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Removal & Installation: Engine: Installation

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install engine lift brackets to the rear of left cylinder head with a suitable bolt. Install engine lift brackets to front of right cylinder head with a suitable bolt. Install a suitable lifting device. The engine will have to be angled in order to install. Use a load positioning sling to assist in angling the engine. Remove engine from stand.
  2. Install the following: Install engine assembly in vehicle.
    3. NOTE: Do not draw engine to transmission using transmission bolts. If everything is aligned properly, engine and transmission will come together.
  3. Loosely install 2 transmission-to-engine bolts. Install left and right side engine mount frame brackets. Tighten engine mount frame bracket through-bolts to 55 ft. lbs. (75 N.m). Install engine mount-to-frame bracket bolts. Tighten engine mount-to-frame bolts to 50 ft. lbs. (65 N.m). Remove engine lift brackets from cylinder heads. Raise vehicle.
  4. Install transmission-to-engine bolts. On A/T models, install torque converter bolts.
  5. On A/T models, install nuts retaining transmission fluid fill tube bracket. On 4WD models, install lower oil pan. See OIL PAN . On A/T models, install nut retaining transmission oil cooler line clip.
  6. On all models, install exhaust pipe to exhaust outlet. Install exhaust manifold pipe to exhaust outlet clamp. Lower vehicle to work through the front fender wheelhouse openings. Install bolt retaining battery negative cable and engine wiring harness ground wire to left side of engine.
  7. Install bolts holding battery cable channel retainer to lower crankcase. Install bolts holding auxiliary battery negative cable and engine wiring harness ground wires to right side of engine.
  8. Install nut holding battery cable bracket to right side of lower crankcase. Install starter. Connect cord for engine coolant heater. Install engine oil pan skid plate.
  9. Install engine protection shield. Lower vehicle. Install bolt and ground wires at rear of left cylinder head. Install generator mounting bracket and bolts.
  10. Install right idler pulley. Install PCV oil separator bracket and fuel bleed with nuts to generator mounting bracket. Install PCV oil separator on bracket. Install a nylon strap for PCV oil separator. Install A/C compressor and power steering pump mounting bracket.
  11. Position engine wiring harness on engine. Position A/C compressor. Install A/C compressor mounting bolts. Install A/C suction hose to accumulator. Install drive belt.
  12. Install power supply cable and nut to glow plug relay. Connect fuel hoses at engine. Install nut and fuel hose bracket to valve rocker arm cover stud.
  13. Connect both fuel injection control module harness connectors. Install engine wire harness in retainer. Install cable junction block and bolt to power steering pump. If equipped, install battery cable to auxiliary generator. Install battery cable to generator. Install battery cable harness clip to bracket.
  14. Connect generator harness connector, A/C refrigerant switch, dual generator harness connector (if equipped) and A/C compressor clutch. Install harness clip to A/C compressor bracket. Install upper radiator support.
  15. Install A/C condenser. See appropriate AIR CONDITIONING article in HVAC. Install charged air cooler. Install radiator. See RADIATOR .
  16. Install outlet radiator hose to radiator and tighten hose clamp. Install hose clips to frame. Install outlet radiator hose to engine and tighten hose clamp. Install lower fan shroud. Install upper fan shroud. See FAN SHROUD .
  17. Connect inlet heater hose to heater core inlet. Firmly push to quick connector onto heater core pipe until you hear an audible click. Install outlet heater hose to outlet radiator hose. Install nut retaining outlet heater hose pipe to fuel filter mounting bracket.
  18. Install bolt retaining heater hose pipe to generator mounting bracket. Install outlet radiator hose to radiator and engine and tighten hose clamps. Install charged air cooler pipes and hoses to turbocharger and charged air cooler.
  19. Install both front fender wheelhouse inner panels. Install both front tires and wheels. Install surge tank. Install air cleaner assembly and bracket. See SURGE TANK .
  20. Connect engine wire harness connectors, mass airflow switch, air continuation pressure cycling switch and surge tank switch. Install engine wire harness clip to accumulator. Install engine wire harness clips to wheelhouse inner panel. Install engine wire harness clip to engine bracket. Torque all fasteners to specification. See TORQUE SPECIFICATIONS .
  21. Install air cleaner outlet duct to air cleaner. Install air cleaner outlet duct to turbocharger. Align duct to air cleaner. Connect batteries negative cables. Fill engine coolant. See DRAINING & REFILLING COOLING SYSTEM . Fill engine with proper capacity and quality of engine oil.
  22. Operate engine, inspect for coolant, oil, fuel, and exhaust leaks. Inspect for proper oil pressure. Inspect for proper engine operation. Install upper intake manifold sight shield. Position hood in normal operating position by moving hood hinge bolts from service position to normal operating position. Road test vehicle for normal operation. Inspect for coolant, oil, or exhaust leaks.
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