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Home >> Chevrolet >> 2001 >> Camaro Base, 2D Convertible, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 63 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the left and right exhaust manifolds. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8 L) or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) .
  2. Install and connect the engine wiring harness to the engine.
  3. Install the lifting device to the engine.
  4. Remove the engine from the engine stand.
  5. Install the engine flywheel. Refer to Engine Flywheel Replacement .
  6. Install the engine to the transmission.
    Fig 1: Installing Engine To The Transmission
    G01728926Courtesy of GENERAL MOTORS CORP.
  7. For the manual transmission, install the flywheel housing to engine bolts (1, 2) and nuts (3).

    Tighten 

    Tighten the flywheel housing to engine bolts (1, 2) and nuts (3) to 95 N.m (70 lb ft).

  8. If equipped with an automatic transmission remove the J 21366 from the transmission.
  9. For the automatic transmission, install the transmission to engine bolts and nut.
    Fig 2: Installing The Transmission To Engine Bolts And Nut
    G01728927Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the transmission to engine bolts and nut to 95 N.m (70 lb ft).

  10. Connect the electrical connectors to the transmission.
  11. If equipped with the manual transmission install left side transmission support (1).
    Fig 3: Installing Left Side Transmission Support
    G01728928Courtesy of GENERAL MOTORS CORP.
  12. Install the left side transmission support brace bolts (2, 3).

    Tighten 

    • Tighten the left side transmission support brace bolts (2) to the transmission to 50 N.m (37 lb ft).
    • Tighten the left side transmission support brace bolts (3) to the engine to 28 N.m (21 lb ft).
  13. If equipped with the manual transmission install right side transmission support (1).
    Fig 4: Installing Right Side Transmission Support
    G01728929Courtesy of GENERAL MOTORS CORP.
  14. Install the right side transmission support brace bolts (3, 4).

    Tighten 

    Tighten the right side transmission support brace bolts (3, 4) to 50 N.m (37 lb ft).

  15. If equipped with the automatic transmission install left side transmission support (4).
    Fig 5: Installing Left Side Transmission Support
    G01728930Courtesy of GENERAL MOTORS CORP.
  16. Install the left side transmission support bolts (3, 5).
  17. Install the left side transmission support nut (1).

    Tighten 

    • Tighten the left side transmission support bolt (3) to 8.5 N.m (75 lb in).
    • Tighten the left side transmission support bolt (5) to 28 N.m (21 lb ft).
    • Tighten the left side transmission support nut (1) to 80 N.m (59 lb ft).
  18. If equipped with the automatic transmission install right side transmission support (4).
    Fig 6: Installing Right Side Transmission Support
    G01728931Courtesy of GENERAL MOTORS CORP.
  19. Install the right side transmission support brace bolts (1, 2, 3).
  20. Install the right side transmission support nut (6).

    Tighten 

    • Tighten the right side transmission support brace bolt (1) to 8.5 N.m (75 lb in).
    • Tighten the right side transmission support bolts (2,3) to 50 N.m (37 lb ft).
    • Tighten the right side transmission support nut (6) to 80 N.m (59 lb ft).
  21. With the aide of an assistant, lower the engine and transmission to the crossmember.
  22. Install the left engine mount bracket (1) and mount bracket stud (2).
    Fig 7: Installing Left Engine Mount Bracket And Mount Bracket Stud
    G01728932Courtesy of GENERAL MOTORS CORP.
  23. Install the left engine mount bracket bolts (3).

    Tighten 

    • Tighten the left engine mount bracket bolt (3) to 102 N.m (75 lb ft).
    • Tighten the left engine mount bracket stud (2) to 87 N.m (64 lb ft).
  24. Install the right engine mount bracket (3) and the engine mount bracket bolts (1, 2).
    Fig 8: Installing Right Engine Mount Bracket And Engine Mount Bracket Bolts
    G01728933Courtesy of GENERAL MOTORS CORP.

    Tighten 

    • Tighten the two right engine mount bracket bolts (1) to 102 N.m (75 lb ft).
    • Tighten the right engine mount bracket bolt (2) to 50 N.m (37 lb ft).
  25. Remove the lifting device from the engine.
  26. Install the generator to the engine.
    Fig 9: Installing Generator To Engine
    G01728934Courtesy of GENERAL MOTORS CORP.
  27. Install the positive cable nut to the generator terminal.

    Tighten 

    Tighten the positive cable nut to generator terminal to 22 N.m (16 lb ft).

  28. Connect the generator electrical connector.
    Fig 10: Connecting Generator Electrical Connector
    G01728935Courtesy of GENERAL MOTORS CORP.
  29. Install the power steering pump.
  30. Install the power steering pump nuts (3).
    Fig 11: Installing Power Steering Pump
    G01728936Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the power steering nuts (3) to 30 N.m (22 lb ft).

  31. Install the A/C compressor bracket and compressor. Refer to COMPRESSOR .
  32. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  33. Remove the safety straps from the crossmember and J 39580.
  34. Lower the vehicle and install the engine and transmission to the vehicle.
  35. Align the crossmember to the vehicle body.
  36. Install the front crossmember bolts.
    Fig 12: Installing Front Crossmember Bolts
    G01728937Courtesy of GENERAL MOTORS CORP.

    Tighten 

    • Tighten the four crossmember bolts to 125 N.m (92 lb ft).
    • Tighten the two crossmember bolts to 145 N.m (107 lb ft).
  37. Install the transmission support bolts.
    Fig 13: Installing Transmission Support Bolts
    G01728938Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the transmission support bolts to 57 N.m (42 lb ft).

  38. Raise the vehicle.
  39. Remove the J 39580 from under the vehicle.
  40. Install the ball joints to the steering knuckles.
  41. Install the left and right upper ball joint nuts.

    Tighten 

    Tighten the upper ball joint nuts to 53 N.m (39 lb ft).

  42. Install the cotter pins to the left and right upper ball joints.
  43. Install the right and left side shock absorber lower mounting bolts.
    Fig 14: Installing Right And Left Side Shock Absorber Lower Mounting Bolts
    G01728939Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the shock absorber lower mounting bolts to 65 N.m (48 lb ft).

  44. Lower the vehicle.
  45. If equipped with the manual transmission Install the transmission control.
  46. Install the engine wire harness through the front of the cowl.
    Fig 15: Installing Engine Wire Harness
    G01728940Courtesy of GENERAL MOTORS CORP.
  47. Connect the engine wiring harness to the instrument panel wiring harness.
    Fig 16: Connecting Engine Wiring Harness To Instrument Panel Wiring Harness
    G01728941Courtesy of GENERAL MOTORS CORP.
  48. Install the hinge pillar trim panel.
  49. Install the right side insulator panel.
  50. Install the PCM. Refer to POWERTRAIN CONTROL MODULE .
  51. Install the engine harness vacuum tube to the bottom of the vacuum check valve.
    Fig 17: Installing Engine Harness Vacuum Tube
    G01728942Courtesy of GENERAL MOTORS CORP.
  52. Connect the forward lamp harness to the engine harness.
  53. Install the front 2 brake pipes to the brake modulator.
  54. Install the brake booster vacuum hose (2) to the intake manifold fitting (1).
    Fig 18: Installing Brake Booster Vacuum Hose
    G01728943Courtesy of GENERAL MOTORS CORP.
  55. Install the outlet hose to the coolant pump.
    Fig 19: Installing Outlet Hose To Coolant Pump
    G01728944Courtesy of GENERAL MOTORS CORP.
  56. Install the inlet hose to the water outlet.
    Fig 20: Installing Inlet Hose To Water Outlet
    G01728945Courtesy of GENERAL MOTORS CORP.
  57. Install the forward lamp harness to the wiring harness clip.
  58. Connect the electronic throttle control (ETC) electrical connector (1).
    Fig 21: Connecting Electronic Throttle Control (ETC) Electrical Connector
    G01728946Courtesy of GENERAL MOTORS CORP.
  59. Install the fuel vapor line (4) to the EVAP canister purge valve (5).
    Fig 22: Installing Fuel Vapor Line To EVAP Canister Purge Valve
    G01728947Courtesy of GENERAL MOTORS CORP.
  60. Install the fuel pipes (2) to the fuel rail.
  61. Install the heater hoses to the drive belt tensioner.
    Fig 23: Installing Heater Hoses To Drive Belt Tensioner
    G01728948Courtesy of GENERAL MOTORS CORP.
  62. Install a new O-ring.
  63. Install the A/C compressor and condenser hose bolt to the accumulator.

    Tighten 

    Tighten A/C compressor and condenser hose bolt at the accumulator to 48 N.m (36 lb ft).

    Fig 24: Installing A/C Compressor And Condenser Hose Bolt To Accumulator
    G01728949Courtesy of GENERAL MOTORS CORP.
  64. Install the engine ground.
  65. Install the engine wiring harness ground bolt (1).
    Fig 25: Installing Engine Wiring Harness Ground Bolt
    G01728950Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the engine wiring harness ground bolt to 25 N.m (18 lb ft).

  66. Raise the vehicle.
  67. Install the brake lines to the brake pipe clip.
  68. Install the front fuel pipe heat shield (2).
    Fig 26: Installing Front Fuel Pipe Heat Shield
    G01728951Courtesy of GENERAL MOTORS CORP.
  69. Install the front fuel pipe heat shield nuts (1).

    Tighten 

    Tighten the front fuel pipe heat shield nuts (1) to 5 N.m (44 lb in).

  70. Install a new O-ring.
  71. Install the A/C compressor and condenser hose nut to the condenser.
    Fig 27: Installing A/C Compressor And Condenser Hose Nut To Condenser
    G01728952Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the A/C compressor and condenser hose nut to the condenser to 16 N.m (12 lb ft).

  72. Install a new O-ring.
  73. Install the A/C compressor and condenser hose bolt to the compressor.

    Tighten 

    Tighten the A/C compressor and condenser hose bolt to 33 N.m (24 lb ft).

    Fig 28: Installing A/C Compressor And Condenser Hose Bolt To Compressor
    G01728953Courtesy of GENERAL MOTORS CORP.
  74. Connect the wheel speed sensors electrical connectors.
    Fig 29: Connecting Wheel Speed Sensors Electrical Connectors
    G01728954Courtesy of GENERAL MOTORS CORP.
  75. Connect the knock sensors electrical connectors.
  76. Install the RF ground strap, cruise control lead and wiring harness ground bolt to the front rail.
    Fig 30: Installing RF Ground Strap, Cruise Control Lead And Wiring Harness Ground Bolt To Front Rail
    G01728955Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the wiring harness ground bolt to 12N.m (106 lb in).

  77. Install the intermediate steering shaft and bolt to the rack.
    Fig 31: Installing Intermediate Steering Shaft And Bolt To Rack
    G01728956Courtesy of GENERAL MOTORS CORP.
  78. Install the stabilizer bar brackets. Refer to STABILIZER SHAFT INSULATOR REPLACEMENT .
  79. Install the left side front air deflector.
  80. On vehicles equipped with a manual transmission, install the clutch actuator cylinder line to the actuator cylinder.
    Fig 32: Installing Clutch Actuator Cylinder Line To Actuator Cylinder
    G01728957Courtesy of GENERAL MOTORS CORP.
  81. If equipped with a automatic transmission, install the range selector lever cable to the cable bracket.
    Fig 33: Installing Range Selector Lever Cable To Cable Bracket.
    G01728958Courtesy of GENERAL MOTORS CORP.
  82. Install the retainer to the range selector lever cable.
    Fig 34: Installing Retainer To Range Selector Lever Cable
    G01728959Courtesy of GENERAL MOTORS CORP.
  83. Install the transmission range selector lever cable to the transmission range selector.
    Fig 35: Installing Transmission Range Selector Lever Cable To Transmission Range Selector
    G01728960Courtesy of GENERAL MOTORS CORP.
  84. Install the torque arm. Refer to TORQUE ARM REPLACEMENT .
  85. Install the propeller shaft.
  86. Install the 3-way catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L ENGINE) .
  87. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels .
  88. If equipped, install the torque converter to flywheel bolts.
  89. Install the starter motor. Refer to STARTER MOTOR (3.8L) .
  90. Lower the vehicle.
  91. Install the air intake duct.
    Fig 36: Installing Air Intake Duct
    G01728961Courtesy of GENERAL MOTORS CORP.
  92. Connect the intake air temperature (IAT) sensor electrical connector.
    Fig 37: Connecting Intake Air Temperature (IAT) Sensor Electrical Connector
    G01728962Courtesy of GENERAL MOTORS CORP.
  93. Install the positive battery cable to the battery.

    Tighten 

    Tighten the positive battery terminal to 15 N.m (11 lb ft).

  94. Install the negative battery cable to the battery.
    Fig 38: Installing Negative Battery Cable To Battery
    G01728963Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the negative battery terminal to 15 N.m (11 lb ft).

  95. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  96. Check and fill the transmission fluid as necessary.
  97. Refill the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM .
  98. Recharge the A/C system. Refer to COOLANT RECOVERY RESERVOIR REPLACEMENT .
  99. Bleed the brakes. Refer to BLEEDING BRAKE SYSTEM .
  100. Bleed the clutch hydraulic system. Refer to BLEEDING .
  101. Perform the crankshaft position (CKP) system variation learn procedure.
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