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Home >> Chevrolet >> 2011 >> Corvette ZR-1 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 6.2L Or 7.0L - Repair Instructions - On Vehicle (2 Of 2) >> Engine Replacement (Except LS9) >> Installation Procedure

Installation Procedure

    NOTE: The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details.
  1. Prepare the engine for installation.
  2. Install the engine mount brackets to the engine block.
  3. Install the engine mount bracket bolts and tighten to 50 N.m (37 lb ft).
  4. Install the J 41798  to the engine. See Special Tools .
  5. Using an engine hoist and the J 41798  raise the engine slightly. See Special Tools .
  6. Remove the engine from the engine stand.
  7. Install the flywheel housing to the engine block.
  8. Install the flywheel housing bolts and tighten to 50 N.m (37 lb ft).
  9. Using an engine hoist and the J 41798  lower the engine onto the crossmember. See Special Tools .
    10. Fig 1: Engine Mount & Nuts
    GM188236Courtesy of GENERAL MOTORS CORP.
  10. Install the engine mount nuts and tighten to 65 N.m (48 lb ft).
  11. Install the spark plugs. Refer to Spark Plug Replacement .
  12. Remove the J 41798  from the engine. See Special Tools .
  13. Install the A/C compressor bracket.
    14. Fig 2: Generator Bracket & Bolts
    GM652357Courtesy of GENERAL MOTORS CORP.
  14. Install the generator bracket and power steering pump bracket.
  15. Install the generator bracket bolts until snug.
  16. Tighten the generator bracket bolts in the following order:
    1. Inner power steering pump reservoir bracket bolt
    2. Upper generator bracket bolt
    3. Outer power steering pump reservoir bracket bolt
    4. Lower generator bracket bolt and tighten to 50 N.m (37 lb ft)
    17. Fig 3: Power Steering Pump, Generator Bracket & Bolts
    GM65354Courtesy of GENERAL MOTORS CORP.
  17. Install the power steering pump, with reservoir, to the generator bracket.
  18. Install the power steering pump brace.
  19. Install the power steering pump bolts and tighten to 25 N.m (18 lb ft).
    20. Fig 4: Special Tool & Power Steering Pump Pulley
    GM65348Courtesy of GENERAL MOTORS CORP.
  20. Using the J 25033-C  install the power steering pump pulley. See Special Tools .
  21. Install the power steering pump pulley hub cap, if necessary.
  22. Install the EBCM. Refer to Electronic Brake Control Module Replacement .
  23. Roll the engine and crossmember underneath the vehicle.
  24. Partially lower the vehicle onto the engine and crossmember.
  25. Install the ground strap and ground strap bolt to the rear of the left cylinder head and tighten the ground strap bolt to 32 N.m (24 lb ft).
  26. Connect the engine oil pressure sensor electrical connector.
  27. Connect the MAP sensor electrical connector.
  28. Connect the CMP sensor electrical connector.
    29. Fig 5: Knock Sensor Electrical Connector -- Left Side
    GM1480894Courtesy of GENERAL MOTORS CORP.
  29. Reconnect the electrical connector (2) for the knock sensor, left side.
    30. Fig 6: Knock Sensor Electrical Connector -- Right Side
    GM1480896Courtesy of GENERAL MOTORS CORP.
  30. Reconnect the electrical connector (2) for the knock sensor, right side.
  31. Vehicles equipped with a manual transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
  32. Position the engine to the proper height and angle in order to install the propeller input shaft.
  33. Insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle, DO NOT force. Rotate the shaft slightly to bring the 2 splines into alignment, if necessary.
  34. Slowly seat the flywheel housing to the driveline.
  35. Install the driveline support bolts and tighten to 50 N.m (37 lb ft).
  36. Connect the master cylinder hose to the clutch actuator hose.
    37. NOTE: DO NOT tighten the flywheel hub collar bolt at this time.
  37. Vehicles equipped with an automatic transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
  38. Position the engine to the proper height and angle in order to install the propeller input shaft.
  39. Install the driveline support bolts and tighten to 50 N.m (37 lb ft).
  40. Hand tighten the flywheel hub collar bolt.
  41. Lower the vehicle onto the crossmember and align the dowels.
    42. Fig 7: View Of Front & Rear Crossmember Nuts
    GM581372Courtesy of GENERAL MOTORS CORP.
    NOTE: Use only hand tools when tightening or torquing crossmember nuts.
  42. By HAND, install new crossmember nuts until snug. Tighten the crossmember nuts to 110 N.m (81 lb ft).
  43. Raise and suitably support the vehicle.
  44. Remove the J 39580  and the J 39580-500  . See Special Tools .
  45. Remove the J 42203  from the vehicle. See Special Tools .
  46. Route the transmission wire harness into place.
  47. Install the transmission wire harness bracket bolts and tighten to 50 N.m (37 lb ft).
    48. Fig 8: Driveline Support Hole Plug Bolts
    GM173638Courtesy of GENERAL MOTORS CORP.
  48. Vehicles equipped with an automatic transmission, remove the previously installed M10-1.5 x 55 mm bolts from the front of the driveline support.
  49. Install 2 plugs in the driveline support and tighten to 50 N.m (37 lb ft).
  50. Connect the front automatic transmission fluid cooler pipes to the rear pipes, if equipped.

    Tighten the automatic transmission fluid cooler pipes to 25 N.m (18 lb ft).

  51. Install the automatic transmission cooler pipe clamp bolt, at the transmission cover, if equipped and tighten to 2.2 N.m (22 lb in).
    52. Fig 9: Transmission Lines - Oil Pan Front
    GM1478646Courtesy of GENERAL MOTORS CORP.
  52. Install the automatic transmission fluid cooler pipe clamp bolt, at the oil pan, if equipped and tighten to 12 N.m (106 lb in).
  53. Install the front transverse leaf spring. Refer to Front Transverse Spring Replacement .
    54. Fig 10: Lower Control Arm Ball Joint Stud & Steering Knuckle
    GM168544Courtesy of GENERAL MOTORS CORP.
  54. Install the lower control arm stud to the steering knuckle.
  55. Install a NEW steering knuckle nut.
    • Tighten the steering knuckle nut to 20 N.m (15 lb ft) to seat the ball joint stud.
    • Torque the steering knuckle nut an additional 210 degrees using J 36660-A  . See Special Tools .
    • Check the steering knuckle nut for a final torque of 55 N.m (41 lb ft)
  56. Connect the ABS electrical connector clips to the crossmember, if equipped.
  57. Install the front stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    58. Fig 11: Transmission Wire Harness & Engine Wire Harness
    GM652266Courtesy of GENERAL MOTORS CORP.
  58. Clip the transmission wire harness the engine wire harness, at the white tape.
  59. Install the transmission wire harness clip bolts to the engine block.
    • Tighten the transmission wire harness clip bolt, near the harness ground, to 32 N.m (23 lb ft).
    • Tighten the transmission wire harness clip bolt, near the oil pan, to 25 N.m (18 lb ft).
  60. Install the EVO electrical connector clips to the crossmember.
    61. Fig 12: Transmission Wire Harness & Electrical Connectors
    GM652265Courtesy of GENERAL MOTORS CORP.
  61. Clip the transmission wire harness to the crossmember.
  62. If equipped with RTD connect the following electrical connectors:
    • Position sensor pigtail
    • Shock absorber damper
    63. Fig 13: View Of Engine Oil Temperature Sensor Electrical Connector
    GM651886Courtesy of GENERAL MOTORS CORP.
  63. Position the ground straps (1, 2) to the engine block.
  64. Install the engine ground strap bolt and tighten to 32 N.m (23 lb ft).
  65. Connect the left HO2S electrical connector.
  66. If equipped, connect the engine oil temperature sensor (3) electrical connector.
    67. Fig 14: Compressor Hose Assembly & Retaining Bolt
    GM82082Courtesy of GENERAL MOTORS CORP.
  67. Install the AC compressor and condenser hose to the A/C compressor.
  68. Install the A/C compressor and condenser hose bolt at the compressor and tighten to 27 N.m (20 lb ft).
    69. Fig 15: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector
    GM651885Courtesy of GENERAL MOTORS CORP.
  69. Connect the right front HO2S sensor electrical connector.
  70. Connect the oil level sensor (2) electrical connector.
  71. Connect the CKP sensor (1) electrical connector.
    72. Fig 16: View Of Oil Cooler, Seal & Bolts
    GM1708343Courtesy of GENERAL MOTORS CORP.
  72. On 7.0L engine, using a new oil cooler seal (3), install the oil cooler (2) and 2 bolts.

    Tighten the oil cooler bolts to 12 N.m (106 lb in).

  73. If the oil cooler hoses were discarded install new hoses. Refer to Engine Oil Cooler Hose/Pipe Replacement (LS9 and LS7) .
    74. Fig 17: Transmission Lines - Oil Pan Front
    GM1478646Courtesy of GENERAL MOTORS CORP.
  74. Install the front transmission cooler line retainer and bolt and tighten to 12 N.m (106 lb in).
    75. Fig 18: Transmission Lines - Oil Pan Rear
    GM1478613Courtesy of GENERAL MOTORS CORP.
  75. Install the rear transmission cooler lines retainer and bolt and tighten to 12 N.m (106 lb in).
    76. Fig 19: Oil Tank Outlet Hose, Bolt & Oil Seal
    GM1708415Courtesy of GENERAL MOTORS CORP.
  76. Using a new oil seal (1) install the oil tank outlet hose (3) and bolt (2) to the oil pan.

    Tighten the outlet hose to oil pan bolt to 22 N.m (16 lb ft).

  77. If the oil tank outlet hose was discarded install a new hose. Refer to Oil Tank Outlet Hose Replacement .
    78. Fig 20: Oil Tank Inlet Hose, Bolt & Oil Seal
    GM1705736Courtesy of GENERAL MOTORS CORP.
  78. Using a new oil seal (1) install the oil tank inlet hose (2) and bolt (3) to the oil pan.

    Tighten the inlet hose to oil pan bolt to 22 N.m (16 lb ft).

  79. If the oil tank inlet hose was discarded install a new hose. Refer to Oil Tank Inlet Hose Replacement .
  80. On all engines, install the starter motor. Refer to Starter Replacement .
    81. Fig 21: View Of Driveline Tunnel Closeout Panel & Bolts
    GM67894Courtesy of GENERAL MOTORS CORP.
  81. Install the driveline close-out panel.
  82. Install the driveline close-out panel bolts and tighten to 12 N.m (106 lb in).
  83. Install the intermediate pipe. Refer to Intermediate Pipe Replacement .
  84. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  85. Lower the vehicle.
    86. Fig 22: Intermediate Steering Shaft & Bolt
    GM187354Courtesy of GENERAL MOTORS CORP.
  86. Install the intermediate steering shaft to the steering gear.
  87. Install the intermediate steering shaft bolt and tighten to 48 N.m (35 lb ft).
    88. Fig 23: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  88. Install the power brake booster vacuum hose.
  89. Install the generator. Refer to Generator Replacement (LS3 or LS7) .
  90. Connect the following electrical connectors to the engine:
    • The fuel injectors
    • The ignition coil main harness connectors
    • The EVAP solenoid
    • The electric throttle motor
    • The ECT sensor
    • The A/C compressor
    91. Fig 24: Heater Hoses & Water Pump
    GM185256Courtesy of GENERAL MOTORS CORP.
  91. Install the heater hoses to the water pump.
    92. Fig 25: Water Pump Inlet & Outlet Hoses
    GM179301Courtesy of GENERAL MOTORS CORP.
  92. Install the radiator hoses to the water pump.
  93. Install the fuel feed hose. Refer to Fuel Line Replacement - Engine .
  94. Connect the EVAP emission canister purge hose at the fuel line.
    95. Fig 26: Fuel Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  95. Install the right fuel injection rail cover.
  96. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (w/o LS9) .
  97. Install the BPMV bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement .
  98. Install the radiator. Refer to Radiator Replacement (LS3, LS7) .
  99. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) .
  100. Program the transmitters. Refer to Remote Control Door Lock and Theft Deterrent Transmitter Programming (without XL8 or Z49) or Remote Control Door Lock and Theft Deterrent Transmitter Programming (with XL8 or Z49) or Remote Control Door Lock and Theft Deterrent Transmitter Programming (New RCDLR ONLY) .
  101. Bleed the clutch hydraulic system, if equipped. Refer to Hydraulic Clutch System Bleeding .
  102. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
  103. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations .
  104. Disable the ignition system.
  105. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
  106. Enable the ignition system.
  107. Start the engine and listen for unusual noises.
  108. Check the vehicle oil pressure gauge and confirm that the engine has acceptable oil pressure.

    If necessary, install an oil pressure gauge and measure the engine oil pressure.

  109. Stop the engine and add oil to the engine oil tank as needed to bring the oil level to the FULL mark (approximately 2.4 liters (2.5 quarts).
  110. Start the engine and run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
  111. Listen for sticking lifters and other unusual noises.
  112. Inspect for fuel, oil, and/or other coolant leaks while the engine is running.
  113. With automatic transmission vehicles perform the following steps:
    1. Shut off the engine.
    2. Allow the engine to cool to room temperature.
    3. Raise the vehicle.
    4. Tighten the prop shaft hub collar bolt to 125 N.m (92 lb ft).
    114. Fig 27: View Of Engine Flywheel Housing Access Plug
    GM71455Courtesy of GENERAL MOTORS CORP.
  114. Install the engine flywheel housing inspection plug.
  115. Perform a final inspection for the proper engine oil and coolant levels.
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