GM Service Manual Online
For 1990-2009 cars only

Special Tools

    • EN-48613 Engine Assembly Remove/Install Pallet
    • EN-48244 Engine Assembly Remove/Install Pallet Supporter

Removal Procedure


    Object Number: 1863838  Size: SH
  1. Discharge the air conditioning (A/C) system, if equipped.
  2. Drain the power steering oil, if equipped.
  3. Warning: Refer to Battery Disconnect Warning in the Preface section.

  4. Disconnect the negative battery cable.
  5. Remove the engine cover. Refer to Engine Cover Replacement.
  6. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
  7. Drain the engine coolant. Refer to Cooling System Draining and Filling.

  8. Object Number: 1864205  Size: SH
  9. Disconnect the fuel hose from the high pressure pump.
  10. Remove the power steering pipe and hose.
  11. Disconnect the fuel return hose from the junction block.
  12. Remove the pipe and hose retaining bracket from the cylinder head cover.
  13. Disconnect the coolant by-pass hose from the intake manifold.
  14. Disconnect the radiator upper hose from the intake manifold.
  15. Disconnect the radiator lower hose from the engine block.

  16. Object Number: 1864206  Size: SH
  17. Remove the engine wiring harness.
  18. • Disconnect the injector connectors.
    • Disconnect the engine oil pressure switch connector.
    • Disconnect the high pressure pump connector.
    • Disconnect the alternator connector.
    • Disconnect the coolant temperature sensor (CTS) connector.
    • Disconnect the common rail pressure sensor connector.
    • Disconnect the electronic throttle control (ETC) connector.
    • Disconnect the EGR vacuum solenoid connector.
    • Disconnect the A/C compressor connector.
    • Disconnect the camshaft position sensor (CMP) connector.
    • Disconnect the turbocharger actuator connector.
    • Disconnect the glow plug wire connector.
    • Disconnect the booster pressure (T-MAP) sensor connector.
    • Disconnect the common rail regulator connector.
    • Disconnect the starter solenoid wiring connector.
    • Disconnect the crankshaft position sensor.
    • Remove the glow plug fuse box.
    • Remove the generator B+ connector nut.
    • Remove the starter solenoid connector nut.
    • Remove the engine ground bolt.
    • Remove the transaxle ground bolt.

    Object Number: 1801541  Size: SH
  19. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
  20. Remove the right/left drive axle shaft.
  21. Remove the transaxle wiring harness.
  22. Remove the shift control cable from the automatic transaxle.

  23. Object Number: 1822611  Size: SH
  24. Remove the select cable from the transaxle.

  25. Object Number: 1822612  Size: SH
  26. Remove the transaxle oil cooler hoses from the automatic transaxle.

  27. Object Number: 1822616  Size: SH
  28. Remove the clutch actuator cylinder pipe from the transaxle.

  29. Object Number: 1864064  Size: SH
  30. Remove the centermember.

  31. Object Number: 1863818  Size: SH
  32. Remove the front exhaust pipe between the pre-catalyst and the DPF pipe. Refer to Front Pipe Replacement.

  33. Object Number: 1864207  Size: SH
  34. Remove the heater hoses.
  35. Remove the A/C compressor pipe from the compressor.

  36. Object Number: 1864209  Size: SH

    Important: Only lower the vehicle far enough to take the weight off the engine and transaxle mount, or damage to the mount and pallet/pallet support failure may occur.

  37. Lower the vehicle and position the engine assembly onto the engine assembly. Remove/install pallet EN-48613 with the EN-48244 .

  38. Object Number: 1864093  Size: SH
  39. Remove the engine mount.

  40. Object Number: 1864211  Size: SH
  41. Remove the transaxle mount bolt from the transaxle.

  42. Object Number: 1822624  Size: SH
  43. Remove the engine and transaxle.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1864209  Size: SH
  1. Install the transaxle to the engine assembly.
  2. Tighten

        • Tighten the transaxle tightening bolts to 75 N·m (55.3 lb ft).
        • Tighten the oil pan flange-to-transaxle bolts to 50 N·m (36.9 lb ft).
  3. Install engine assembly to the vehicle by using the remove/install pallet EN-48613 with the EN-48244 .

  4. Object Number: 1864211  Size: SH
  5. Install the transaxle mount bolts.
  6. Tighten
    Tighten the transaxle mount bracket retaining bolts (1) to 40 N·m (30 lb ft).


    Object Number: 1864093  Size: SH
  7. Install the engine mount bolt.
  8. Tighten
    Tighten the engine mount bracket retaining bolt to 65 N·m (47.9 lb ft).


    Object Number: 1864206  Size: SH
  9. Remove EN-48613 with the EN-48244 from the vehicle.
  10. Install the engine wiring harness.
  11. • Connect the injector connectors.
    • Connect the engine oil pressure switch connector.
    • Connect the high pressure pump connector.
    • Connect the alternator connector.
    • Connect the coolant temperature sensor (CTS) connector.
    • Connect the common rail pressure sensor connector.
    • Connect the electronic throttle control (ETC) connector.
    • Connect the EGR vacuum solenoid connector.
    • Connect the A/C compressor connector.
    • Connect the camshaft position sensor (CMP) connector.
    • Connect the turbocharger actuator connector.
    • Connect the glow plug wire connector.
    • Connect the booster pressure (T-MAP) sensor connector.
    • Connect the common rail regulator connector.
    • Connect the starter solenoid wiring connector.
    • Connect the crankshaft position sensor.
    • Install the glow plug fuse box.

    Tighten
    Tighten the glow plug fuse box bolts to 10 N·m (88.5 lb in).

    • Install the generator B+ connector nut.

    Tighten
    Tighten the generator B+ connector nut to 25 N·m (18.4 lb ft).

    • Install the starter solenoid connector nut.

    Tighten
    Tighten the starter solenoid connector nut to 15 N·m (11.1 lb ft).

    • Install the engine ground bolt.

    Tighten
    Tighten the engine block ground bolt to 25 N·m (18.4 lb ft).

    • Install the transaxle ground bolt.

    Tighten
    Tighten the transaxle ground bolt to 25 N·m (18.4 lb ft).