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Home >> Cadillac >> 2021 >> CT4 V, RWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 2.7L (L3B) - Repair Instructions - Ct4 (6 Of 6) >> Engine Replacement (AWD) >> Installation Procedure

Installation Procedure

  1. GM5064715Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Do NOT install the fuel injector nozzle housing seals until AFTER the injectors are installed on the fuel rail.

    Fuel Injector Seal Spacer (1) - Install NEW [4x]

    Fuel Injector Seal (2) - Install NEW [4x]

    2. NOTE:

    Arrows show proper orientation to install the bushing. The bushing will fit flush against the injector.

  2. Fuel Injector Bushing (3) - Install NEW [4x]
  3. GM5064709Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.

    NOTE:

    Use a fiberless, lint free swab to apply the lubrication to the O-ring before installation.

    Holding the largest diameter/body (2) of the injector only, insert the injector assembly (2) into the fuel rail. Ensure correct orientation of the electrical connector.

    4. CAUTION:

    Ensure the fuel injector retainer is properly installed. Failure to completely install the retainers may degrade fuel injection system performance or cause system malfunction.

  4. Fuel Injector Retainer (1) - Install NEW
  5. Repeat for remaining injectors until all are installed and retained in fuel rail.
  6. GM4840511Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DO NOT use any type of lubricant when installing the NEW combustion seals on the fuel injector tip.

    Install EN-51955-1  long protector (1) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-51955-1  long protector (1).

  7. Using EN-51955-4  pusher (3), install the seal (2) into the recessed area (4) of the fuel injector, then remove the EN-51955-1  long protector.
  8. Compress the seal (2) using EN-51955-3  pre-sizer (5).
  9. Using EN-51955-5  sizer (6), resize the seal.
  10. Install EN-51955-2  short protector (7) onto the fuel injector tip. Place a second NEW seal (8) on EN-51105-2  short protector (7).
  11. Using EN-51955-4  pusher (3), install the seal (8) into the remaining recessed area (9) of the fuel injector, then remove EN-51105-2  short protector.
  12. Compress the seal (8) using EN-51955-3  pre-sizer (5).
  13. Using EN-51955-5  sizer (6), resize the seal.
  14. GM2918356Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The fuel injector seals must fit properly in the relative groove. Overlapping of the fuel injector seals with the external surface of the injector must be avoided. Avoid handling the injector tip seals as much as possible to avoid damage.

    Check both of the fuel injector combustion seals on each fuel injector for correct seat:

    • The seal must not be too large, buckled, or corrugated (1)
    • The seal must be fixed tight and accurate (2)
  15. If the seals are not installed correctly, remove the incorrect seal and replace with a NEW seal.
  16. GM5004038Courtesy of GENERAL MOTORS COMPANY

    Water Pump (2) - Install

    17. CAUTION:

    Refer to Fastener Caution

  17. Water Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
  18. GM5004011Courtesy of GENERAL MOTORS COMPANY

    Heater Outlet Pipe Bolt (1) - Install and tighten - Fastener Specifications

  19. GM5004035Courtesy of GENERAL MOTORS COMPANY

    Water Pump Inlet Gasket (3) - Install NEW

  20. Water Inlet (2) - Install
  21. Tighten the hose clamp on the water pump.
  22. Water Outlet Bolt (1) - Install and tighten [3x] - Fastener Specifications
  23. GM5133846Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Hand place the fuel injection fuel rail into the position on the cylinder head.

    Fuel Injection Fuel Rail (1) - Move into position

    24. NOTE:

    Install the four fuel injection fuel rail bolts hand tight only, DO NOT apply any torque.

  24. Fuel Injection Fuel Rail Bolt (2) - Install and hand tighten [4x]
  25. Tighten the two outer fuel injection fuel rail bolts by alternating in steps of 1/2 turn, until the fuel injection fuel rail (1) is fully seated.
  26. Fuel Injection Fuel Rail Bolt (2) - Tighten [4x] - Fastener Specifications
  27. Electrical Connector (3) - Connect [3x]
  28. GM5132483Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Connect all electrical connectors around the fuel rail and knock sensors.

  29. Fuel Injection Fuel Rail Noise Shield (1) - Install
  30. GM5927147Courtesy of GENERAL MOTORS COMPANY

    Engine Mount Bracket (2) - Install

    31. CAUTION:

    Refer to TORQUE-TO-YIELD FASTENER CAUTION

  31. Engine Mount Bracket Bolt (1) - Install NEW and tighten [4x] - Fastener Specifications
  32. GM5657228Courtesy of GENERAL MOTORS COMPANY

    Ignition Coil (2) - Install [4x]

  33. Ignition Coil Bolt (1) - Install and tighten [8x] - Fastener Specifications
  34. GM5022674Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • The camshaft MUST be at the base circle position before the fuel pump is installed.
    • At the base circle position, the EN-52443  High Pressure Fuel Pump Alignment Tool (5) will sit flush with the cylinder head.

    Install the EN-52443  High Pressure Fuel Pump Alignment Tool (5) and turn the crankshaft until the camshaft lobe is at the base circle position.

  35. Remove the EN-52443  High Pressure Fuel Pump Alignment Tool (5).
  36. Lubricate the valve lifter follower (4) with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
  37. Valve Lifter Follower (4) - Install
  38. Fuel Pump Seal (3) - Install NEW
  39. Fuel Pump (2) - Install
    40. CAUTION:

    Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

  40. Fuel Pump Stud (1) - Install and tighten [2x] - Fastener Specifications
  41. Electrical Connector @ Fuel Pump - Connect
  42. GM5478583Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Fuel Pump Insulator (1) - Install

  43. GM5478561Courtesy of GENERAL MOTORS COMPANY

    Fuel Injection Pump Bracket (3) - Install

  44. Fuel Pump Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
  45. Fuel Pump Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
  46. GM5404599Courtesy of GENERAL MOTORS COMPANY

    Fuel Feed Intermediate Pipe (2) - Install NEW

  47. Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
  48. GM5404598Courtesy of GENERAL MOTORS COMPANY

    Nut @ Fuel Feed Intermediate Pipe (1) - Install and hand tighten [2x]

  49. Nut @ Fuel Feed Intermediate Pipe (1) - Tighten [2x] - Fastener Specifications
  50. GM5129475Courtesy of GENERAL MOTORS COMPANY

    Install the fuel feed pipe (1) to the fuel pump and the fuel feed pipe - underbody. Metal Collar Quick Connect Fitting Service

  51. GM5129466Courtesy of GENERAL MOTORS COMPANY

    Fuel Feed Pipe Bolt (1) - Install and tighten - Fastener Specifications

  52. GM5335664Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Phenolic spacer must be present to prevent galvanic/corrosive reaction and/or excessive temperature conduction between engine mount bracket and engine mount. Replace mount if phenolic spacer is missing or damaged. Failure to ensure phenolic spacer is intact and not damaged can lead to premature failure of engine mount and/or engine mount bracket.

    Inspect each engine mount to ensure the phenolic spacer (1) is in place and not damaged.

  53. GM5020150Courtesy of GENERAL MOTORS COMPANY

    J-36854  Engine Stand Remove - Engine (1)

  54. Install the engine to the cradle.
  55. Support the transmission with a suitable jack.
  56. GM5536478Courtesy of GENERAL MOTORS COMPANY

    Remove the J-21366  Converter Holding Strap (1) from the transmission bell housing.

  57. GM5522056Courtesy of GENERAL MOTORS COMPANY

    Install the transmission to the engine.

  58. Connect the electrical connectors and hoses as necessary.
  59. Remove the straps and binders securing the powertrain to the support table.
  60. Ensure the following components are clear from the frame:
    • Vacuum lines
    • Steering knuckles
    • Electrical wiring harnesses
    • Oil cooler lines
  61. GM5598887Courtesy of GENERAL MOTORS COMPANY

    EN-51768  Engine Support Fixture Adapter Bolts- M8 (2) - Remove

  62. EN-36857  Engine Lift Bracket Set (1) - Remove
  63. GM5323001Courtesy of GENERAL MOTORS COMPANY

    EN-51768  Engine Support Fixture Adapter Bolts- M8 (2) - Remove

  64. EN-36857  Engine Lift Bracket Set (1) - Remove
  65. Support the transmission with a suitable jack.
  66. GM5522047Courtesy of GENERAL MOTORS COMPANY

    Transmission Bolt (2) - Install and tighten [3x] - Fastener Specifications

  67. Transmission Stud (1) - Install and tighten - Fastener Specifications
  68. GM5523009Courtesy of GENERAL MOTORS COMPANY

    Transmission Stud (1) - Install and tighten -Fastener Specifications

  69. GM5522052Courtesy of GENERAL MOTORS COMPANY

    Transmission Bolt (1) - Install and tighten [3x] - Fastener Specifications

  70. Transmission Stud (2) - Install and tighten - Fastener Specifications
  71. Connect the transmission vent hose to the engine.
  72. GM5522054Courtesy of GENERAL MOTORS COMPANY

    Connect the electrical connector. (1)

  73. Install the 5 retainers (2).
  74. GM5924292Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness Retainer (1) - Install

  75. Connect the electrical connector. (2)
  76. GM5342773Courtesy of GENERAL MOTORS COMPANY

    Prepare the transmission torque converter bolts (1) for installation as follows:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
    77. NOTE:

    For proper alignment of all torque converter bolts, install the first torque converted bolt in the oval shaped hole.

    NOTE:

    Rotate the harmonic balancer center bolt clockwise ONLY, to align the torque converter bolt with the starter opening.

  77. Transmission Torque Converter Bolt (1) - Install and tighten [6x] - Fastener Specifications
  78. GM5525793Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Install NEW

  79. Apply a small amount of lubricant to the front wheel drive intermediate shaft (2) splines. Adhesives, Fluids, Lubricants, and Sealers
  80. Install the front wheel drive intermediate shaft (2) into the front differential carrier (3).
  81. GM5525786Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The Front Wheel Drive Intermediate Shaft and Front Differential Carrier are to be installed as a assembly.

    Position and secure the front differential carrier (2) on a transmission jack.

  82. Install the front wheel drive intermediate shaft (1) and the front differential carrier (2).
  83. GM5344075Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bolt (1) - Install and hand tighten

  84. GM5344077Courtesy of GENERAL MOTORS COMPANY

    Front Differential Carrier Bolt (1) - Install and hand tighten [2x]

  85. Front Differential Carrier Bolt (2) - Install and hand tighten
  86. Front Differential Carrier Bolt - Tighten [4x] - Fastener Specifications
  87. GM5458092Courtesy of GENERAL MOTORS COMPANY

    Install the front axle vent hose (1).

  88. Remove the engine hoist and lifting hardware, re-install harness retainer bolt at the right front of engine.
  89. GM5335541Courtesy of GENERAL MOTORS COMPANY

    Engine Mount Nut- Left Side (1) - Install and tighten - Fastener Specifications

  90. GM5335537Courtesy of GENERAL MOTORS COMPANY

    Engine Mount Nut- Right Side (1) - Install and tighten - Fastener Specifications

  91. Connect the transmission vent hose to the transmission.
  92. Align the torque converter to flex plate orientation marks made during the removal procedure.
  93. GM5316589Courtesy of GENERAL MOTORS COMPANY

    Install the air conditioning compressor (3).

  94. Air Conditioning Compressor Bolt (2) - Install and tighten - Fastener Specifications
  95. Air Conditioning Compressor Nut (1) - Install and tighten -Fastener Specifications
  96. GM5479911Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Compressor Nut (1) - Install and tighten - Fastener Specifications

  97. GM5510090Courtesy of GENERAL MOTORS COMPANY

    Generator (1) - Install

  98. GM5510084Courtesy of GENERAL MOTORS COMPANY

    Generator Bolt (1) - Install and tighten [2x] - Fastener Specifications

  99. GM5510068Courtesy of GENERAL MOTORS COMPANY

    Auxiliary Generator Battery Jumper Cable (2) - Install

  100. Battery Positive Cable Nut (1) - Install and tighten - Fastener Specifications
  101. Electrical Connector (5) - Connect
  102. If the generator is being replaced, transfer the radiator inlet hose bracket (3) to the NEW generator.
  103. Radiator Inlet Hose Bracket Bolt (4) - Install and tighten - Fastener Specifications
  104. GM5417288Courtesy of GENERAL MOTORS COMPANY

    Auxiliary Generator Battery Jumper Cable (2) - Install

  105. Battery Positive Cable Nut (1) @ Starter Solenoid - Install and tighten - Fastener Specifications
  106. Electrical Connector (4) - Connect
  107. Starter (3) - Install
  108. GM5417249Courtesy of GENERAL MOTORS COMPANY

    Starter Bolt (2) - Install and tighten [2x] - Fastener Specifications

  109. Starter Stud (1) - Install and tighten - Fastener Specifications
  110. GM5417233Courtesy of GENERAL MOTORS COMPANY

    Auxiliary Generator Battery Jumper Cable (2) - Install

  111. Auxiliary Generator Battery Jumper Cable Terminal Nut (1) - Install and tighten - Fastener Specifications
  112. Retainer (3) - Engage
  113. GM5144023Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Flow Control Valve Seal (2) - Install NEW

  114. Engine Coolant Flow Control Valve (1) - Install
  115. GM5144011Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Flow Control Valve Bolt (1) - Install and tighten [5x] - Fastener Specifications

  116. GM5143899Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Temperature Sensor Electrical Connector (2) @ Engine Coolant Flow Control Valve - Connect

  117. Electrical Connector (1) @ Engine Coolant Flow Control Valve - Connect [2x]
  118. GM5517143Courtesy of GENERAL MOTORS COMPANY

    Slide the hose clamp (3) back into position and engage the clamp. Hose Clamp Replacement Guidelines - Spring Type

  119. Thermostat Bypass Hose (2) @ Engine Coolant Flow Control Valve - Install
  120. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  121. GM5143856Courtesy of GENERAL MOTORS COMPANY

    Radiator Inlet Hose (4) @ Engine Coolant Flow Control Valve - Install

  122. Engine Oil Cooler Coolant Inlet Hose (3) @ Engine Coolant Flow Control Valve - Install
  123. Engine Coolant Flow Control Valve Hose (2) @ Engine Coolant Flow Control Valve - Install
  124. Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
  125. GM5141724Courtesy of GENERAL MOTORS COMPANY

    Engine Coolant Thermostat Housing Bracket Bolt (1) - Install and tighten - Fastener Specifications

  126. GM5135192Courtesy of GENERAL MOTORS COMPANY

    Exhaust Manifold Outlet Pipe Gasket (3) - Install NEW

  127. Exhaust Manifold Outlet Pipe (2) - Install
  128. Exhaust Manifold Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
  129. GM5135183Courtesy of GENERAL MOTORS COMPANY

    Exhaust Manifold Outlet Pipe Bolt (1) - Install and tighten - Fastener Specifications

  130. GM5045008Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Gasket (3) - Install NEW [4x]

  131. Crankcase Vent Passage Seal (4) - Install NEW
  132. GM5145544Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold (2) - Install

  133. Intake Manifold Bolt (1) - Install and hand tighten [6x]
  134. Intake Manifold Bolt (1) - Tighten in sequence [6x] - Fastener Specifications
  135. GM5145608Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Cover (1) - Install

  136. GM5402098Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Canister Purge Pump (2) - Install

  137. Evaporative Emission Canister Purge Pump Bolt (1) - Install and tighten [3x] - Fastener Specifications
  138. GM5517398Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness Retainer (1) @ Evaporative Emission Canister Purge Pump Bracket (2) - Connect

  139. GM5128762Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Canister Purge Tube (3) - Connect

  140. GM5003920Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Tube Seal (3) - Install NEW

  141. Oil Level Indicator Tube (2) - Install
  142. Oil Level Indicator Tube Bracket Bolt (1) - Install and tighten - Fastener Specifications
  143. Oil Level Indicator (4) - Install
  144. GM5333497Courtesy of GENERAL MOTORS COMPANY

    Position harness to new engine.

  145. Connect the electrical connector. (1)
  146. Install the retainers. (2)
  147. GM5335427Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness Retainer (1) - Engage [6X]

  148. Connect electrical connectors, retainers at engine mounts, and related components as needed.
  149. GM5417288Courtesy of GENERAL MOTORS COMPANY

    Auxiliary Generator Battery Jumper Cable (2) - Install

  150. Battery Positive Cable Nut (1) @ Starter Solenoid - Install and tighten - Fastener Specifications
  151. Electrical Connector (4) - Connect
  152. Starter (3) - Install
  153. GM5417249Courtesy of GENERAL MOTORS COMPANY

    Starter Bolt (2) - Install and tighten [2x] - Fastener Specifications

  154. Starter Stud (1) - Install and tighten - Fastener Specifications
  155. GM5417233Courtesy of GENERAL MOTORS COMPANY

    Auxiliary Generator Battery Jumper Cable - Install

  156. Auxiliary Generator Battery Jumper Cable Terminal Nut (1) - Install and tighten - Fastener Specifications
  157. Retainer (3) - Engage
  158. GM5918235Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Stud (1) - Install NEW and tighten [2x] - Fastener Specifications

  159. GM5004022Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.

    Turbocharger Oil Return Pipe Gasket (5) - Install NEW

  160. Turbocharger Oil Feed Pipe Gasket (4) - Install NEW
  161. Turbocharger Oil Return Pipe Gasket (3) - Install NEW
  162. Turbocharger Oil Feed Pipe (2) @ Compressor Air Intake Turbocharger - Install
  163. Turbocharger Oil Feed Pipe Bolt (1) @ Compressor Air Intake Turbocharger - Install and tighten [2x] - Fastener Specifications
  164. GM5146550Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Gasket (2) - Install NEW

  165. Turbocharger Assembly (1) - Install
  166. GM5146546Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Nut (1) - Install NEW and hand tighten [2x]

  167. Turbocharger Bolt (2) - Install NEW and hand tighten [2x]
  168. Tighten the 2 turbocharger nuts (1) and the 2 turbocharger bolts (2) in sequence. Fastener Specifications
  169. GM5146481Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Oil Feed Pipe Bolt (4) - Install and tighten [4x] - Fastener Specifications

  170. Turbocharger Brace (3) - Install
  171. Turbocharger Bracket Bolt (2) - Install and tighten [2x] - Fastener Specifications
  172. Turbocharger Brace Nut (1) - Install and tighten - Fastener Specifications
  173. GM5156836Courtesy of GENERAL MOTORS COMPANY

    Positive Crankcase Ventilation Tube (1) - Install NEW

  174. GM5517316Courtesy of GENERAL MOTORS COMPANY

    Electrical Connector (2) - Connect [2x]

  175. Retainer (1) - Connect [3x]
  176. GM5395366Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed and Return Pipe Gasket (2) - Install NEW

  177. Turbocharger Coolant Feed and Return Pipe (1) - Install
  178. GM5395358Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed and Return Pipe Bolt (1) - Install [2x] - Fastener Specifications

  179. GM5395343Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed Hose (2) @ Turbocharger Coolant Feed and Return Pipe - Install

  180. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  181. GM5395335Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Coolant Feed and Return Pipe (2) @ Exhaust Manifold Outlet Pipe - Install

  182. Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  183. GM5395337Courtesy of GENERAL MOTORS COMPANY

    Compressor Air Intake Turbocharger Wastegate Actuator Rod (3) @ Turbocharger Wastegate Actuator - Connect

  184. Compressor Air Intake Turbocharger Wastegate Actuator Link Clip (2) - Install
  185. Compressor Air Intake Turbocharger Wastegate Actuator Link Spring (1) - Install
  186. GM5403768Courtesy of GENERAL MOTORS COMPANY

    Catalytic Converter Gasket (3) - Install NEW

  187. Exhaust Pipe Clamp (2) - Install NEW but do NOT tighten.
    188. NOTE:

    Ensure that the catalytic converter gasket is fully seated on the warm up three-way catalytic converter inlet flange.

  188. Warm Up Three-Way Catalytic Converter (1) - Install
  189. GM5442538Courtesy of GENERAL MOTORS COMPANY

    Catalytic Converter Brace (3) - Install

  190. Catalytic Converter Brace Bolt (2) - Install and tighten [2x] - Fastener Specifications
  191. Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
  192. GM5403738Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Inspect on all sides of the warm up three-way catalytic converter to verify it is fully seated prior to tightening the exhaust pipe clamp.

    Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications

  193. GM5399124Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Component Fastener Tightening Caution

    NOTE:

    A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers

    Using the appropriate tool, install the heated oxygen sensor (1). Fastener Specifications

  194. Connect the electrical connector.
  195. GM5407967Courtesy of GENERAL MOTORS COMPANY

    Water Pump Cover (2) - Install

  196. Water Pump Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
  197. GM5494001Courtesy of GENERAL MOTORS COMPANY

    Retainer (1) - Install

  198. GM5395459Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Heat Shield (1) - Install

  199. GM5395458Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications

  200. GM5395457Courtesy of GENERAL MOTORS COMPANY

    Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications

  201. GM5399121Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Component Fastener Tightening Caution

    NOTE:

    A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers

    Using the EN-6179  Heated Oxygen Sensor Remover/Installer, install the heated oxygen sensor (1). Fastener Specifications

  202. Connect the electrical connector.
  203. GM5003904Courtesy of GENERAL MOTORS COMPANY

    Belt Idler Pulley (1) - Install and tighten - Fastener Specifications

  204. GM5500583Courtesy of GENERAL MOTORS COMPANY

    Drive Belt Tensioner (4) - Install

  205. Drive Belt Tensioner Bolt (3) - Install and tighten [2x] - Fastener Specifications
  206. GM5500497Courtesy of GENERAL MOTORS COMPANY

    Drive Belt Idler Pulley (2) - Install and tighten - Fastener Specifications

  207. GM5156329Courtesy of GENERAL MOTORS COMPANY

    Position the drive belt (2) onto all but one of the idler pulleys.

  208. Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise, then hold tension.
  209. Install the drive belt (2) onto the last idler pulley. Check to ensure that the drive belt is centered on each pulley, and fully seated into ribbed pulleys.
  210. Slowly release tension from the drive belt tensioner (1).
  211. Inspect the drive belt (2) again to ensure centered on each pulley.
  212. GM5399142Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Inlet Air Tube (2) @ Turbocharger (3) - Install

  213. Retainer Spring (1) - Engage
  214. GM5399157Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Install

  215. Retainer Spring (1) - Engage
  216. GM5344068Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Intermediate Shaft Bracket (1) - Install

  217. Front Wheel Drive Intermediate Shaft Bracket Bolt (2) - Install and tighten [3x] - Fastener Specifications
  218. GM5927150Courtesy of GENERAL MOTORS COMPANY

    Engine Mount Bracket (2) - Install

    219. CAUTION:

    Refer to TORQUE-TO-YIELD FASTENER CAUTION .

  219. Engine Mount Bracket Bolt (1) - Install NEW and tighten [4x] - Fastener Specifications
  220. GM5504525Courtesy of GENERAL MOTORS COMPANY

    Apply a small amount of lubricant to the front wheel drive intermediate shaft splines. Adhesives, Fluids, Lubricants, and Sealers

  221. Front Wheel Drive Intermediate Shaft Seal (2) - Install NEW
  222. Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Install NEW
  223. GM5341102Courtesy of GENERAL MOTORS COMPANY

    Apply a small amount of grease to the front wheel drive intermediate shaft splines. Adhesives, Fluids, Lubricants, and Sealers

    NOTE:

    Ensure that the front wheel drive half shaft (1) is securely engaged to the front wheel drive intermediate shaft.

    Front Wheel Drive Half Shaft (1) - Install

  224. GM5504571Courtesy of GENERAL MOTORS COMPANY

    Steering Linkage Outer Tie Rod (1) @ Steering Knuckle - Install

  225. Steering Linkage Outer Tie Rod Nut (2) - Install and tighten - Fastener Specifications
  226. GM5504544Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to TORQUE-TO-YIELD FASTENER CAUTION .

    Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener Specifications

  227. GM5341525Courtesy of GENERAL MOTORS COMPANY

    Retaining Ring (2) @ Front Wheel Drive Half Shaft (1) - Install NEW

  228. GM5507536Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Shaft Retaining Ring (2) @ Front Wheel Drive Half Shaft (1) - Install NEW

  229. GM5341523Courtesy of GENERAL MOTORS COMPANY

    Front Wheel Drive Half Shaft (1) - Install

  230. GM5341521Courtesy of GENERAL MOTORS COMPANY

    Partially install the front wheel drive half shaft (1) into the front differential carrier.

  231. Remove the DT-51504  Seal Protector (2) from the front axle shaft seal.
    232. NOTE:

    Ensure that the front wheel drive half shaft (1) is securely engaged to the front wheel drive intermediate shaft.

  232. Completely install the front wheel drive half shaft (1) into the front differential carrier.
  233. GM5507513Courtesy of GENERAL MOTORS COMPANY

    Steering Linkage Outer Tie Rod (2) @ Steering Knuckle - Install

  234. Steering Linkage Outer Tie Rod Nut (1) - Install and tighten - Fastener Specifications
  235. GM5507500Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to TORQUE-TO-YIELD FASTENER CAUTION .

    Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener Specifications

  236. Connect the remaining electrical connectors and hoses as necessary.
  237. Remove the straps and binders securing the powertrain to the support table.
  238. Ensure the following components are clear from the frame:
    • Vacuum lines
    • Steering knuckles
    • Electrical wiring harnesses
    • Oil cooler lines
  239. GM5541631Courtesy of GENERAL MOTORS COMPANY

    Position the engine and transmission (1) on the GE-52200-A  Propulsion System Lift (2) to the vehicle and raise into position.

  240. GM5335619Courtesy of GENERAL MOTORS COMPANY

    Drivetrain and Front Suspension Cradle Front Bolt (2) - Install and tighten [4x] - Fastener Specifications

  241. Drivetrain and Front Suspension Cradle Rear Bolt (1) - Install and tighten [2x] - Fastener Specifications
  242. Raise and support the vehicle. Lifting and Jacking the Vehicle
  243. Remove the GE-52200-A  Propulsion System Lift from under the vehicle.
  244. GM5330297Courtesy of GENERAL MOTORS COMPANY

    Intermediate Steering Shaft (1) @ Electric Belt Drive Rack and Pinion Steering Gear - Install

  245. GM5330303Courtesy of GENERAL MOTORS COMPANY

    Prepare the intermediate steering shaft lower bolt (1) at the electric belt drive rack and pinion steering gear for installation as follows:

    1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth.
    2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  246. GM5330303Courtesy of GENERAL MOTORS COMPANY

    Intermediate Steering Shaft Lower Bolt (1) @ Electric Belt Drive Rack and Pinion Steering Gear - Install and tighten - Fastener Specifications

  247. Remove the device preventing the steering column from rotating.
  248. GM5335427Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness Retainer (1) - Engage [6X]

  249. Connect electrical connectors at engine mounts.
  250. GM5324557Courtesy of GENERAL MOTORS COMPANY

    Connect the steering gear electrical connectors. (1)

  251. GM5485960Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission Fluid Cooling Exchanger (2) - Install

  252. Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Install and tighten [3x] - Fastener Specifications
  253. GM5485959Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Pipe Seal (1) - Install NEW [2x]

  254. GM5485958Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.

    Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Automatic Transmission Fluid Cooling Exchanger - Install

  255. Transmission Fluid Cooler Pipe Connector Bolt (1) - Install and tighten [2x] - Fastener Specifications
  256. GM5485957Courtesy of GENERAL MOTORS COMPANY

    Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (4) @ Automatic Transmission Fluid Cooling Exchanger - Install

  257. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose Clamp (3) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  258. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) @ Automatic Transmission Fluid Cooling Exchanger - Install
  259. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  260. GM5485767Courtesy of GENERAL MOTORS COMPANY

    Transmission Fluid Cooler Thermal Bypass Valve Gasket (1) - Install NEW [4x]

  261. GM5485765Courtesy of GENERAL MOTORS COMPANY

    Transmission Cooler Bypass Valve (2) - Install

  262. Transmission Fluid Cooler Thermal Bypass Valve Bolt (1) - Install and tighten - Fastener Specifications
  263. GM5485764Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.

    Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Cooler Bypass Valve - Install

  264. Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
  265. GM5485763Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.

    Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Cooler Bypass Valve - Install

  266. Transmission Fluid Cooler Pipe Nut (1) - Install and tighten - Fastener Specifications
  267. GM5317837Courtesy of GENERAL MOTORS COMPANY

    Front Crossmember Brace-Left Side (3) - Install

  268. Front Crossmember Brace Nut-Left Side (2) - Install and tighten - Fastener Specifications
  269. Front Crossmember Brace Bolt-Left Side (1) - Install and tighten [4x] - Fastener Specifications
  270. GM5318200Courtesy of GENERAL MOTORS COMPANY

    Front Crossmember Brace-Right Side (3) - Install

  271. Front Crossmember Brace Nut-Right Side (2) - Install and tighten - Fastener Specifications
  272. Front Crossmember Brace Bolt-Right Side (1) - Install and tighten [4x] - Fastener Specifications
  273. GM5399464Courtesy of GENERAL MOTORS COMPANY

    Front Crossmember Brace (2) - Install

  274. Front Crossmember Brace Nut (1) - Install and tighten [4x] - Fastener Specifications
  275. Remove straps used to support the radiator.
  276. GM5326445Courtesy of GENERAL MOTORS COMPANY

    Transmission Mount Bracket Bolt (1) - Loosely install [4x]

  277. GM5326445Courtesy of GENERAL MOTORS COMPANY

    Transmission Mount Bracket Bolt (1) - Tighten [4x] - Fastener Specifications

  278. Remove the jack from beneath the transmission.
  279. Reposition and connect wiring harness and hoses as needed.
  280. GM5081182Courtesy of GENERAL MOTORS COMPANY

    Install the electronic transmission range selector manual park release cable (2) to the electronic transmission range selector manual park release cable bracket on the transmission.

  281. Clip the electronic transmission range selector manual park release cable (1) retainer to the electronic transmission range selector manual park release cable bracket.
  282. GM5081117Courtesy of GENERAL MOTORS COMPANY

    Connect the electronic transmission range selector manual park release cable terminal to the manual shift shaft.

  283. Install the electronic transmission range selector manual park release cable clamp bolt (1) and tighten. Fastener Specifications
  284. GM5811468Courtesy of GENERAL MOTORS COMPANY

    Apply a thin layer of grease to the transmission output shaft splines (1). Adhesives, Fluids, Lubricants, and Sealers

  285. Loosely install a NEW propeller shaft hub clamp (3) to the propeller shaft joint boot.
  286. Support and secure the propeller shaft (2) to a suitable hydraulic jack stand.
  287. Propeller Shaft (2) - Install
  288. GM5317838Courtesy of GENERAL MOTORS COMPANY

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  289. Propeller Shaft Bearing Support Bolt (1) - Install and tighten [2x] - Fastener Specifications
  290. Remove the hydraulic jack stand supporting the propeller shaft.
  291. GM5317835Courtesy of GENERAL MOTORS COMPANY

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  292. Align the relationship marks (2) made on the propeller shaft and the rear differential flange.
  293. Rear Propeller Shaft Bolt (1) - Install [3x]
  294. Rear Propeller Shaft Nut (3) - Loosely install [3x]
  295. Rear Propeller Shaft Bolt (1) - Tighten [3x] - Fastener Specifications
  296. GM5811460Courtesy of GENERAL MOTORS COMPANY
  297. Ensure that the drive shaft boot is completely seated in the output shaft groove prior to crimping the propeller shaft hub clamp (1).
  298. Using the DT-35910  Drive Axle Seal Clamp Pliers (2), crimp the propeller shaft hub clamp (1) until the final crimped outer diameter (a) is 39 - 41 mm (1.54 - 1.61 in).
  299. GM5339607Courtesy of GENERAL MOTORS COMPANY

    If the transfer case front output shaft boot (1) was removed, perform the following:

    1. Loosely install a NEW transfer case front output shaft boot clamp (2) to the groove of the transfer case front output shaft boot (1).
    2. Install the transfer case front output shaft boot (1) to the front axle propeller shaft groove ensuring that it is completely engaged.
    3. Using the DT-35910  Drive Axle Seal Clamp Pliers (3), crimp the transfer case front output shaft boot clamp (2) until the final crimped diameter (a) of 37.5 mm (1.48 in) is achieved.
  300. GM5339608Courtesy of GENERAL MOTORS COMPANY

    Loosely install a NEW transfer case front output shaft boot clamp (3) into the groove of the transfer case front output shaft boot (2).

  301. Front Axle Propeller Shaft (1) - Install
  302. GM5339603Courtesy of GENERAL MOTORS COMPANY

    Prepare the 6 front axle propeller shaft bolts (1) for installation as follows:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  303. Align the marks made between the front axle propeller shaft (2) and the front differential carrier flange.
  304. Front Axle Propeller Shaft Washer (3) - Install [3x]
  305. Install and tighten the 6 front axle propeller shaft bolts (1) in a crisscross pattern. Fastener Specifications
  306. GM5481383Courtesy of GENERAL MOTORS COMPANY

    Ensure that the front transfer case front output shaft boot (2) is completely engaged into the transfer case front output shaft.

  307. Ensure that the front transfer case front output shaft boot clamp (1) is completely engaged into the front transfer case front output shaft boot (2).
  308. GM5339609Courtesy of GENERAL MOTORS COMPANY

    Using the DT-35910  Drive Axle Seal Clamp Pliers (1), crimp the transfer case front output shaft boot clamp (2) until the final crimped diameter (a) of 37.5 mm (1.48 in) is achieved.

  309. GM5334107Courtesy of GENERAL MOTORS COMPANY

    Front Axle Propeller Shaft Heat Shield (3) - Install

  310. Front Axle Propeller Shaft Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
  311. Front Axle Propeller Shaft Heat Shield Stud (2) - Install and tighten - Fastener Specifications
  312. GM5334717Courtesy of GENERAL MOTORS COMPANY

    Floor Panel Number 2 Cross Bar Reinforcement (2) - Install

  313. Floor Panel Number 2 Cross Bar Reinforcement Bolt (1) - Install and tighten [4x] - Fastener Specifications
  314. GM5309833Courtesy of GENERAL MOTORS COMPANY

    Exhaust Intermediate Underbody Heat Shield (2) - Install

  315. Exhaust Heat Shield Bolt (1) - Install and tighten [6x] - Fastener Specifications
  316. GM5309214Courtesy of GENERAL MOTORS COMPANY

    Catalytic Converter Gasket (2) - Install NEW

  317. Exhaust Muffler (1) - Install
  318. {If equipped} Electrical Connector @ Exhaust Control Valve Actuator - Connect
  319. GM5309211Courtesy of GENERAL MOTORS COMPANY

    Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Install

  320. Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Install
  321. GM5309202Courtesy of GENERAL MOTORS COMPANY

    Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Install

  322. Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Install
  323. GM5400756Courtesy of GENERAL MOTORS COMPANY

    Floor Panel Reinforcement (2) - Install

  324. Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Install and tighten [6x] - Fastener Specifications
  325. GM5400642Courtesy of GENERAL MOTORS COMPANY

    Underbody Rear Air Deflector- Right Side (5) - Install

  326. Underbody Rear Air Deflector Nut (3) - Install and tighten [3x] - Fastener Specifications
  327. Underbody Rear Air Deflector Bolt (2) - Install and tighten [3x] - Fastener Specifications
  328. Underbody Rear Air Deflector Nut (4) - Install and tighten [2x] - Fastener Specifications
  329. Rear Wheelhouse Liner Bolt (1) - Install and tighten - Fastener Specifications
  330. GM5424018Courtesy of GENERAL MOTORS COMPANY

    Rear Tire Front Air Deflector- Right Side (2) - Install

  331. Rear Tire Front Air Deflector Bolt (1) - Install and tighten [2x] - Fastener Specifications
  332. GM5400553Courtesy of GENERAL MOTORS COMPANY

    Underbody Rear Air Deflector- Left Side (5) - Install

  333. Underbody Rear Air Deflector Nut (2) - Install and tighten [3x] - Fastener Specifications
  334. Underbody Rear Air Deflector Bolt (3) - Install and tighten [3x] - Fastener Specifications
  335. Underbody Rear Air Deflector Nut (4) - Install and tighten [2x] - Fastener Specifications
  336. Rear Wheelhouse Liner Bolt (1) - Install and tighten - Fastener Specifications
  337. GM5424015Courtesy of GENERAL MOTORS COMPANY

    Rear Tire Front Air Deflector- Left Side (2) - Install

  338. Rear Tire Front Air Deflector Bolt (1) - Install and tighten [2x] - Fastener Specifications
  339. GM5326436Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Stabilizer Shaft Link (1) @ Stabilizer Shaft - Reposition [2x]

  340. GM5326435Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Stabilizer Shaft Link Nut- Lower (1) - Install and tighten [2x] - Fastener Specifications

  341. GM5472805Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Wheel Speed Sensor (2) - Install [2x]

  342. Front Wheel Speed Sensor Bolt (1) - Install and tighten [2x] - Fastener Specifications
  343. GM5430376Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Brake Caliper - Install (1) [2x]

  344. Front Brake Caliper Bolt (2) - Install and tighten [4x] - Fastener Specifications
  345. Lower the vehicle.
  346. GM5314157Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    New Air Conditioning sealing washers should never be exposed to any type of oil or lubricant, the rubber material may absorb the oil causing failures during installation or the life of the vehicle.

    Air Conditioning Condenser Hose Seal (2) - Install NEW

  347. Air Conditioning Refrigerant Heat Exchanger (1) @ Air Conditioning Condenser - Install
  348. GM5314143Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Compressor and Condenser Hose Seal (2) - Install NEW

  349. Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (1) @ Air Conditioning Condenser - Install
  350. GM5315482Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Condenser Tube Clip (2) - Install

  351. Air Conditioning Condenser Hose Nut (1) @ Air Conditioning Condenser - Install and tighten - Fastener Specifications
  352. GM5314114Courtesy of GENERAL MOTORS COMPANY

    Position the air conditioning refrigerant heat exchanger to its original position.

  353. Air Conditioning Evaporator Tube Clip Bracket Bolt (4) - Install and tighten - Fastener Specifications
  354. Air Conditioning Evaporator Thermal Expansion Valve Seal (3) - Install NEW
  355. Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (2) @ Air Conditioning Refrigerant Heat Exchanger - Install
  356. Air Conditioning Compressor Hose Nut (1) - Install and tighten - Fastener Specifications
  357. GM5479910Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Connector Bracket (2) - Install

  358. Engine Wiring Harness Connector Bracket Nut (1) - Install and tighten - Fastener Specifications
  359. GM5460376Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Compressor and Condenser Hose Seal (3) - Install NEW

  360. Air Conditioning Compressor Hose Seal (2) - Install NEW
  361. Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (1) @ Air Conditioning Compressor - Install
  362. GM5315475Courtesy of GENERAL MOTORS COMPANY

    Air Conditioning Compressor Hose Nut (1) - Install and tighten - Fastener Specifications

  363. GM5321065Courtesy of GENERAL MOTORS COMPANY

    Connect the electrical connectors. (1) [3x]

  364. GM5417160Courtesy of GENERAL MOTORS COMPANY

    Reconnect the 3 electrical connectors (1) to the engine control module.

  365. GM5315881Courtesy of GENERAL MOTORS COMPANY

    Body Wiring Harness Junction Block Bracket (2) - Install

  366. Body Wiring Harness Fuse Block Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
  367. GM5315648Courtesy of GENERAL MOTORS COMPANY

    Install the engine wiring harness fuse block bracket (2) to the body wiring harness junction block bracket (3). Re-engage the 3 retaining tabs (1).

  368. GM5315623Courtesy of GENERAL MOTORS COMPANY

    Install the 2 electrical connectors (1) and engage the 2 retaining covers (2).

  369. GM5314788Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Junction Block (3) - Install

  370. Retaining Tab (2) - Engage [4x]
  371. Engine Wiring Harness Junction Block Bolt (1) - Install and tighten [1x] - Fastener Specifications
  372. GM5311887Courtesy of GENERAL MOTORS COMPANY

    Engine Wiring Harness Fuse Block Cover (2) - Install

  373. Retainer (1) - Engage [2x]
  374. GM5315620Courtesy of GENERAL MOTORS COMPANY

    Battery Positive Cable Nut (1) - Install and tighten - Fastener Specifications

  375. Auxiliary Generator Battery Jumper Cable (2) - Install
  376. Battery Positive Cable (3) - Install
  377. GM5314636Courtesy of GENERAL MOTORS COMPANY

    Battery Distribution Engine Compartment Fuse Block (2) - Install

  378. Retaining Tab (1) - Engage [2x]
  379. GM5314604Courtesy of GENERAL MOTORS COMPANY

    Forward Lamp Wiring Harness (10) - Install [2x]

    380. CAUTION:

    Refer to Fastener Caution

  380. Forward Lamp Wiring Harness Terminal Nut (2) - Install and tighten [2x] - Fastener Specifications
  381. Engine Wiring Harness (9) - Install [2x]
  382. Engine Wiring Harness Terminal Nut M6 (3) - Install and tighten - Fastener Specifications
  383. Engine Wiring Harness Terminal Nut M8 (4) - Install and tighten - Fastener Specifications
  384. Auxiliary Generator Battery Jumper Cable (8) - Install
  385. Auxiliary Generator Battery Jumper Cable Nut (5) - Install and tighten - Fastener Specifications
  386. Battery Positive Cable (7) - Install
  387. Battery Positive Cable Nut (6) - Install and tighten - Fastener Specifications
  388. Battery Distribution Engine Compartment Fuse Block Cover (1) - Install
  389. GM5472775Courtesy of GENERAL MOTORS COMPANY

    Heater Outlet Hose (2) @ Heater Outlet Pipe - Install

  390. Heater Outlet Hose Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  391. GM5472679Courtesy of GENERAL MOTORS COMPANY

    Heater Inlet Hose (3) @ Exhaust Manifold Outlet Pipe - Install

  392. Heater Inlet Hose Clamp (2) - Engage - Hose Clamp Replacement Guidelines - Spring Type
  393. GM5472821Courtesy of GENERAL MOTORS COMPANY

    Radiator Surge Tank Inlet Hose (2) - Install

  394. Radiator Surge Tank Inlet Hose Clamp (1) - Engage [3x] - Hose Clamp Replacement Guidelines - Spring Type
  395. Remove the shop cloths and clean up any residual coolant.
  396. Raise and support the vehicle. Lifting and Jacking the Vehicle
  397. GM5423336Courtesy of GENERAL MOTORS COMPANY

    Radiator Air Front Lower Baffle (1) - Install

  398. GM5423335Courtesy of GENERAL MOTORS COMPANY

    Radiator Air Front Lower Baffle Retainer (1) - Install [3x]

  399. GM5407648Courtesy of GENERAL MOTORS COMPANY

    Front Bumper Fascia Center Air Deflector (1) - Install

  400. GM5407644Courtesy of GENERAL MOTORS COMPANY

    Front Bumper Fascia Center Air Deflector Retainer (3) - Install [2x]

  401. Front Bumper Fascia Center Air Deflector Bolt (2) - Install and tighten [5x] - Fastener Specifications
  402. Front Bumper Fascia Center Air Deflector Screw (1) - Install and tighten [6x] - Fastener Specifications
  403. GM5468709Courtesy of GENERAL MOTORS COMPANY

    Front Bumper Fascia Center Air Deflector Screws (1) - Install and tighten [3x] - Fastener Specifications

  404. GM5407645Courtesy of GENERAL MOTORS COMPANY

    Front Bumper Fascia Center Air Deflector Screws (1) - Install and tighten [10x] - Fastener Specifications

  405. GM5420502Courtesy of GENERAL MOTORS COMPANY

    Front Compartment Air Deflector (2) - Install

  406. Front Compartment Air Deflector Bolt (1) - Install and tighten [4x] - Fastener Specifications
  407. GM5396496Courtesy of GENERAL MOTORS COMPANY

    Front Wheelhouse Liner Bolt (3) - Install and tighten - Fastener Specifications

  408. Engine Front Splash Shield Retainer (2) - Install [2x]
  409. Engine Front Splash Shield Bolt (1) - Install and tighten - Fastener Specifications
  410. GM5396453Courtesy of GENERAL MOTORS COMPANY

    Front Wheelhouse Liner Bolt (1) - Install and tighten - Fastener Specifications

  411. Engine Front Splash Shield Retainer (2) - Install [2x]
  412. Engine Front Splash Shield Bolt (3) - Install and tighten - Fastener Specifications
  413. GM5396438Courtesy of GENERAL MOTORS COMPANY

    Front Bumper Fascia Center Air Deflector Bolt (1) - Install and tighten [5x] - Fastener Specifications

  414. Front Bumper Fascia Air Deflector Retainer (2) - Install [2x]
  415. GM5312788Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Wheelhouse Liner (3) - Install [2x]

  416. Front Wheelhouse Liner Retainer (2) - Install [6x]
  417. Front Wheelhouse Liner Bolt (1) - Install and tighten [4x] - Fastener Specifications
  418. GM5312762Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Wheelhouse Liner Retainer (3) - Install

  419. Front Wheelhouse Liner Bolt (2) - Install and tighten [10x] - Fastener Specifications
  420. Front Bumper Fascia Bolt (1) - Install [6x] - Fastener Specifications
  421. GM5312525Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Engine Front Splash Shield (3) - Install [2x]

  422. Engine Front Splash Shield Retainer (2) - Install [2x]
  423. Engine Front Splash Shield Bolt (1) - Install [10x] - Fastener Specifications
  424. GM5394612Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Left side shown, right side similar.

    Front Tire Front Air Deflector Bolt (1) - Install [8x] - Fastener Specifications

  425. Front Tire Front Air Deflector (2) - Install [2x]
  426. GM5312791Courtesy of GENERAL MOTORS COMPANY

    Heater Inlet Hose (2) @ Engine Coolant Thermostat Housing Pipe - Install

  427. Heater Inlet Hose Retainer (1) - Engage - Plastic Collar Quick Connect Fitting Service
  428. GM5427430Courtesy of GENERAL MOTORS COMPANY

    Radiator Upper Bracket (2) - Install [2x]

  429. Radiator Upper Bracket Bolt (3) - Install and tighten [4x] - Fastener Specifications
  430. Wiring Harness Retainer (1) - Install
  431. GM5420297Courtesy of GENERAL MOTORS COMPANY

    Radiator Air Upper Baffle (2) - Reposition

  432. Install the front 3 radiator air upper baffle retainers (1).
  433. Connect the cooling fan electrical connector.
  434. Connect the ground wire on the frame before installing the air cleaner.
  435. GM5399073Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Assembly (1) - Install

  436. GM5399053Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Bolt (1) - Install and tighten - Fastener Specifications

  437. Connect the electrical connector and install all wiring harnesses to the air cleaner assembly.
  438. GM5398967Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Outlet Duct (1) - Install

  439. Connect the electrical connector.
  440. GM5512092Courtesy of GENERAL MOTORS COMPANY

    Positive Crankcase Ventilation Tube (4) - Connect

  441. GM5398955Courtesy of GENERAL MOTORS COMPANY

    Positive Crankcase Ventilation Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service

  442. Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
  443. GM5395515Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Canister Purge Tube (1) - Install - Plastic Collar Quick Connect Fitting Service

  444. GM5427515Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness Retainer (1) @ Air Cleaner Assembly - Install [4x]

  445. Connect the electrical connector.
  446. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation
  447. Connect the battery. Battery Negative Cable Disconnection and Connection
  448. Recharge the refrigerant. REFRIGERANT RECOVERY AND RECHARGING
  449. Remove the oil fill cap.
  450. GM5432174Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Install

  451. GM5432171Courtesy of GENERAL MOTORS COMPANY

    Push down on the front of the intake manifold cover (2).

  452. Intake Manifold Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
  453. Install the oil fill cap.
  454. GM5456829Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Ensure the intake manifold cover insulator retainers fully engage the intake manifold cover studs.

    Intake Manifold Cover Insulator (1) - Install

  455. GM5456746Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications

    456. NOTE:

    Prelube is necessary if the engine is replaced or overhauled.

  456. If the engine is replaced with a new engine or has been overhauled, perform the Engine Prelubing procedure. Engine Prelubing 
  457. If the engine is not being replaced or overhauled, fill the engine oil. Engine Oil and Oil Filter Replacement
  458. If replacing the engine control module, it is necessary to reprogram the replacement module. CONTROL MODULE REFERENCES
  459. Perform the engine oil life reset. GM Oil Life System Resetting (With Scan Tool) , or GM Oil Life System Resetting (Without Scan Tool)
  460. Perform the crankshaft position variation learn. CRANKSHAFT POSITION VARIATION LEARN
  461. Perform the throttle body idle air flow compensation reset. Throttle Body Idle Air Flow Compensation Reset 
  462. Inspect the exhaust system for leaks.
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