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Home >> Isuzu >> 2007 >> i-290 LS, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 78 (Engine Mechanical - 4.6L - 2 Of 4) >> On-Vehicle Repair Instructions (2 Of 2) >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Cadillac DTS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Front Engine Mount Bracket Bolts/Nuts
    GM1660849Courtesy of GENERAL MOTORS CORP.
  1. Install the front engine mount bracket.
    2. NOTE: Refer to Fastener Notice .
  2. Install the front engine mount bracket bolts/nuts.

    Tighten:  Tighten the bolts/nuts 50 N.m (37 lb ft).

  3. Install an engine lift chain to the engine lift brackets and attach an engine lifting device.
  4. Remove the engine assembly from the engine stand.
    5. Fig 2: Identifying Upper Transaxle Bolts
    GM1665471Courtesy of GENERAL MOTORS CORP.
  5. Carefully position and install the engine to the supported frame and transaxle, aligning the engine dowel pins to the transaxle.
  6. Install the upper transaxle bolts.

    Tighten:  Tighten the bolts to 75 N.m (55 lb ft).

    7. Fig 3: Identifying Rear Transaxle Bolt
    GM1665472Courtesy of GENERAL MOTORS CORP.
  7. Install the rear transaxle bolt.

    Tighten:  Tighten the bolt to 75 N.m (55 lb ft).

    8. Fig 4: Identifying Engine Mount To Frame Nut
    GM1665465Courtesy of GENERAL MOTORS CORP.
  8. Install the front engine mount to frame nut.

    Tighten:  Tighten the nut to 80 N.m (59 lb ft).

    9. Fig 5: Identifying Right Engine Mount Bracket
    GM1660851Courtesy of GENERAL MOTORS CORP.
  9. Position the rear engine mount bracket to the engine and transaxle.
  10. Install the rear engine mount bracket bolts and stud.

    Tighten:  Tighten the bolts/stud to 73 N.m (54 lb ft).

    11. Fig 6: View Of Right Engine Mount To Frame Nut
    GM1665467Courtesy of GENERAL MOTORS CORP.
  11. Install the rear engine mount to frame nut.

    Tighten:  Tighten the nut to 80 N.m (59 lb ft).

  12. Remove the engine lifting device and lift chain.
    13. Fig 7: View Of Transaxle Brace & Bolt
    GM1660864Courtesy of GENERAL MOTORS CORP.
  13. Install the transaxle brace.
  14. Install the transaxle brace bolt.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

    15. Fig 8: View Of Lower Engine Mount Bracket-To-Engine Stud Nuts
    GM1660847Courtesy of GENERAL MOTORS CORP.
  15. Tighten the front engine mount bracket nut with the transaxle brace behind it.

    Tighten:  Tighten the nut to 50 N.m (37 lb ft).

    16. Fig 9: Identifying Transaxle Brace Bolts & Bolts
    GM1665474Courtesy of GENERAL MOTORS CORP.
  16. Position the transaxle brace to the engine and transaxle.
  17. Install the transaxle brace bolts to the engine.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    18. Fig 10: Identifying Transaxle Brace Bolt/Stud
    GM1665473Courtesy of GENERAL MOTORS CORP.
  18. Install the transaxle brace bolt/stud to the transaxle.

    Tighten:  Tighten the bolt/stud to 50 N.m (37 lb ft).

    19. Fig 11: Identifying Engine Lift Bracket
    GM1660883Courtesy of GENERAL MOTORS CORP.
  19. Install the transaxle brace to the lift bracket studs.
  20. Install the transaxle brace bolt.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

  21. Install the transaxle brace nuts.

    Tighten:  Tighten the nut to 50 N.m (37 lb ft).

    22. Fig 12: View Of A/C Compressor Suction Hose
    GM1665090Courtesy of GENERAL MOTORS CORP.
  22. Remove the plug from the A/C compressor suction port.
  23. Remove and discard the old sealing washer from the compressor end of the suction hose.
  24. Install a NEW sealing washer to the compressor end of the suction hose.
  25. Install the A/C compressor suction hose the compressor.
  26. Install the A/C compressor suction hose nut at the compressor.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

  27. Secure the suction hose to the engine.
    28. Fig 13: View Of A/C Compressor Discharge Hose
    GM1665087Courtesy of GENERAL MOTORS CORP.
  28. Remove the plug from the A/C compressor discharge port.
  29. Remove and discard the old sealing washer from the compressor end of the discharge hose.
  30. Install a NEW sealing washer to the compressor end of the discharge hose.
  31. Install the A/C compressor discharge hose the compressor.
  32. Install the A/C compressor discharge hose nut at the compressor.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

  33. Secure the discharge hose to the engine.
    34. Fig 14: Identifying Power Steering Inlet Pipe
    GM1665461Courtesy of GENERAL MOTORS CORP.
  34. Install the power steering inlet pipe fitting to the power steering pump.

    Tighten:  Tighten the fitting to 27 N.m (20 lb ft).

  35. Install the power steering inlet pipe bracket to the stud.
  36. Install the power steering inlet pipe nut (1) to the rear engine mount bracket stud.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    37. Fig 15: Identifying Power Steering Outlet Hose
    GM1665464Courtesy of GENERAL MOTORS CORP.
  37. Install the power steering outlet hose to the reservoir.
  38. Position the power steering outlet hose clamp at the pump reservoir.
  39. Install the power steering outlet pipe bolt to the engine mount strut bracket.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    40. Fig 16: View Of Engine Harness Electrical Connectors
    GM1665451Courtesy of GENERAL MOTORS CORP.
  40. Install the engine harness to the engine.
  41. Position the engine harness grounds (1, 3, and 5) to the engine block.
  42. Install the engine harness ground bolts (2, 4, and 6).

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  43. Connect the engine harness electrical connector to the transaxle.
    44. Fig 17: View Of Engine Harness Electrical Connector & Clips
    GM1665455Courtesy of GENERAL MOTORS CORP.
  44. Connect the engine harness electrical connector (3) to the HO2S.
  45. Install the CPA retainer.
  46. Install the engine harness clip (1) to the engine bracket.
    47. Fig 18: Locating Engine Harness Electrical Connectors
    GM1665453Courtesy of GENERAL MOTORS CORP.
  47. Connect the engine harness electrical connectors to the following:
    • The AIR pump (1)
    • The brake modulator (2)
    48. Fig 19: View Of Engine Harness Electrical Connectors
    GM1663951Courtesy of GENERAL MOTORS CORP.
  48. Install the engine harness clip (1) to the boss on the engine block.
  49. Connect the following engine harness electrical connectors:
    • The oil pressure sensor (2)
    • The oil level sensor (3)
    • The A/C compressor (4)
    • The generator (5)
    50. Fig 20: View OF Engine Harness Electrical Connector
    GM1665105Courtesy of GENERAL MOTORS CORP.
  50. Connect the engine harness electrical connector to the A/C pressure sensor.
    51. Fig 21: Disconnecting/Connecting Engine Harness Clip At Steering Gear Heat Shield
    GM1665450Courtesy of GENERAL MOTORS CORP.
  51. Connect the engine harness electrical connector (1) to the VSS.
  52. Install the engine harness clips (2, 3) to the rear engine mount bracket and steering gear shield.
    53. Fig 22: Locating Engine Harness Electrical Connectors
    GM1663209Courtesy of GENERAL MOTORS CORP.
  53. Connect the engine harness electrical connector (6) to the ECT sensor.
  54. Install the engine harness ground (5) to the stud.
  55. Install the engine harness ground nut (4).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  56. Install the engine harness clip (2) to the steering gear shield.
  57. Connect the engine harness electrical connector (3) to the power steering sensor.
    58. Fig 23: View Of Engine Harness Electrical Connectors
    GM1665460Courtesy of GENERAL MOTORS CORP.
  58. Connect the engine harness electrical connector (1) to the engine valley jumper harness electrical connector.
    59. Fig 24: Identifying Engine Harness Electrical Connectors
    GM1665457Courtesy of GENERAL MOTORS CORP.
  59. Connect the following engine harness electrical connectors to the top of the engine:
    • The starter inline (1)
    • The AIR check valve (4)
    60. Fig 25: Identifying Engine Harness Electrical Connectors
    GM1662120Courtesy of GENERAL MOTORS CORP.
  60. Connect the following engine harness electrical connectors to the front of the engine:
    • The fuel injectors (1)
    • The ICM (3)
    • The MAP sensor (4)
    • the throttle actuator (5)
  61. Install the engine harness clip (2) to the fuel rail stud.
    62. Fig 26: Locating Engine Harness Electrical Connectors
    GM1662118Courtesy of GENERAL MOTORS CORP.
  62. Connect the following engine harness electrical connectors to the rear of the engine:
    • The EVAP solenoid (1)
    • The EGR valve (2)
    • The fuel injectors (3)
    • The ICM (4)
    63. Fig 27: Locating ICM Ground Strap & Bolt
    GM1662923Courtesy of GENERAL MOTORS CORP.
  63. Position the ICM ground strap (2) to the cylinder head.
  64. Install the ICM ground strap bolt (3) to the right cylinder head.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    65. Fig 28: View Of AIR Pipe Outlet Pipe
    GM1665399Courtesy of GENERAL MOTORS CORP.
  65. Install the AIR pipe over the studs.
  66. Connect the AIR outlet pipe quick connect fitting to the check valve. Refer to Plastic Collar Quick Connect Fitting Service .
  67. Install the AIR pipe outlet pipe nut (2) to the check valve bracket stud.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

  68. Install the AIR pipe outlet pipe nut (3) to the transaxle stud.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    69. Fig 29: View Of AIR Outlet Hose
    GM1665332Courtesy of GENERAL MOTORS CORP.
  69. Connect the AIR outlet hose to the AIR outlet pipe.
  70. Position the AIR outlet hose clamp at the AIR outlet pipe.
    71. Fig 30: Identifying Secondary AIR Pump Inlet Tube/Hose
    GM1665331Courtesy of GENERAL MOTORS CORP.
  71. Install the AIR inlet hose.
  72. Connect the AIR inlet hose quick connect fitting to the AIR pump. Refer to Plastic Collar Quick Connect Fitting Service .
  73. Install the AIR inlet hose retainer to the transaxle stud.
    74. Fig 31: Identifying Heater Outlet Pipe
    GM1665330Courtesy of GENERAL MOTORS CORP.
  74. Install the heater outlet pipe to the engine and stud.
  75. Install the heater outlet pipe nut (2) to the transaxle stud.

    Tighten:  Tighten the nut to 25 N.m (18 lb ft).

  76. Position the heater outlet pipe clamp (1) at the water pump housing.
    77. Fig 32: Identifying Rearward Engine Frame-To-Body Bolts
    GM1665303Courtesy of GENERAL MOTORS CORP.
  77. Position the engine/transaxle assembly under the vehicle.
    78. IMPORTANT: Ensure clearance is maintained between the engine/transaxle assembly and the following:
    • The A/C compressor components
    • The brake pipes
    • The heater hoses
    • The radiator hoses
    • The wheel speed sensor leads
    • The wiring harnesses
  78. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
  79. Install the 6 bolts (1) attaching the frame to the body. (Left side shown, right side similar).

    Tighten:  Tighten the bolts to 191 N.m (141 lb ft).

  80. Install the front fascia. Refer to Front Bumper Fascia Replacement .
    81. Fig 33: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  81. Raise the vehicle off of the J 39580  or the jack stands.
  82. Remove the J 39580  or jack stands from under the frame.
    83. Fig 34: Identifying Flywheel-To-Torque Converter Bolts
    GM1665177Courtesy of GENERAL MOTORS CORP.
  83. Align the flywheel with the marks made during the removal.
  84. Install the flywheel to torque converter bolts. (Engine removed for clarity).

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    85. Fig 35: View Of Torque Converter Cover
    GM1662586Courtesy of GENERAL MOTORS CORP.
  85. Position the torque converter cover.
  86. Install the torque converter cover bolt.

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

    87. Fig 36: Identifying Transaxle To Engine Brace Bolts
    GM1662583Courtesy of GENERAL MOTORS CORP.
  87. Install the transaxle brace.
  88. Install the transaxle brace bolts.

    Tighten:  Tighten the bolts to 47 N.m (35 lb ft).

    89. Fig 37: Identifying Oxygen Sensor Wiring Harness Heat Shield
    GM1665113Courtesy of GENERAL MOTORS CORP.
  89. Connect the engine harness electrical connector to the HO2S.
  90. Install the oxygen sensor wiring harness heat shield. Refer to Oxygen Sensor Wiring Harness Heat Shield Replacement .
    91. Fig 38: Identifying Steering Gear & Related Attachments
    GM1665092Courtesy of GENERAL MOTORS CORP.
    CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
  91. Install the intermediate shaft to the steering gear.
  92. Install the intermediate shaft pinch bolt.

    Tighten:  Tighten the bolt to 45 N.m (33 lb ft).

  93. Install the intermediate steering shaft cover.
    94. Fig 39: View Of A/C Suction Hose & Condenser
    GM1708344Courtesy of GENERAL MOTORS CORP.
  94. Remove the plug from the A/C condenser suction port.
  95. Unsecure the A/C compressor suction hose from the engine.
  96. Remove and discard the old sealing washer from the condenser end of the suction hose.
  97. Install a NEW sealing washer to the condenser end of the suction hose.
  98. Install the A/C compressor suction hose to the condenser.
  99. Install the A/C compressor suction hose nut.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

    100. Fig 40: View Of A/C Discharge Hose & Condenser
    GM1708342Courtesy of GENERAL MOTORS CORP.
  100. Remove the plug from the A/C condenser discharge port.
  101. Unsecure the A/C compressor discharge hose from the engine.
  102. Remove and discard the old sealing washer from the condenser end of the discharge hose.
  103. Install a NEW sealing washer to the condenser end of the discharge hose.
  104. Install the A/C compressor discharge hose to the condenser.
  105. Install the A/C compressor discharge hose nut.

    Tighten:  Tighten the nut to 16 N.m (12 lb ft).

    106. Fig 41: Identifying Rear Brake Pipes/Lines
    GM1665085Courtesy of GENERAL MOTORS CORP.
  106. Remove the plugs from the open brake lines.
  107. Connect the rear brake pipes to the front brake pipes.

    Tighten:  Tighten the fittings to 20 N.m (15 lb ft).

    108. Fig 42: Identifying Front Brake Pipe Bracket
    GM1665084Courtesy of GENERAL MOTORS CORP.
  108. Install the front brake pipe bracket (4) to the body frame rail.
  109. Tighten the nut (1) securing the right front brake pipe bracket (4) to the body frame rail.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    110. Fig 43: Identifying Front Brake Pipe Bracket
    GM1665082Courtesy of GENERAL MOTORS CORP.
  110. Install the front brake pipe bracket (4) to the body frame rail.
  111. Tighten the nut (2) securing the left front brake pipe bracket (4) to the body frame rail.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    112. Fig 44: Identifying Electronic Suspension Front Position Sensor Link
    GM1665080Courtesy of GENERAL MOTORS CORP.
  112. Install the front air deflector. Refer to Front Air Deflector Replacement .
  113. Connect the electronic suspension front position sensor link to the lower control arms ball stud, if equipped.
    114. Fig 45: Identifying Engine Harness Grommets & Clips
    GM1665075Courtesy of GENERAL MOTORS CORP.
  114. Install the engine harness clip (3) to the ride lever sensor bracket.
  115. Install the engine harness grommet (2) to the frame rail bracket.
  116. Install the front wheels. Refer to Tire and Wheel Removal and Installation .
  117. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement - Rear .
  118. Lower the vehicle.
    119. Fig 46: Locating Strut Tower Bolts
    GM1665072Courtesy of GENERAL MOTORS CORP.
  119. Install the left and right side strut tower bolts (1). (Left side shown, right side similar).

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    120. Fig 47: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
  120. Remove the J 42640  from the steering column.
    121. Fig 48: Identifying Upper Transaxle Oil Cooler Pipe Bolt & Bolt
    GM1665069Courtesy of GENERAL MOTORS CORP.
  121. Connect the transaxle oil cooler pipes to the radiator.
  122. Slide the plastic caps onto the transaxle oil cooler pipe quick connect fittings.
  123. Tighten the upper transaxle oil cooler pipe bolt (1) to the fan shroud.

    Tighten:  Tighten the bolt to 6 N.m (53 lb in).

    124. Fig 49: View Of Master Cylinder & Brake Booster
    GM1708313Courtesy of GENERAL MOTORS CORP.
  124. Unsecure the master cylinder from the engine and position the master cylinder the brake booster.
  125. Install the master cylinder nuts.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

    126. Fig 50: Identifying Heater Inlet & Outlet Hoses
    GM1664574Courtesy of GENERAL MOTORS CORP.
  126. Install the heater inlet (2) and outlet (3) hoses to the heater pipes.
  127. Position the heater inlet (1) and outlet (2) hose clamps at the heater pipes.
    128. Fig 51: Identifying Surge Tank Inlet Hose/Pipe
    GM1662131Courtesy of GENERAL MOTORS CORP.
  128. Install the surge tank inlet hose to the surge tank.
  129. Position the radiator surge tank inlet hose clamp at the surge tank.
    130. Fig 52: View Of Radiator Outlet Hose At Thermostat Housing
    GM1664571Courtesy of GENERAL MOTORS CORP.
  130. Install the radiator outlet hose (2) to the thermostat housing.
  131. Using the J 38185  position the radiator outlet hose clamp (1).
    132. Fig 53: View Of Radiator Inlet Hose & Clamp
    GM1664570Courtesy of GENERAL MOTORS CORP.
  132. Install the radiator inlet hose (2) to the water pump housing.
  133. Using the J 37097-A  position the radiator inlet hose clamp (1). See Special Tools .
    134. Fig 54: View Of Transaxle Shift Cable
    GM1664523Courtesy of GENERAL MOTORS CORP.
  134. Install the transaxle shift cable to the bracket.
  135. Connect the transaxle shift cable end (2) to the range selector lever (1).
    136. Fig 55: Identifying Transaxle Shift Cable Retainer
    GM1664519Courtesy of GENERAL MOTORS CORP.
  136. Install the transaxle shift cable retainer (1).
    137. Fig 56: Identifying Transaxle Shift Cable
    GM1664517Courtesy of GENERAL MOTORS CORP.
  137. Install the transaxle shift cable clip to the shift cable bracket.
    138. Fig 57: Identifying Engine Ground Cable
    GM1664485Courtesy of GENERAL MOTORS CORP.
  138. Position the ground strap to the frame rail.
  139. Install the engine ground strap bolt (1) to the right side frame rail.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    140. Fig 58: View Of Engine Harness & Clips
    GM1662854Courtesy of GENERAL MOTORS CORP.
  140. Install the engine harness (1) to the BEC.
    141. Fig 59: Locating Junction Block
    GM1664483Courtesy of GENERAL MOTORS CORP.
  141. Install the junction block.
  142. Install the junction block bolts.

    Tighten:  Tighten the bolts to 6.5 N.m (58 lb in).

    143. Fig 60: Identifying Air Cleaner Lower Housing
    GM1664479Courtesy of GENERAL MOTORS CORP.
  143. Connect the engine harness electrical connectors to the ECM.
  144. Engage the lever locks.
    145. Fig 61: Identifying Engine Harness Electrical Connectors
    GM1664478Courtesy of GENERAL MOTORS CORP.
  145. Connect the engine harness electrical connector to the body harness electrical connector.
  146. Engage the lever lock.
    147. Fig 62: View Of Engine Harness Electrical Connectors
    GM1664476Courtesy of GENERAL MOTORS CORP.
  147. Connect the engine harness electrical connector to the TCM.
  148. Engage the lever lock.
    149. Fig 63: Identifying Starter Solenoid Cable To Bussed Electrical Center
    GM1663997Courtesy of GENERAL MOTORS CORP.
  149. Install the starter cable to the BEC terminal.
  150. Install the starter cable clip (4) to the BEC.
  151. Install the nut (1) securing the starter cable to the BEC.

    Tighten:  Tighten the nut to 15 N.m (11 lb ft).

    152. Fig 64: View Of Junction Block Cover
    GM1664482Courtesy of GENERAL MOTORS CORP.
  152. Install the junction block cover.
  153. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
  154. Install the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement .
    155. Fig 65: Fuel Feed & EVAP Line
    GM1662130Courtesy of GENERAL MOTORS CORP.
  155. Connect the fuel feed and EVAP line quick-connect fittings (1, 2). Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
    156. Fig 66: View Of Brake Booster Vacuum Hose
    GM1663944Courtesy of GENERAL MOTORS CORP.
  156. Connect the brake booster vacuum hose to the vacuum connection.
  157. Position the brake booster vacuum hose clamp at the engine port.
  158. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  159. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  160. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac-N-Fill) .
  161. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
  162. Recharge the A/C refrigerant system. Refer to Refrigerant Recovery and Recharging .
  163. Bleed the power steering system. Refer to Power Steering System Bleeding .
  164. Check the wheel alignment. Refer to Measuring Wheel Alignment .
  165. Pre-lube the engine. Refer to Engine Prelubing .
  166. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  167. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
  168. Start the engine and listen for abnormal conditions.
  169. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
  170. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
  171. While the engine continues to idle raise and support the vehicle.
  172. Inspect for oil, coolant and exhaust leaks while the engine is idling.
  173. Lower the vehicle.
  174. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
  175. Perform a final inspection for the proper engine oil and coolant levels.
  176. Road test the vehicle.
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