For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 35271 Flywheel Holder

• | J 36854 Heavy Duty Automotive Engine Stand

1. Discharge and recover the refrigerant if the vehicle is equipped with A/C. Refer to HVAC.
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. Disconnect the positive battery cable.
5. Open the fuel filler cap to relieve pressure in the fuel tank.
6. Install the cap after relieving fuel tank pressure.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
9. Remove the four bolts and the front skid plate from the vehicle (if equipped).
10. Drain the power steering fluid from the reservoir. Refer to Power Steering System in Steering.
11. Disconnect the power steering fluid hoses from the power steering pump. Refer to Power Steering System in Steering.
12. Place a drain pan or suitable container under the engine oil pan.
13. Remove the engine oil drain plug from the engine oil pan. Drain the engine oil.
14. Remove the clutch housing lower plate from manual transmission equipped vehicles. Refer to Manual Transmission.

Remove the torque converter housing lower plate from automatic transmission equipped vehicles. Refer to Automatic Transmission.

15. Remove two bolts and the clutch cable from the clutch release arm and bracket on manual transmission vehicles.
16. Disconnect the automatic transmission fluid hoses from the clamps on automatic transmission equipped vehicles.
17. Remove the clutch lower plate on manual transmission vehicles.
18. Remove the torque converter lower plate on automatic transmission equipped vehicles.
19. Use the J 35271 in order to lock the drive plate. Remove the torque converter bolts on automatic transmission equipped vehicles
20. Remove the two nuts and the front pipe/Three Way Catalytic Converter (TWC) (3) from the exhaust manifold (1).
21. Disconnect the clutch cable from the retaining straps on manual transmission vehicles.
22. Support the transmission. Remove the two bolts separating from the cylinder block. Refer to Automatic Transmission or Manual Transmission.
23. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
24. Remove the engine mount lower nuts and washers.
25. Lower the vehicle.
26. Remove the upper coolant hose from the radiator.
27. Disconnect the A/C lines from the compressor, if equipped. Refer to HVAC.
28. Remove the four bolts securing the shroud to the radiator and four fan clutch mounting nuts.
29. Remove the following together:

• | The shroud

• | The fan clutch

• | The cooling fan

30. Remove the radiator assembly. Refer to Radiator Replacement in Engine Cooling.
31. Disconnect the air intake pipe from the engine Refer to Engine Coolant Inlet Pipe Replacement in Engine Cooling.
32. Disconnect the accelerator cable and the automatic transmission kickdown cable from the throttle body on automatic transmission equipped vehicles.
33. Remove the following from the intake manifold:

• | The PCV valve

• | The EGR valve

• | The EGR temperature sensor

34. Remove the coolant hose from the IAC valve.
35. Remove the IAC air hose from the IAC valve.
36. Disconnect the fuel feed hose at the fuel feed hose union (1).
37. Remove the fuel return hose from the fuel return line.
38. Disconnect the (PCV) hose from the PCV valve.
39. Remove the coolant hose from the thermostat housing.
40. Remove the coolant bypass and the heater inlet hoses from the intake manifold.
41. Remove the lower coolant hose from the radiator.
42. Disconnect the following electrical connectors:

• | Main engine harness electrical connectors at the bulkhead

• | TP sensor

• | IAC valve

• | HO2S1

• | ECT sensor (4)

• | ECT sending unit

• | A/C ECT switch (A/C equipped vehicles) (3)

• | Wiring harness from retaining clamps

• | Injector wiring harness (2)

• | Generator

• | (PSP) switch

• | (EGRT) sensor

• | Exhaust gas recirculation solenoid vacuum valve (1)

• | Exhaust gas recirculation by-pass valve

43. Remove the following vacuum hoses:

• | Vacuum hose at sure tank, 3 way connector

• | EGR pressure transducer

• | EGR valve

• | Brake booster supply hose

• | Vacuum modulator supply hose (automatic equipped vehicles)

• | EVAP canister and hoses

• | MAP sensor hose from the sensor.

44. Remove the distributor from the distributor case. Refer to Distributor Replacement in Engine Electrical.
45. Remove the hood from the vehicle. Refer to Hood Replacement in Body Front End.
46. Install the engine hoist to the engine.
47. Remove the engine mounting bracket-to-frame bolts.

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

48. 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.
49. Remove the pressure plate assembly and the clutch disc on manual transmission equipped vehicles only.
50. Remove the six bolts and the flywheel from the crankshaft.
51. Place the engine assembly onto the J 36854 .
52. 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. Apply GM P/N 12345493, 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.

4. Install the flywheel. Secure the flywheel with six retaining bolts.

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

5. Install the pressure plate assembly and the clutch disc on manual transmission equipped vehicles.
6. 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.
7. Install the engine mounting bracket-to-frame bolts.

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

8. Install the two left-side engine mount-to-engine bolts. Do not tighten fully.

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

9. Remove the engine hoist.
10. Install the hood from the vehicle. Refer to Hood Replacement .
11. Install distributor into the distributor case. Refer to Distributor Replacement in Engine Electrical.
12. Install the following vacuum hoses:

• | EGR pressure transducer

• | EGR valve

• | Brake booster supply hose

• | Vacuum modulator supply hose (automatic equipped vehicles)

• | EVAP canister and hoses

• | (MAP) sensor hose from the sensor

13. Disconnect the following electrical connectors:

• | (TP) sensor

• | IAC valve

• | HO2S1

• | ECT sensor (4)

• | ECT sending unit

• | A/C ECT switch (A/C equipped vehicles) (3)

• | Wiring harness from retaining clamps

• | Injector wiring harness (2)

• | Generator

• | (PSP) switch

• | (EGRT) sensor

• | Exhaust gas recirculation solenoid vacuum valve (1)

• | Exhaust gas recirculation by-pass valve

14. Install the lower coolant hose to the radiator.
15. Secure the hose with a hose clamp.
16. Install the coolant bypass and the heater inlet hoses to the intake manifold.
17. Secure the hose with a hose clamp.
18. Install the coolant hose to the thermostat housing.
19. Install the PCV hose the PCV valve.
20. Install the fuel return hose to the fuel return line.
21. Install the fuel feed hose at the fuel return hose union (1).
22. Install the IAC air hose to the IAC valve.
23. Install the coolant hose to the IAC valve.
24. Install the following to the intake manifold:

• | The positive crankcase ventilation (PCV) valve

• | The EGR valve

• | The EGR temperature sensor

25. Connect the accelerator cable and the automatic transmission kickdown cable on automatic transmission equipped vehicles to the throttle body.
26. Install the air intake pipe to the engine. Refer to Engine Coolant Inlet Pipe Replacement in Engine Cooling.
27. Install the following:

• | The fan clutch

• | The cooling fan

• | The shroud

28. Secure with four fan clutch nuts and four shroud bolts.

Tighten

• | Tighten the fan clutch nuts to 11 N·m (97 lb in).

• | Tighten the shroud bolts to 11 N·m (97 lb in).

29. Install the A/C lines at the compressor if the vehicle is equipped. Refer to HVAC.
30. Install the upper coolant hose to the radiator. Secure the hose with a hose clamp.
31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
32. Install the engine mount lower nuts and washers.

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

33. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
34. Install the transmission to the cylinder block. Refer to Automatic Transmission or Manual Transmission.
35. Connect the clutch cable tot he retaining straps on manual transmission equipped vehicles.
36. Install the front pipe/TWC (3) to the exhaust manifold (2).
37. Secure the front pipe/TWC with two nuts.

Tighten
Tighten the front pipe/TWC assembly-to-exhaust manifold nuts to 50 N·m (37 lb ft).

38. Use a J 35271 in order to lock the drive plate. Install the torque converter bolts on automatic transmission equipped vehicles.

Tighten
Tighten the torque converter bolts to 54 N·m (40 lb ft).

39. Install the torque converter lower plate on automatic transmission equipped vehicles.
40. Install the clutch housing lower plate on manual transmission equipped vehicles.
41. Install the automatic transmission fluid hoses to the clamps on automatic transmission equipped vehicles.
42. Install the clutch cable to the bracket and the clutch release arm on manual transmission equipped vehicles.
43. Install the engine oil drain plug with the new gasket (1).

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

44. Install the front skid plate, if vehicle equipped. Secure the front skid plate with four bolts.

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

45. Connect the power steering hoses to the power steering pump. Refer to Power Steering Gear and Pump in Steering.
46. Lower the vehicle.
47. Refill the cooling system as necessary. Refer to Cooling System Draining and Filling in Engine Cooling.
48. Refill the power steering fluid. Refer to Power Steering Gear and Pump in Steering.
49. Connect the negative and positive battery cables.
50. Evacuate and charge the A/C system if the vehicle is equipped. Refer to HVAC.