Installation Procedure

Important 

The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details.

1. Prepare the engine for installation. Refer to ENGINE PRELUBING  and ENGINE BALANCING  .
2. Install the engine mount brackets to the engine block.
   NOTE: Refer to FASTENER NOTICE .
3. Install the engine mount bracket bolts.

   Tighten 

   Tighten the engine mount bracket bolts to 50 N.m (37 lb ft).

4. Install the J 41798  to the engine.
   Fig 1: Installing Flywheel Housing To Engine Block

   Courtesy of GENERAL MOTORS CORP.
5. Using a engine hoist and the J 41798  raise the engine slightly.
6. Remove the engine from the engine stand.
7. Install the flywheel housing to the engine block.
8. Install the flywheel housing bolts.

   Tighten 

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

9. Using a engine hoist and the J 41798  lower the engine onto the crossmember.
10. Install the engine mount nuts.
    Fig 2: Installing Engine Mount Nuts

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the engine mount nuts to 65 N.m (48 lb ft).

11. Install the spark plugs. Refer to SPARK PLUGS .
12. Remove the J 41798  from the engine.
13. Clean the exhaust manifold AIR pipe gasket flange, if necessary.
14. Install a NEW AIR pipe gasket and the pipe.
    Fig 3: Installing AIR Pipe Gasket And Pipe

    Courtesy of GENERAL MOTORS CORP.
15. Install the AIR pipe bolts.

    Tighten 

    Tighten the AIR pipe bolts to 20 N.m (15 lb ft).

16. Install the A/C compressor bracket. Refer to COMPRESSOR MOUNTING BRACKET REPLACEMENT in Heating, Ventilation, and Air Conditioning.
17. Install the generator bracket and power steering pump bracket.
    Fig 4: Installing Generator Bracket And Power Steering Pump Bracket

    Courtesy of GENERAL MOTORS CORP.
18. Install the generator bracket bolts until snug.
19. Tighten the generator bracket bolts in the following order:
    1. 19.1. Inner power steering pump reservoir bracket bolt
    2. 19.2. Upper generator bracket bolt
    3. 19.3. Outer power steering pump reservoir bracket bolt
    4. 19.4. Lower generator bracket bolt

       Tighten 

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

20. Install the power steering pump (with reservoir) to the generator bracket.
    Fig 5: Installing Power Steering Pump

    Courtesy of GENERAL MOTORS CORP.
21. Install the power steering pump brace.
22. Install the power steering pump bolts.

    Tighten 

    Tighten the power steering pump bolts to 25 N.m (18 lb ft).

23. Using the J 25033-C  install the power steering pump pulley.
    Fig 6: Installing Power Steering Pump Pulley

    Courtesy of GENERAL MOTORS CORP.
24. Install the power steering pump pulley hub cap, if necessary.
25. Roll the engine and crossmember underneath the vehicle.
26. Partially lower the vehicle onto the engine and crossmember.
27. Install the ground strap (6) and ground strap bolt (5) to the rear of the left cylinder head.

    Tighten 

    Tighten the ground strap bolt (5) to 32 N.m (24 lb ft).

28. Route the electrical harness and connect the following electrical connectors at the rear of the engine:
    • The knock sensor wire harness (1)
    • The engine oil pressure sensor (2)
    • The MAP sensor (3)
    • The CMP sensor (4)
    Fig 7: Connecting Electrical Connectors At Rear Of Engine

    Courtesy of GENERAL MOTORS CORP.
29. Connect the vacuum hose to the MAP sensor.
30. Clean the exhaust manifold AIR gasket flange, if necessary.
31. Install a NEW AIR pipe gasket and the pipe (with check valve) to the right exhaust manifold.
32. Install the AIR pipe bolts until snug.
    Fig 8: Installing AIR Pipe Gasket And Pipe

    Courtesy of GENERAL MOTORS CORP.
33. Install the AIR pipe bracket bolt (at the rear of the cylinder head).
    Fig 9: Installing AIR Pipe Bracket Bolt (At Rear Of Cylinder Head)

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the AIR pipe bolts to 20 N.m (15 lb ft).

34. Vehicles equipped with a manual transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
35. Position the engine to the proper height and angle in order to install the propeller input shaft.
36. Insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle, Do Not Force. Rotate the shaft slightly to bring the 2 splines into alignment, if necessary.
    Fig 10: Installing Propeller Input Shaft

    Courtesy of GENERAL MOTORS CORP.
37. Slowly seat the flywheel housing to the driveline.
38. Install the driveline support bolts.

    Tighten 

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

39. Clip the clutch actuator hose to the clutch actuator hose clip.
40. Connect the master cylinder hose to the clutch actuator hose.
    Fig 11: Connecting Master Cylinder Hose To Clutch Actuator Hose

    Courtesy of GENERAL MOTORS CORP.

    Important:  Do not tighten the flywheel hub collar bolt at this time.

41. Vehicles equipped with an automatic transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
42. Position the engine to the proper height and angle in order to install the propeller input shaft.
    Fig 12: Installing Propeller Input Shaft

    Courtesy of GENERAL MOTORS CORP.
43. Install the driveline support bolts.

    Tighten 

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

44. Hand tighten the flywheel hub collar bolt.
45. Lower the vehicle onto the crossmember and align the dowels.

    Important:  Use only hand tools when tightening or torquing crossmember nuts.

46. By HAND, install new crossmember nuts until snug.
    Fig 13: Installing Crossmember Nuts

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the crossmember nuts to 110 N.m (81 lb ft).

47. Raise and suitably support the vehicle.
48. Remove the J 39580  and the J 39580-500  .
49. Remove the J 42203  from the vehicle.
50. Route the transmission wire harness into place.
51. Install the transmission wire harness bracket bolts.
    Fig 14: Installing Transmission Wire Harness Bracket Bolts

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the transmission wire harness bracket bolts to 50 N.m (37 lb ft).

52. Vehicles equipped with an automatic transmission, remove the previously installed M10-1.5 x 55 mm bolts from the front of the driveline support.
53. Install 2 plugs in the driveline support.
    Fig 15: Installing Plugs In Driveline Support

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the driveline support plugs to 50 N.m (37 lb ft).

54. Connect the front automatic transmission fluid cooler pipes to the rear pipes, if equipped.
    Fig 16: Installing Automatic Transmission Cooler Pipes

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the automatic transmission fluid cooler pipes to 25 N.m (18 lb ft).

55. Install the automatic transmission cooler pipe clamp bolt (at the transmission cover), if equipped.

    Tighten 

    Tighten the automatic transmission fluid cooler pipe clamp bolt (at the transmission cover) to 2.2 N.m (22 lb in).

56. Install the automatic transmission fluid cooler pipe clamp bolt (at the oil pan), if equipped.
    Fig 17: Installing Automatic Transmission Fluid Cooler Pipe Clamp Bolt (At Oil Pan)

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the automatic transmission fluid cooler pipe clamp bolt (at the oil pan) to 12 N.m (106 lb in).

57. Install the front transverse leaf spring. Refer to FRONT TRANSVERSE SPRING REPLACEMENT in Front Suspension.
58. Install the lower control arm stud to the steering knuckle.
    Fig 18: Installing Lower Control Arm Stud To Steering Knuckle

    Courtesy of GENERAL MOTORS CORP.
59. Install a NEW steering knuckle nut.

    Tighten 

    1. 59.1. Tighten the steering knuckle nut to 20 N.m (15 lb ft) to seat the ball joint stud.
    2. 59.2. Torque the steering knuckle nut an additional 210 degrees using J 36660-A  .
    3. 59.3. Check the steering knuckle nut for a final torque of 55 N.m (41 lb ft).
60. Connect the ABS electrical connector clips to the crossmember (if equipped).
61. Install the front stabilizer shaft. Refer to STABILIZER SHAFT REPLACEMENT in Front Suspension.
62. Clip the transmission wire harness the engine wire harness (at the white tape).
63. Install the transmission wire harness clip bolts to the engine block.
    Fig 19: Installing Transmission Wire Harness Clip Bolts To Engine Block

    Courtesy of GENERAL MOTORS CORP.

    Tighten 

    1. 63.1. Tighten the transmission wire harness clip bolt (near the harness ground) to 32 N.m (23 lb ft)
    2. 63.2. Tighten the transmission wire harness clip bolt (near the oil pan) to 25 N.m (18 lb ft)
64. Install the EVO electrical connector clips to the crossmember.
65. Clip the transmission wire harness to the crossmember.
    Fig 20: Clipping Transmission Wire Harness To Crossmember

    Courtesy of GENERAL MOTORS CORP.
66. If equipped with RTD connect the following electrical connectors:
    • Position sensor pigtail
    • Shock absorber damper
67. Position the ground straps (1 and 2) to the engine block.
    Fig 21: Locating Electrical Connectors

    Courtesy of GENERAL MOTORS CORP.
68. Install the engine ground strap bolt.

    Tighten 

    Tighten the engine wire harness ground bolt to 32 N.m (23 lb ft).

69. Connect the left HO2S electrical connector.
70. Connect the engine oil temperature sensor (3) electrical connector.
71. Install the AC compressor and condenser hose to the A/C compressor.
    Fig 22: Installing AC Compressor And Condenser Hose To A/C Compressor

    Courtesy of GENERAL MOTORS CORP.
72. Install the A/C compressor and condenser hose bolt (at compressor).

    Tighten 

    Tighten the A/C compressor and condenser hose bolt (at compressor) to 27 N.m (20 lb ft).

73. Connect the right front HO2S sensor electrical connector.
74. Connect the oil level sensor (2) electrical connector.
    Fig 23: Connecting Sensor Electrical Connectors

    Courtesy of GENERAL MOTORS CORP.
75. Connect the CKP sensor (1) electrical connector.
76. Install the starter motor. Refer to STARTER MOTOR in Engine Electrical.
77. Install the driveline close-out panel.
    Fig 24: Installing Driveline Close-Out Panel

    Courtesy of GENERAL MOTORS CORP.
78. Install the driveline close-out panel bolts.

    Tighten 

    Tighten the driveline close-out panel bolts to 12 N.m (106 lb in).

79. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
80. Install the front tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
81. Lower the vehicle.
82. Connect the AIR pump hose to the AIR pipe.
    Fig 25: Connecting AIR Pump Hose To Air Pipe

    Courtesy of GENERAL MOTORS CORP.
83. Install the intermediate steering shaft to the steering gear.
84. Install the intermediate steering shaft bolt.

    Tighten 

    Tighten the intermediate steering shaft bolt to 48 N.m (35 lb ft).

    Fig 26: Installing Intermediate Steering Shaft To Steering Gear

    Courtesy of GENERAL MOTORS CORP.
85. Install the power brake booster vacuum hose.
    Fig 27: Installing Power Brake Booster Vacuum Hose

    Courtesy of GENERAL MOTORS CORP.
86. Install the generator. Refer to GENERATOR in Engine Electrical.
87. Connect the following electrical connectors to the engine:
    • The fuel injectors (1)
    • The ignition coil main harness connectors
    • The EVAP solenoid (2)
    • The electric throttle motor (3)
    • The TP sensor
    • The ECT sensor
    • The A/C compressor
    Fig 28: Connecting Electrical Connectors To Engine

    Courtesy of GENERAL MOTORS CORP.
88. Install the heater hoses to the water pump.
    Fig 29: Installing Heater Hoses To Water Pump

    Courtesy of GENERAL MOTORS CORP.
89. Install the radiator hoses to the water pump.
    Fig 30: Installing Radiator Hoses To Water Pump

    Courtesy of GENERAL MOTORS CORP.
90. Install the fuel feed hose. Refer to FUEL LINE DISCONNECT FITTINGS .
91. Connect the EVAP emission canister purge hose at the fuel line.
92. Install the right fuel injection rail cover.
    Fig 31: Installing Right Fuel Injection Rail Cover

    Courtesy of GENERAL MOTORS CORP.
93. Install the accessory drive belt. Refer to DRIVE BELT REPLACEMENT-ACCESSORY  .
94. Install the BPMV bracket. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) BRACKET REPLACEMENT in Antilock Brake System.
95. Install the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
96. Recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
97. Program the transmitters. Refer to TRANSMITTER PROGRAMMING in Keyless Entry.
98. Bleed the clutch hydraulic system, if equipped. Refer to HYDRAULIC CLUTCH BLEEDING in Clutch.
99. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR .
100. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Maintenance.
101. Disable the ignition system.
102. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
103. Enable the ignition system.
104. Start the engine and listen for unusual noises.
105. Check the vehicle oil pressure gauge and confirm that the engine has acceptable oil pressure.

     If necessary, install an oil pressure gauge and measure the engine oil pressure.

106. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
107. Listen for sticking lifters and other unusual noises.
108. Inspect for fuel, oil, and/or other coolant leaks while the engine is running.
109. With automatic transmission vehicles perform the following steps:
     1. 109.1. Shut off the engine.
     2. 109.2. Allow engine to cool to room temperature.
     3. 109.3. Raise the vehicle.
     4. 109.4. Tighten the prop shaft hub collar bolt (1).

        Tighten 

        Tighten the propeller shaft hub collar bolt to 125 N.m (92 lb ft).

     Fig 32: Tightening Propeller Shaft Hub Collar Bolt

     Courtesy of GENERAL MOTORS CORP.
110. Install the engine flywheel housing inspection plug.
     Fig 33: Installing Engine Flywheel Housing Inspection Plug

     Courtesy of GENERAL MOTORS CORP.
111. Perform a final inspection for the proper engine oil and coolant levels.