For 1990-2009 cars

#### Tool Required

J 36854 Heavy Duty Automotive Engine Stand

### Removal Procedure

1. 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.

2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the front skid plate from the vehicle (if equipped).
6. Drain the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
7. Drain the engine oil.
8. Remove the flywheel inspection cover (1).
9. Remove the 2 bolts and separate the front pipe assembly from the exhaust manifold on vehicles without the three way warm up (TWC) catalytic converter.
10. Lower the vehicle.
11. Remove the hood from the vehicle. Refer to Hood Replacement in Body Front End.
12. Remove the upper radiator hose (2) from the vehicle.
13. Remove the lower radiator hose (1) from the vehicle.
14. Remove the radiator overflow hose from the radiator.
15. Remove the 4 radiator shroud clips.
16. Remove 1 bolt from each side of the radiator upper support.
17. Lean the fan shroud toward the engine and lift the radiator up and out of the vehicle.
18. Remove the four fan mounting nuts (1). Use a second wrench to hold the fan shaft.
19. Remove the fan and the fan shroud.
20. If equipped with A/C, remove the A/C compressor upper brace.
21. Remove the A/C and power steering bracket bolts (1).
22. Remove the A/C and power steering bracket as an assembly and position aside.
23. Remove the bolt and the throttle cable bracket (1) from the intake manifold.
24. Remove the cable from the throttle body bellcrank (3) and position aside.
25. Remove the intake air tube.
26. Remove the heater hoses (3) from the heater core. Mark the location of the inlet and outlet hoses for correct installation.
27. Disconnect the fuel feed hose (1) and the fuel return hose (2).
28. Disconnect the following electrical connectors:

• | The 2 ignition coil connectors.

• | The fuel injector wiring harness main connector.

• | The throttle position sensor (TPS) connector.

• | The manifold absolute pressure (MAP) sensor connector.

• | The idle air control (IAC) valve connector.

• | The ground wires from the intake manifold

• | The exhaust gas recirculation (EGR) valve (1).

• | The engine coolant temperature (ECT) sensor connector.

• | The EVAP canister purge valve connector.

• | The heated oxygen sensor 1 (HO2S1).

• | The power steering pressure (PSP) switch wire.

• | The generator wires.

• | The oil pressure switch wire.

• | The intake air temperature (IAT) sensor connector.

• | The mass air flow (MAF) sensor connector.

• | The camshaft position sensor (CMP) connector.

• | Disconnect the crankshaft position sensor (CKP) connector.

29. Remove the wiring harness from the retaining clamps.
30. Remove the brake booster vacuum line from the intake manifold.
31. Disconnect the starter solenoid wires (2) and position them aside.
32. Remove the 2 bolts (1) and the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
33. Remove the transmission to engine bolts.
34. Remove the 2 nuts from the top side of the engine mounts.
35. Install an engine hoist to the engine.

Important: Before lifting the engine, ensure that all of the hoses, pipes, electrical wires and cables are disconnected from the engine and positioned aside.

36. Remove the engine assembly from the vehicle by sliding the assembly toward the front side of the engine compartment. Carefully lift the engine assembly from the vehicle verifying clearance on all sides.
37. Remove the pressure plate assembly and the clutch disc on manual transmission equipped vehicles. Refer to Clutch Assembly Replacement in Clutch.
38. Mark the flywheel-to-engine position.
39. Remove the 6 bolts and the flywheel from the crankshaft.
40. Place the engine assembly onto the J 36854 .
41. Disconnect the engine hoist.

### 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. Align the flywheel-to-engine marks and install the flywheel
4. Apply GM P/N 12345493 (Canadian P/N 10953488), or the equivalent, to the flywheel retaining bolt threads.

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.

5. Install the flywheel retaining bolts (1) to the crankshaft. Use the J 35271 to lock the flywheel.

Tighten
Cross tighten the 6 flywheel retaining bolts to 78 N·m (58 lb ft).

6. Install the clutch disc and pressure plate assembly. Refer to Clutch Assembly Replacement in Clutch.
7. Install the engine assembly. Lower the engine into the front of the engine compartment while ensuring clearance on all sides, slide the assembly toward the rear.
8. Install the engine mount nuts.

Tighten
Tighten engine mount nuts to 50 N·m (37 lb ft).

9. Remove the engine hoist.
10. Install the transmission to engine bolts.

Tighten
Tighten the bolts to 85 N·m (62 lb ft).

11. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
12. Connect the starter solenoid wires (2).
13. Install the flywheel inspection cover (1).

Tighten
Tighten the flywheel inspection cover bolts to 10 N·m (89 lb in).

14. Connect the front pipe assembly to the exhaust manifold (vehicles without PUP converter).

Tighten
Tighten the 2 bolts to 50 N·m (37 lb ft).

15. Connect the front pipe assembly to the exhaust manifold (vehicles with the PUP converter).

Tighten
Tighten the 3 nuts to 50 N·m (37 lb ft).

16. Install the engine block-to-catalytic converter support bracket (vehicles with the PUP converter).

Tighten
Tighten the 3 nuts to 50 N·m (37 lb ft).

17. Install the heater hoses (1) to the heater core.
18. Connect the fuel feed and the fuel return hoses (1,2).
19. Position the harness in the vehicle and connect the wiring harness to the retaining clamps.
20. Connect the following components:

• | The manifold absolute pressure (MAP) sensor (1) connector.

• | The ground wires to the intake manifold (2).

• | The exhaust gas recirculation (EGR) valve (4).

• | The brake booster vacuum line (3).

21. Connect the following components:

• | The 2 ignition coil connectors

• | The fuel injector wiring harness connector

• | The throttle position sensor (TP) (4) connector

• | The idle air control (IAC) valve (3) connector

• | The engine coolant temperature (ECT) sensor (2) connector

• | The EVAP canister purge valve connector

• | The heated oxygen sensor 1 (HO2S1)

• | The power steering pressure (PSP) switch wire

• | The generator wires

• | The oil pressure switch wire

• | The intake air temperature (IAT) sensor connector

• | The mass air flow (MAF) sensor connector

• | The camshaft position sensor (CMP) connector

• | Connect the crankshaft position sensor (CKP) connector.

22. Connect the main engine harness electrical connectors at the bulkhead.
23. Install the wiring harness to the retaining clamps.
24. Install the intake air pipe.
25. Install the accelerator cable (3) to the throttle body bellcrank.
26. Install the accelerator cable bracket (1) to the intake manifold.

Tighten
Tighten the accelerator cable bracket bolt to 10 N·m (89 lb in).

27. Install the power steering pressure and return lines to the power steering pump.
28. Position the A/C and power steering bracket in place.
29. Install the A/C and power steering bracket bolts (1).
30. Install the A/C compressor upper brace.

Tighten
Tighten the bolts to 23 N·m (17 lb ft).

31. Install the fan and the fan shroud to the vehicle.
32. Install the four fan mounting nuts (1). Use a second wrench to hold the fan shaft.

Tighten
Tighten the nuts to 11 N·m (97 lb in).

33. Lean the fan shroud toward the engine and install the radiator.
34. Install 1 bolt to each side of the radiator upper support.
35. Align the shroud to the radiator and install the shroud clips.
36. Install the radiator overflow hose to the radiator.
37. Install the upper radiator hose (2) to the vehicle.
38. Install the lower radiator hose (1) to the vehicle.
39. Install the front skid plate, if equipped. Secure the front skid plate with four bolts.

Tighten
Tighten the front skid plate bolts to 55 N·m (40 lb ft).

40. Install the engine oil drain plug with a new gasket.

Tighten
Tighten the engine oil drain plug to 35 N·m (26 lb ft).

41. Fill the crankcase with oil.
42. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
43. Install the hood to the vehicle. Refer to Hood Replacement in Body Front End.
44. Connect the positive battery cable.

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

45. Connect the negative battery cable.

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

46. Run the engine and inspect for the following:

• | Engine oil leaks

• | Engine exhaust leaks

• | Transmission fluid leaks

• | Engine coolant leaks

• | Fuel leaks