Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required

J 41427 Engine Lift Bracket

1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the underbody shields. Refer to Steering Linkage Shield Replacement in Steering Linkage (Non-Rack and Pinion)
5. Remove the flange nuts holding the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
6. Remove the oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.



7. Remove the stud holding the starter wiring harness clip and if equipped, transmission cooler lines.
8. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.



9. Remove the transmission cover.
10. Remove the transmission.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - NV 3500.




11. Remove the engine mounts through-bolt.
12. Lower the vehicle.
13. Remove the air cleaner outlet duct from the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
14. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
15. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls.
16. Remove the cruise control cable from the throttle linkage and the accelerator control cable bracket, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
17. Remove the inlet and outlet radiator hoses from the engine. Refer to Radiator Hose Replacement in Engine Cooling.
18. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement In Heating Ventilation and Air Conditioning.
19. Remove the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.



20. Disconnect the following electrical connectors:

•	The fuel meter body assembly (1)

•	The manifold absolute pressure (MAP) sensor (3)

•	The EVAP canister purge solenoid valve (2)




21. Disconnect the following electrical connectors:

•	The A/C compressor high pressure switch (4), if equipped

•	The A/C clutch switch (1), if equipped

•	The throttle position (TP) sensor (2)

•	The idle air control (IAC) motor (3)




22. Disconnect the following electrical connectors:

•	The engine oil pressure gauge sensor (3)

•	The distributor (2)

•	The knock (KS) sensor (1)




23. Disconnect the following electrical connectors:

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

•	The ignition coil (4)

•	The ignition control module (ICM) (3)

24. Remove the engine wiring harness clip (2) from the accelerator control cable bracket.



25. Remove the engine wiring harness with the clip from the throttle body.



26. Remove the engine wiring harness from the engine wiring harness brackets.



27. Disconnect the crankshaft position (CKP) sensor (1)
28. Remove the engine wiring harness and clip (2) from the front of the engine.



29. Remove the negative battery cable bolt.
30. Remove the negative battery cable and clips from the accelerator control cable bracket.
31. Position the negative battery cable out of the way.



32. Remove the engine wiring harness and clip from the accelerator cable bracket.
33. Remove the accelerator cable bracket from the generator mounting bracket.
34. Remove the generator. Refer to Generator Replacement in Engine Electrical.
35. Move and secure the engine wiring harness out of the way.



36. Remove the bolt holding the ground strap to the left cylinder head.



37. Remove the bolt for the fuel pipe bracket.
38. Remove the bolt and ground wire.



39. Remove the bolt holding the ground wires to the right cylinder head.
40. Remove the bolt holding the wiring harness retainer to the right cylinder head.



41. Remove the oil fill tube.
42. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating Ventilation and Air Conditioning.



43. Remove the nuts holding power steering pump rear bracket to the engine.



44. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement .

•	The power steering pump can remain on the mounting bracket.

•	The hoses do not require removal.

•	Secure the mounting bracket out of the way.




45. Disconnect the power brake booster vacuum hose from the intake manifold.
46. Disconnect the vacuum hose for the A/C system from the intake manifold.
47. Disconnect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
48. Disconnect the EVAP canister purge solenoid valve hose. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.
49. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.



50. Remove the EGR valve inlet pipe from the intake and exhaust manifold.



51. Remove the nut and the engine wiring harness bracket from the right side of the upper intake manifold.



52. Install the J 41427 to the right rear and the left front of the intake manifold.

Tighten
Tighten the retaining bolts to 15 N·m (11 lb ft)

53. Use an engine lifting device to remove the engine from the vehicle.
54. Remove the following items from the engine:

•	The generator mounting bracket. Refer to Accessory Mounting Brackets Replacement .

•	The engine mount engine side brackets. Refer to Engine Mount Replacement .

Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required

J 41427 Engine Lift Bracket

1. Install the following items to the engine:

•	The generator mounting bracket. Refer to Accessory Mounting Brackets Replacement .

•	The engine mount engine side brackets. Refer to Engine Mount Replacement .

2. Install the engine into the vehicle.




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.

3. Install the through-bolts and nuts for the engine mounts.

Tighten
Tighten the through-bolt nuts to 63 N·m (46 lb ft)

4. Remove the engine lift brackets.
5. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.
6. Install the intake manifold bolts.

Tighten

1. Tighten the bolts the first pass to 3 N·m (27 lb in).
2. Tighten the bolts the second pass to 12 N·m (106 lb in).
3. Tighten the bolts the third pass to 15 N·m (11 lb ft).
7. Install the EGR valve inlet pipe to the intake and exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
8. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
9. Connect the EVAP canister purge solenoid valve hose. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.
10. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.



11. Connect the power brake booster vacuum hose to the intake manifold.
12. Connect the vacuum hose for the A/C system to the intake manifold.



13. Install the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement .
14. Install the nuts holding the power steering pump rear bracket to the engine.

Tighten
Tighten the power steering pump rear bracket nuts to 41 N·m (30 lb ft).

15. Install the A/C compressor, if equipped. Refer to Air Conditioning Compressor Replacement in Heating Ventilation and Air Conditioning.



16. Install the oil fill tube in the valve rocker arm cover.
17. Install the oil fill tube on the intake manifold stud and install the nut.

Tighten
Tighten the oil fill tube nut to 12 N·m (106 lb in).

18. Install the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.



19. Install the bolt holding the ground strap to the left cylinder head.

Tighten
Tighten the ground strap bolt to 35 N·m (26 lb ft).




20. Install the bolt for the fuel pipe bracket.

Tighten
Tighten the fuel pipe bracket bolt to 30 N·m (22 lb ft).

21. Install the ground wire and bolt.

Tighten
Tighten the ground wire bolt to 35 N·m (26 lb ft).




22. Install the bolt holding the ground wires to the rear of the right cylinder head.

Tighten
Tighten the ground wires bolt to 35 N·m (26 lb ft).

23. Install the bolt holding the wiring harness retainer to the rear of the right cylinder head.

Tighten
Tighten the wiring harness retainer bolt to 35 N·m (26 lb ft).

24. Install the generator. Refer to Generator Replacement in Engine Electrical.



25. Install the accelerator control cable bracket to the generator mounting bracket.

Tighten
Tighten the bracket bolt to 25 N·m (18 lb ft).

26. Install the engine wiring harness and clip to the accelerator cable bracket.



27. Install the negative battery cable and clips to the accelerator cable bracket.
28. Install the negative battery cable bolt.

Tighten
Tighten the negative battery cable bolt to 17 N·m (13 lb ft).




29. Connect the crankshaft position (CKP) sensor (1)
30. Install the engine wiring harness and clip (2) to the front of the engine.



31. Install the engine wiring harness bracket and nut to for the right side to the upper intake manifold stud.

Tighten
Tighten engine wiring harness bracket nut to 12 N·m (106 lb in).




32. Install the engine wiring harness to the engine wiring harness brackets.



33. Install the engine wiring harness and clip to the throttle body.



34. Connect the following electrical connectors:

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

•	The ignition coil (4)

•	The ignition control module (ICM) (3)

35. Install the engine wiring harness clip (2) to the accelerator control cable bracket.



36. Connect the following electrical connectors:

•	The engine oil pressure gauge sensor (3)

•	The distributor (2)

•	The knock (KS) sensor (1)




37. Connect the following electrical connectors:

•	The A/C compressor high pressure switch (4), if equipped

•	The A/C clutch switch (1), if equipped

•	The throttle position (TP) sensor (2)

•	The idle air control (IAC) motor (3)




38. Connect the following electrical connectors:

•	The fuel meter body assembly (1)

•	The manifold absolute pressure (MAP) sensor (3)

•	The EVAP canister purge solenoid valve (2)

39. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
40. Install the inlet and outlet radiator hose to the engine. Refer to Radiator Hose Replacement in Engine Cooling.
41. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating Ventilation and Air Conditioning.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
42. Install a NEW accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Control.
43. Install the cruise control cable, if equipped to the accelerator cable bracket and the throttle body. Refer to Cruise Control Cable Replacement in Cruise Control.
44. Raise the vehicle.
45. Install the transmission.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - NV 3500.




46. Install the transmission cover.

Tighten
Tighten the transmission cover bolts to 12 N·m (106 lb in).

47. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.



48. Install the bolt holding the starter wiring harness clip and if equipped, transmission cooler lines.

Tighten
Tighten the bracket bolt to 12 N·m (106 lb in).

49. Install the oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
50. Install the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
51. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement .
52. Install the underbody shield. Refer to Steering Linkage Shield Replacement in Steering Linkage (Non-Rack and Pinion).
53. Lower the vehicle.
54. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
55. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
56. Install the air cleaner outlet duct to the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
57. Install the hood. Refer to Hood Replacement in Body Front End.
58. Connect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
59. Operate and test the engine. Refer to Engine Set-Up and Testing .