refer to Cooling System Draining and Filling in Engine Cooling.
5. Remove the following coolant hoses. Refer to Radiator Hose Replacement in Engine Cooling:

•	The inlet and outlet radiator hoses to the engine

•	The heater hoses from the engine

6. Remove the upper radiator shroud. Refer to Fan Shroud Replacement in Engine Cooling.



7. 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

•	The A/C clutch switch

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature sensor

•	The ignition control module (ICM)

•	The generator

•	The crankshaft position (CKP) sensor

•	The engine oil pressure gauge sensor

8. Release the engine wiring harness retainers and move the wiring harness aside.



9. Remove the bolt and the battery negative cable at the engine.



10. Remove the bolt holding the ground strap to the left cylinder head.
11. Remove the bolt holding the ground wires to the right cylinder head.
12. Remove the bolt holding the wiring harness retainer to the right cylinder head.




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.
13. Disconnect the accelerator control cable from the throttle shaft. Refer to Accelerator Controls Cable Replacement in Engine Controls.
14. Remove the cruise control cable. Refer to Cruise Control Cable Replacement in Cruise Control.



15. Remove the engine cooling fan. Refer to Fan Replacement in Engine Cooling.
16. Remove the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.
17. Remove the oil fill tube bolt from the air cleaner outlet duct bracket.
18. Remove the oil fill tube from the right valve rocker arm cover.




Important: You do not need to discharge the A/C refrigerant.

19. Remove the air conditioning compressor, if equipped. Set the compressor aside. Refer to Air Conditioning Compressor Replacement in HVAC.



20. Remove the nuts holding the power steering pump rear bracket to the engine.



21. Remove the power steering pump bracket.

The power steering pump can remain on the mounting bracket.

The power steering hoses do not require removal.

21.1.

Remove the 3 bolts and the nut.

21.2.

Slide the mounting bracket off of the stud.

21.3.

Secure the mounting bracket out of the way.

22. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.
23. Disconnect the vacuum brake booster hose from the intake manifold.
24. Disconnect the vacuum hose for the A/C system from the intake manifold.
25. Disconnect the purge solenoid valve harness from the EVAP canister. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.
26. Remove the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.



27. Disconnect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.



28. Remove the inlet pipe clamp bolt from the EGR valve .
29. Remove the EGR valve inlet pipe from the intake manifold and the exhaust manifold.



30. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
31. Remove the flange nuts holding the exhaust pipe to the exhaust manifolds.
32. Remove the oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
33. Remove the transmission oil fill tube. Refer to Transmission Fluid Filler Tube and Seal Replacement in Automatic Transmission.



34. Remove the bolt holding the starter motor wiring harness and the transmission oil cooler lines.



35. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
36. Remove the bolts and the transmission cover.
37. Remove the bolts that retain the torque converter to the flywheel. Refer to Transmission Replacement in Automatic Transmission.
38. Remove both engine mount through-bolts.
39. Remove the brackets and the bolts that retain the transmission to engine. Refer to Transmission Replacement in Automatic Transmission.
40. Lower the vehicle.




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.

41. Install the J 41427 to the left front and right rear of the lower intake manifold.

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

42. Attach an engine lifting device in order to remove the engine from the vehicle.

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.

Tools Required

J 41427 Engine Lift Bracket

1. Install the engine into the vehicle.




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.

2. Install the front engine mount through-bolts and nuts.

Tighten
Tighten the to 101 N·m (74 lb ft).

3. Remove the J 41427 and the lifting device.
4. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower intake manifold bolts.

Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings.

5. 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 second pass to 12 N·m (106 lb in).
3. Tighten the bolts the third pass to 15 N·m (11 lb ft).



6. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.
7. Install the inlet pipe clamp bolt to the EGR valve .

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 to exhaust manifold nut to 25 N·m (18 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N·m (18 lb ft).
8. Install the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
9. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
10. Connect the purge solenoid valve harness to the EVAP canister. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.
11. Connect the vacuum brake booster hose to the intake manifold.
12. Connect the vacuum hose for the A/C system to the intake manifold.
13. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
14. Install the power steering bracket.
15. Install the nuts holding the power steering pump rear bracket to the engine.

Tighten
Tighten the nuts to the engine to 41 N·m (30 lb ft).

16. Install the A/C compressor and the bolts, if equipped.

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

17. Install the oil fill tube to the valve rocker arm cover.
18. Install the oil fill tube bolt to the air cleaner outlet duct bracket.

Tighten
Tighten the oil fill tube bolts to 25 N·m (18 lb ft).

19. Install the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.
20. Install the following coolant hoses:

•	The inlet and outlet radiator hoses to the engine. Refer to Radiator Hose Replacement in Engine Cooling.

•	Connect both heater hoses to the engine. Refer to Heater Hoses Replacement in HVAC.

21. Install the engine cooling fan. Refer to Fan Replacement in Engine Cooling.




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.
22. Install a new accelerator control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls.
23. Install the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.



24. Install the battery negative cable bolt to the engine.

Tighten
Tighten the battery negative cable bolt to 35 N·m (26 lb ft).




25. Install the bolt holding the ground strap to the left cylinder head.

Tighten
Tighten the ground strap bolt to 35 N·m (26 lb ft).




26. Install the bolt holding the ground wires to the rear of the right cylinder head.

Tighten
Tighten the ground wire bolts to 35 N·m (26 lb ft).

27. Install the bolt holding the wiring harness retainer to the rear of the right cylinder head.

Tighten
Tighten the wiring harness retainer bolt to 35 N·m (26 lb ft).




28. Position the engine wiring harness.
29. Install the wiring harness in the retainers.
30. 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

•	The A/C clutch switch

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor

•	The ignition control module (ICM)

•	The generator

•	The crankshaft position (CKP) sensor

•	The engine oil pressure gauge sensor

31. Raise the vehicle.
32. Align and install the brackets and the bolts that retain the transmission to the engine. Refer to Transmission Replacement in Automatic Transmission.
33. Install the bolts that retain the torque converter to the engine flywheel.

Tighten
Tighten the bolts to 75 N·m (55 lb ft).




34. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Pipe Replacement in Engine Exhaust.



35. Install the bolts and the transmission cover.

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

36. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
37. Install the bolt holding the starter motor wire harness and the transmission cooler lines.

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

38. Install the oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
39. Install the transmission oil fill tube. Refer to Transmission Fluid Filler Tube and Seal Replacement in Automatic Transmission.
40. Install a new oil filter. Refer to Engine Oil and Oil Filter Replacement .
41. Lower the vehicle.



42. Install the air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
43. Install the PCV tube to the air cleaner outlet duct.
44. Install the upper radiator shroud. Refer to Fan Shroud Replacement in Engine Cooling.
45. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
46. Fill the engine with oil. Refer to the Owner's Manual for the recommended grade and capacity.
47. Connect the battery negative cable.
48. Operate and test the engine. Refer to Engine Set-Up and Testing .