For 1990-2009 cars

#### Tools Required

• | J 36854 Heavy Duty Automotive Engine Stand

• | J 36660-A Torque Angle Meter

### Removal Procedure

1. Remove the engine cover (1).
2. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.

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.

3. Disconnect the negative battery cable.
4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
5. Drain the engine oil.
6. Remove the washer hose at the hood.
7. Remove the hood. Refer to Hood Replacement in Body and Front End.
8. Disconnect the electrical connectors at the four coils (1, 2, 3, 4).
9. Remove the serpentine drive belt. Refer to Drive Belt Replacement .
10. If vehicle is equipped with A/C, discharge and remove the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation, and Air Conditioning.
11. If vehicle is equipped with a manual transmission, remove the following components:

• | The crankshaft pulley--Refer to Crankshaft Pulley Replacement .

• | The generator--Refer to Generator Replacement in Engine Electrical.

• | The drive belt tensioner--Refer to Drive Belt Tensioner Replacement .

12. Remove the accelerator cable from the throttle body (1).
13. Remove the accelerator cable from the accelerator cable bracket.
14. For vehicles equipped with automatic transmission, remove the following components:

• | The transmission TV cable from the throttle body

• | The transmission TV cable from the accelerator cable bracket

15. Disconnect the intake air temperature (IAT) sensor.
16. Remove the air cleaner hose and cap assembly.
17. Disconnect the two wire harness retaining clips from the air cleaner lower case.
18. Remove the following items from the air cleaner case:

• | The one bolt

• | The vacuum switching valve (VSV) bracket

19. Remove the air filter (1).
20. Remove the following items:

• | The three bolts

• | The air cleaner lower box (3)

21. Remove the upper radiator hose.
22. Remove the washer fluid tank mounting bolt.
23. Position the washer fluid tank aside.
24. Disconnect the washer pump connector.
25. Disconnect the washer pump fluid line.
26. Cap the washer pump fluid output in order to prevent the washer fluid from escaping.
27. Remove the upper generator mounting bolt.
28. Remove the following items at the engine mount bracket:

• | The one bolt

• | The ground wire

29. Disconnect all the necessary hoses in order to remove the engine.
30. Disconnect all the necessary electrical connections in order to remove the engine.
31. Disconnect the oxygen sensor connector.
32. Remove the following items:

• | The two oxygen sensor nuts

• | The oxygen sensor

• | The oxygen sensor gasket

33. Remove the following items:

• | The wiring harness bracket bolts

• | The wiring harness brackets

34. Unroute the engine harness.
35. Set the engine harness aside.
36. Remove the lower radiator hose from the thermostat housing.
37. Remove the upper starter bolt.
38. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
39. Remove the following items from the right side of the vehicle:

• | The lower engine splash shield bolts

• | The splash shield

• | The right side drive axle--Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

40. Remove the following items from the left side of the vehicle:

• | The lower engine splash shield bolts

• | The splash shield

41. Disconnect the starter motor electrical connectors.
42. Remove the following items:

• | The starter bolts (1, 2)

• | The starter

43. Remove inspection cover.
44. If the vehicle is equipped with an automatic transmission, remove the six torque converter bolts.
45. Remove the following items from the power steering pump:

• | The power steering pump through bolts (1)

• | The power steering pump nuts

46. Remove the power steering pump.
47. Position the power steering pump aside.
48. Remove oxygen sensor.
49. Remove the following items from the front exhaust pipe to the manifold:

• | The two bolts (1, 2)

• | The springs

50. Remove the following items from the axle shaft boot heat shield:

• | The one nut

• | The two bolts

51. Remove the axle shaft heat shield.
52. Remove the four lower transmission to engine mounting bracket bolts.
53. Lower the vehicle.
54. Install the engine support fixture. Refer to Engine Support Fixture .
55. Remove the two upper transmission to engine mounting bolts.
56. Remove the following items from the right side engine mount:

• | The two nuts (3)

• | The four bolts (1)

57. Remove the right side engine mount.
58. Remove the following items from the vehicle:

• | The three right side engine mount bolts

• | The bracket

59. Verify that all wires and hoses are disconnected.
60. Verify that all wires and hoses are positioned aside.
61. Remove the engine assembly from the vehicle.
62. If equipped with a manual transmission, remove the clutch and pressure plate.
63. Remove the eight flywheel retaining bolts.
64. Remove the flywheel from the crankshaft.
65. Place the engine assembly onto the J 36854 .

### Installation Procedure

1. Install the engine hoist.
2. Remove the engine assembly from the J 36854 .

Notice: Apply the proper amount of the sealant to the fastener when assembling this component. Excessive use of the sealant can prohibit the component from being assembled properly or allow the fastener to loosen. A component or fastener that is not assembled properly can loosen or fall off leading to extensive engine damage.

3. Apply GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads (1).

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.

4. For vehicles equipped with an Automatic Transmission, install the flywheel retaining bolts (1-8) to the crankshaft.

Tighten
Tighten the eight flywheel retaining bolts in sequence for Automatic Transmission to 83 N·m (61 lb ft).

5. For vehicles equipped with a Manual Transmission, install the flywheel retaining bolts to the crankshaft.

Tighten
Tighten the eight flywheel retaining bolts in sequence for Manual Transmission to 49 N·m (36 lb ft). After the proper torque has been reached, use a J 36660-A and tighten the flywheel bolts an additional 90 degrees.

6. For vehicles equipped with manual transmission, install the following items. Refer to Clutch Assembly Replacement in Clutch:

• | The pressure plate assembly

• | The clutch disc

7. Install the engine assembly. Lower the engine into the engine compartment while ensuring clearance on all sides.
8. Install the two upper transmission to engine mounting bolts.
9. Install the four lower transmission to engine mounting bolts.

Tighten
Tighten the transmission to engine mounting bolts to 64 N·m (47 lb ft).

10. Install the right side engine mounting bracket.

Tighten
Tighten the engine mounting bracket bolts to 54 N·m (40 lb ft).

11. Use the three engine mounting bracket bolts in order to secure the right side engine mounting bracket.

Tighten
Tighten right-side engine mount-to-engine bracket bolts to 54 N·m (40 lb ft).

12. Install the right side engine mount.
13. Use the two nuts (3) and the four bolts (1, 2, 4, 5) in order to secure the right side mounting insulator.

Tighten
Tighten the right side engine mount bolts and nuts to 54 N·m (40 lb ft).

14. Remove the engine hoist.

Notice: Apply the proper amount of the sealant to the fastener when assembling this component. Excessive use of the sealant can prohibit the component from being assembled properly or allow the fastener to loosen. A component or fastener that is not assembled properly can loosen or fall off leading to extensive engine damage.

15. Raise and support the vehicle.
16. Install the four lower transmission to engine mounting bolts.

Tighten
Tighten the four lower transmission to engine mounting bolts to 67 N·m (49 lb ft).

17. Install the axle shaft heat shield.
18. Use the one nut and two bolts in order to secure the axle shaft heat shield.

Tighten

• | Tighten the axle shaft heat shield nut to 18 N·m (13 lb ft).

• | Tighten the axle shaft heat shield bolts to 18 N·m (13 lb ft).

19. Install the right side drive axle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
20. Install the exhaust pipe to the exhaust manifold.
21. Use the two bolts and the springs (1, 2) in order to secure the exhaust pipe to the exhaust manifold.

Tighten
Tighten the exhaust pipe flange bolts to 62 N·m (46 lb ft).

22. Position the power steering pump at the mounting location.
23. Use the two bolts (1) and the nuts in order to secure the power steering pump.

Tighten
Tighten the power steering pump mounting bolts to 37 N·m (27 lb ft).

24. If the vehicle is equipped with an automatic transmission, install the six torque converter bolts.

Tighten
Tighten the six torque converter bolts to 35 N·m (26 lb ft).

25. Install the starter.
26. Use the starter bolts (1, 2) in order to secure the starter.

Tighten
Tighten the starter bolts to 30 N·m (22 lb ft).

27. Connect the starter motor electrical connections.
28. Install the left side lower engine splash shield.
29. Use the six bolts in order to secure the left side lower engine splash shield.

Tighten
Tighten the left side engine splash shield bolts to 10 N·m (89 lb in).

30. Install the right side lower engine splash shield.
31. Use the six bolts in order to secure the right side lower engine splash shield.

Tighten
Tighten the right side engine splash shield bolts to 10 N·m (89 lb in).

32. Lower the vehicle.
33. Install the upper starter bolt.

Tighten
Tighten the upper starter bolt to 30 N·m (22 lb ft).

34. Install the lower radiator hose to the thermostat housing.
35. Reroute the engine harness. Reposition the engine harness as necessary.
36. Install the engine wiring harness brackets.
37. Use the engine wiring harness bracket bolts in order to secure the engine wiring harness.
38. Install the following items:

• | The oxygen sensor

• | The oxygen sensor gasket

39. Use the two oxygen sensor nuts in order to secure the oxygen sensor.

Tighten
Tighten the oxygen sensor nuts to 44 N·m (32 lb ft).

40. Connect the oxygen sensor connector.
41. Connect all necessary electrical connectors.
42. Connect all necessary hoses.
43. Install the ground wire to the engine mount bracket.
44. Use the one ground wire bolt in order to secure the ground wire to the engine mount bracket.

Tighten
Tighten the one ground wire bolt to 15 N·m (11 lb ft).

45. Install the upper generator mounting bolt.

Tighten
Tighten the upper generator mounting bolt to 23 N·m (17 lb ft).

46. Remove the cap from the washer pump outlet.
47. Connect the washer pump fluid line to the washer fluid tank.
48. Connect the washer pump electrical connector.
49. Install the washer fluid tank.
50. Use the one washer fluid tank bolt in order to secure the washer fluid tank.

Tighten
Tighten the washer fluid reservoir mounting bolt to 10 N·m (89 lb in).

51. Install the upper radiator hose.
52. Install the air cleaner lower box.
53. Use the three air cleaner lower box bolts in order to secure the air cleaner lower box.
54. Install the air filter.
55. Install the vacuum switching valve (VSV) bracket to the air cleaner case.
56. Use the one VSV bracket bolt in order to secure the VSV bracket.
57. Connect the two wiring harness retainer clips to the air cleaner lower case.
58. Install the air cleaner hose and cap assembly (1).
59. Connect the intake air temperature (IAT) sensor.
60. For vehicles equipped with automatic transmission, install the following components:

• | The transmission TV cable to the accelerator cable bracket

• | The transmission TV cable to the throttle body

61. Install the accelerator cable to the accelerator cable bracket.
62. Install the accelerator cable to the throttle body (1).
63. Install the serpentine drive belt. Refer to Drive Belt Replacement .
64. If vehicle is equipped with A/C, install the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
65. If vehicle is equipped with a manual transmission, install the following components:

• | Crankshaft pulley--Refer to Crankshaft Pulley Replacement

• | Generator--Refer to Generator Replacement in Engine Electrical

• | Drive belt tensioner. Refer to Drive Belt Tensioner Replacement

66. Install the four ignition coils (1, 2, 3, 4).
67. Install the engine cover (1).
68. Install the hood. Refer to Hood Replacement in Body and Accessories.
69. Connect the windshield washer hose at the hood.
70. Fill the engine oil.
71. Fill the cooling system.

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.

72. Connect the negative battery cable to the battery.

Tighten
Tighten the battery cable bolt to 15 N·m (11 lb ft).