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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 (LS9) >> Installation Procedure

Installation Procedure

  1. Prepare the engine for installation.
  2. Install the engine mount brackets to the engine block.
    3. CAUTION: Refer to Fastener Caution .
  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. Remove the J 41798  from the engine. See Special Tools .
  12. Install the EBCM. Refer to Electronic Brake Control Module Replacement .
  13. Roll the engine and crossmember underneath the vehicle.
  14. Partially lower the vehicle onto the engine and crossmember.
  15. Install the ground strap and ground strap bolt to the rear of the left cylinder head. Tighten the ground strap bolt to 32 N.m (24 lb ft).
  16. Connect the engine oil pressure sensor electrical connector.
  17. Connect the MAP sensor electrical connector.
  18. Connect the CMP sensor electrical connector.
    19. Fig 2: Knock Sensor Electrical Connector -- Left Side
    GM1480894Courtesy of GENERAL MOTORS CORP.
  19. Reconnect the electrical connector (2) for the knock sensor, left side.
    20. Fig 3: Knock Sensor Electrical Connector -- Right Side
    GM1480896Courtesy of GENERAL MOTORS CORP.
  20. Reconnect the electrical connector (2) for the knock sensor, right side.
  21. Vehicles equipped with a manual transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
  22. Position the engine to the proper height and angle in order to install the propeller input shaft.
  23. 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.
  24. Slowly seat the flywheel housing to the driveline.
    25. Fig 4: View Of Driveline & Bolts
    GM71466Courtesy of GENERAL MOTORS CORP.
  25. Install the driveline support bolts and tighten to 50 N.m (37 lb ft).
  26. Connect the master cylinder hose to the clutch actuator hose.
  27. Hand tighten the flywheel hub collar bolt.
  28. Lower the vehicle onto the crossmember and align the dowels.
    29. Fig 5: View Of Front & Rear Crossmember Nuts
    GM581372Courtesy of GENERAL MOTORS CORP.
    NOTE: Use only hand tools when tightening or torquing crossmember nuts.
  29. By HAND, install new crossmember nuts until snug. Tighten the crossmember nuts to 110 N.m (81 lb ft).
  30. Raise and suitably support the vehicle.
  31. Remove the J 39580  and the J 39580-500  . See Special Tools .
  32. Remove the J 42203  from the vehicle. See Special Tools .
    33. Fig 6: Lower Control Arm Ball Joint Stud & Steering Knuckle
    GM168544Courtesy of GENERAL MOTORS CORP.
  33. Install the lower control arm stud to the steering knuckle.
  34. Install a NEW steering knuckle nut.
    1. Tighten the steering knuckle nut to 20 N.m (15 lb ft) to seat the ball joint stud.
    2. Torque the steering knuckle nut an additional 210 degrees using J 36660-A  . See Special Tools .
    3. Check the steering knuckle nut for a final torque of 55 N.m (41 lb ft).
  35. Connect the ABS electrical connector clips to the crossmember, if equipped.
  36. Install the front stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    37. Fig 7: Transmission Wire Harness & Engine Wire Harness
    GM652266Courtesy of GENERAL MOTORS CORP.
  37. Clip the transmission wire harness and the engine wire harness, at the white tape.
  38. Install the transmission wire harness clip bolts to the engine block.
    1. Tighten the transmission wire harness clip bolt, near the harness ground, to 32 N.m (23 lb ft).
    2. Tighten the transmission wire harness clip bolt, near the oil pan, to 25 N.m (18 lb ft).
  39. Install the EVO electrical connector clips to the crossmember.
    40. Fig 8: Transmission Wire Harness & Electrical Connectors
    GM652265Courtesy of GENERAL MOTORS CORP.
  40. Clip the transmission wire harness to the crossmember.
  41. If equipped with RTD connect the following electrical connectors:
    • Position sensor pigtail
    • Shock absorber damper
    42. Fig 9: View Of Engine Oil Temperature Sensor Electrical Connector
    GM651886Courtesy of GENERAL MOTORS CORP.
  42. Position the ground straps (1, 2) to the engine block.
  43. Install the engine ground strap bolt. Tighten the engine wire harness ground bolt to 32 N.m (23 lb ft).
  44. Connect the left HO2S electrical connector.
  45. If equipped, connect the engine oil temperature sensor (3) electrical connector.
    46. Fig 10: Compressor Hose Assembly & Retaining Bolt
    GM82082Courtesy of GENERAL MOTORS CORP.
  46. Install the AC compressor and condenser hose to the A/C compressor.
  47. Install the A/C compressor and condenser hose bolt at the compressor and tighten to 27 N.m (20 lb ft).
    48. Fig 11: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector
    GM651885Courtesy of GENERAL MOTORS CORP.
  48. Connect the right front HO2S sensor electrical connector.
  49. Connect the oil level sensor (2) electrical connector.
  50. Connect the CKP sensor (1) electrical connector.
    51. Fig 12: Oil Tank Outlet Hose, Bolt & Oil Seal
    GM1708415Courtesy of GENERAL MOTORS CORP.
  51. 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).
  52. If the oil tank outlet hose was discarded, install a new hose. Refer to Oil Tank Outlet Hose Replacement .
    53. Fig 13: Oil Tank Inlet Hose, Bolt & Oil Seal
    GM1705736Courtesy of GENERAL MOTORS CORP.
  53. 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).
  54. If the oil tank inlet hose was discarded, install a new hose. Refer to Oil Tank Inlet Hose Replacement .
  55. Install the starter motor. Refer to Starter Replacement .
    56. Fig 14: View Of Driveline Tunnel Closeout Panel & Bolts
    GM67894Courtesy of GENERAL MOTORS CORP.
  56. Install the driveline close-out panel.
  57. Install the driveline close-out panel bolts and tighten to 12 N.m (106 lb in).
  58. Install the intermediate pipe. Refer to Intermediate Pipe Replacement .
  59. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  60. Lower the vehicle.
    61. Fig 15: Steering Column, Upper Coupling & Bolt
    GM70106Courtesy of GENERAL MOTORS CORP.
  61. Install the intermediate steering shaft to the steering gear.
  62. Install the intermediate steering shaft bolt and tighten to 48 N.m (35 lb ft).
  63. Install the generator. Refer to Generator Replacement (LS9) .
  64. 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
  65. Install the radiator hoses to the water pump.
    66. Fig 16: Intercooler Cooling System Hoses
    GM2140036Courtesy of GENERAL MOTORS CORP.
  66. Connect the intercooler cooling system hoses (1).
  67. Install the fuel feed hose. Refer to Fuel Line Replacement - Engine .
  68. Connect the EVAP emission canister purge hose at the fuel line.
  69. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (LS9) .
  70. Install the BPMV bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement .
  71. Install the radiator. Refer to Radiator Replacement (LS9) .
  72. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) .
  73. Bleed the clutch hydraulic system, if equipped. Refer to Hydraulic Clutch System Bleeding .
  74. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
  75. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations .
  76. Disable the ignition system.
  77. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
  78. Enable the ignition system.
  79. Start the engine and listen for unusual noises.
  80. 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.

  81. 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).
  82. Start the engine and run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
  83. Listen for sticking lifters and other unusual noises.
  84. Inspect for fuel, oil, and/or other coolant leaks while the engine is running.
    85. Fig 17: View Of Engine Flywheel Housing Access Plug
    GM71455Courtesy of GENERAL MOTORS CORP.
  85. Install the engine flywheel housing inspection plug.
  86. Perform a final inspection for the proper engine oil and coolant levels.
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