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Home >> Isuzu >> 2007 >> i-290 LS, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 84 (Engine Mechanical - 3.7L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Isuzu i-370, 2007 GMC Canyon, and 2007 Chevrolet Colorado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.
  2. Remove the engine from the engine stand.
  3. If equipped with an automatic transmission, install the automatic transmission flywheel locator. Refer to Automatic Transmission Flywheel Locator Installation .
  4. Ensure the torque converter is fully engaged with the transmission oil pump (M30 only).
    5. Fig 1: View Of Engine Lift Chain
    GM1350755Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure clearance is maintained between the engine and the following:
    • The A/C compressor
    • The A/C hoses
    • The engine mounts
    • The engine wiring harness
    • The fuel hose/pipes
    • The heater outlet hose/pipe
    • The power steering pump
    • The radiator
    • The transmission input shaft (MA5 only)
    • The transmission oil cooler pipes (M30 only)
  5. Carefully lower the engine into the engine compartment, aligning the engine dowels with the transmission.
    6. Fig 2: View Of Transmission Mounting Bolts & Engine Dowels
    GM1302115Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure the torque converter turns freely while tightening the transmission mounting bolts (M30 only).
  6. Align the engine dowels (1) with the transmission.
  7. Loosely install the 2 transmission mounting bolts (2).

    Ensure the dowels (1) are fully engaged into the transmission.

  8. Remove the jack from under the vehicle.
  9. Position the engine mounts to the engine.
    10. Fig 3: View Of Engine Mount - Right
    GM1201374Courtesy of GENERAL MOTORS CORP.
  10. Install the bolts securing the right engine mount to the engine block.

    The engine lift devise may have to be raised or lowered slightly to install these bolts.

    11. NOTE: Refer to Fastener Notice .
    Fig 4: Locating Installation Starter Bolt - Right
    GM1273485Courtesy of GENERAL MOTORS CORP.
  11. To aid in the installation of the bolts, start bolt in this position (1) first.

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

    12. Fig 5: View Of Engine Mount - Left
    GM1201372Courtesy of GENERAL MOTORS CORP.
  12. Install the bolts securing the left engine mount to the engine block.

    The engine lift devise may have to be raised or lowered slightly to install these bolts.

    13. Fig 6: Locating Installation Starter Bolt - Left
    GM1273486Courtesy of GENERAL MOTORS CORP.
  13. To aid in the installation of the bolts, start bolt in this position (1) first.

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

  14. Lower the engine fully on to the engine mounts.
  15. Remove the engine lift chain from the engine lift brackets.
  16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    17. Fig 7: View Of Transmission Mounting Bolts & Engine Dowels
    GM1302115Courtesy of GENERAL MOTORS CORP.
  17. Tighten the 2 transmission mounting bolts (2) previously installed.

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

    18. Fig 8: View Of Transmission Mounting Bolts
    GM1302117Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Ensure the studded mounting bolts (2) are located in the correct position.
    • The heater pipe (1) must be secured with the 2 upper mounting bolts.
  18. Install the remaining transmission mounting bolts.

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

  19. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure (M30 only).
  20. Repeat the following steps for all 3 torque converter bolts (M30 only):
    1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt holes in the flexplate/flywheel through the service slot.
    2. To aid in alignment of the torque converter to the flexplate/flywheel, install all 3 torque converter bolts before fully tightening using one of the following:
      • 18 mm crowfoot wrench
      • Short T50 TORX bit

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

    21. Fig 9: View Of Inspection Plug
    GM1350754Courtesy of GENERAL MOTORS CORP.
  21. Install the inspection plug (3) to the transmission (1) (M30 only).
    22. Fig 10: View Of Transmission Oil Cooler Pipe Bracket Bolt
    GM1350748Courtesy of GENERAL MOTORS CORP.
  22. Install the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (M30 only).

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

  23. Install the exhaust seal. Refer to Exhaust Seal Replacement .
    24. Fig 11: View Of Service Slot Plug
    GM1302113Courtesy of GENERAL MOTORS CORP.
  24. Install the service slot plug.
  25. Install the applicable components:
    • RWD

      Install the crossmember. Refer to Crossmember Replacement - Transmission (2WD) .

    • 4WD
      1. Position the differential carrier assembly to the frame.
        2. Fig 12: View Of Mounting Bracket To Frame Bolts
        GM1339814Courtesy of GENERAL MOTORS CORP.
      2. Install the differential carrier assembly bushing to frame bolts.

        Tighten:  Tighten the bolts to 152 N.m (112 lb ft).

      3. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement .
    26. Fig 13: View Of Fuel Hose/Pipe Bracket & Nuts (M30)
    GM1350750Courtesy of GENERAL MOTORS CORP.
  26. Install the nuts (2) securing the fuel hose/pipe bracket (1) to the transmission (M30 only).

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

  27. Connect the fuel hose/pipe retainer (4) to the range selector cable bracket (3) (M30 only).
    28. Fig 14: View Of Fuel Hose/Pipe Bracket & Nuts (MA5)
    GM1302111Courtesy of GENERAL MOTORS CORP.
  28. Install the nuts securing the fuel hose/pipe brackets to the transmission (MA5 only).

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

    29. Fig 15: View Of Engine Mount-To-Frame Bracket Bolt - Left
    GM1201502Courtesy of GENERAL MOTORS CORP.
  29. Install the left engine mount-to-frame bracket bolt.

    Tighten:  Tighten the bolt to 85 N.m (63 lb ft).

    30. Fig 16: View Of Engine Wiring Harness
    GM1350744Courtesy of GENERAL MOTORS CORP.
  30. Connect the engine wiring harness retainer (5) to the engine oil pan rail.
  31. Install the 3 bolts securing the engine wiring ground leads (2) to the engine block.

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

  32. Lower the vehicle to chest level in order to access the components through the wheelhouse.
  33. Connect the engine wiring harness connector (3) to the CKP sensor (1).
    34. Fig 17: View Of J 38185
    GM1350742Courtesy of GENERAL MOTORS CORP.
  34. Position the J 38185  (2) to the clamp (1) in order to connect the heater outlet hose to the heater outlet hose fitting (3).
  35. Install the bolt (5) securing the heater outlet hose/pipe to the left engine mount (4).

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

    36. Fig 18: View Of #1 Knock Sensor & Engine Oil Pan Rail Engine Wiring Harness Connectors
    GM1352025Courtesy of GENERAL MOTORS CORP.
  36. Connect the engine wiring harness retainer (4) to the engine oil pan rail.
  37. Connect the engine wiring harness connector to the KS 1 (2).
    38. Fig 19: View Of KS Engine Wiring Harness Connector
    GM1352023Courtesy of GENERAL MOTORS CORP.
  38. Connect the engine wiring harness connector (3) to the KS 2 (1).
  39. Connect the coolant heater cord to the coolant heater, if equipped.
    40. Fig 20: View Of EVAP Canister Purge Solenoid Valve Engine Wiring Harness Connector
    GM1352021Courtesy of GENERAL MOTORS CORP.
  40. Connect the engine wiring harness connector to the EVAP canister purge solenoid valve.
    41. Fig 21: Locating Negative Battery Cable
    GM1313636Courtesy of GENERAL MOTORS CORP.
  41. Install the bolt (4) securing the battery negative cable (5) to the engine block (1).

    Tighten:  Tighten the bolt to 35 N.m (26 lb ft).

    42. Fig 22: Locating Positive Battery Cable
    GM1313639Courtesy of GENERAL MOTORS CORP.
  42. Connect the battery positive cable (2) to the starter and install the starter terminal nut (1).

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

  43. Connect the lead (4) to the starter solenoid and install the starter solenoid "S" terminal nut (3).

    Tighten:  Tighten the nut to 3.5 N.m (31 lb in).

    44. Fig 23: View Of Wiring Harness Retainers
    GM1350692Courtesy of GENERAL MOTORS CORP.
  44. Secure the following wiring harness retainers to the engine wiring harness bracket:
    • The battery cable
    • The engine (4, 6)
    • The MAP sensor (5)
  45. Lower the vehicle.
    46. Fig 24: Identifying Intake Manifold External Components
    GM1350689Courtesy of GENERAL MOTORS CORP.
  46. Connect the MAP sensor wiring harness retainer (4) to the intake manifold (5).
  47. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement .
  48. Connect the brake booster hose (6) to the brake booster.
  49. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
  50. Connect the evaporative emission EVAP pipe at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service .
  51. Connect the fuel feed pipe to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
    52. Fig 25: View Of Intake Manifold Engine Wiring Harness Retainer
    GM1350691Courtesy of GENERAL MOTORS CORP.
  52. Connect the engine wiring harness retainer (1) to the intake manifold (2).
    53. Fig 26: View Of Engine Mount-To-Frame Bracket Bolt - Right
    GM1201503Courtesy of GENERAL MOTORS CORP.
  53. Install the right engine mount-to-frame bracket bolt.

    Tighten:  Tighten the bolt to 85 N.m (63 lb ft).

    54. Fig 27: View Of Power Steering Pump & Mounting Bolts
    GM1201379Courtesy of GENERAL MOTORS CORP.
  54. Position the power steering pump to the power steering pump bracket.
  55. Install the power steering pump mounting bolts.

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

    56. Fig 28: View Of Inlet Heater Hose Quick Connect
    GM1350735Courtesy of GENERAL MOTORS CORP.
  56. Connect the inlet heater hose quick connect (1) to the heater core (2).
    57. Fig 29: Identifying J 44220
    GM1350731Courtesy of GENERAL MOTORS CORP.
  57. Remove the J 44220  from the cylinder head.
    58. Fig 30: View Of A.I.R. Injection Pipe Cover
    GM858290Courtesy of GENERAL MOTORS CORP.
  58. Position the AIR pipe cover and NEW gasket to the cylinder head.
  59. Install the AIR pipe cover studs.

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

  60. Install the transmission filler tube (M30 only). Refer to Filler Tube and Seal Replacement .
    61. Fig 31: View Of Engine Wiring Harness Conduit
    GM1765151Courtesy of GENERAL MOTORS CORP.
  61. Engage the engine wiring harness conduit to the camshaft cover.
    62. Fig 32: View Of Intake CMP Sensor Engine Wiring Harness Connector
    GM1350719Courtesy of GENERAL MOTORS CORP.
  62. Connect the engine wiring harness connector to the Intake CMP sensor.
    63. Fig 33: View Of Engine Wiring Harness Connections To Camshaft Cover & Throttle Body
    GM1350717Courtesy of GENERAL MOTORS CORP.
  63. Connect the engine wiring harness retainer (3) to the camshaft cover (4).
  64. Connect the engine wiring harness connector (2) to the throttle body (1).
    65. Fig 34: View Of Engine Ignition Coil Wiring Harness Electrical Connectors
    GM1765152Courtesy of GENERAL MOTORS CORP.
  65. Connect the engine wiring harness electrical connectors to the ignition coils.
    66. Fig 35: View Of Engine Wiring Harness Electrical Connectors
    GM1765153Courtesy of GENERAL MOTORS CORP.
  66. Connect the engine wiring harness connectors to the following components:
    • The fuel injector harness (1)
    • The HO2S (2)
    • The ECT sensor (3)
    67. Fig 36: View Of CMP Sensor Connector, Exhaust Camshaft Actuator Connector & Engine Wiring Harness Retainer
    GM1350714Courtesy of GENERAL MOTORS CORP.
  67. Connect the engine wiring harness retainer (2) to the camshaft cover (3).
  68. Connect the engine wiring harness connectors to the following components:
    • The exhaust CMP sensor (5)
    • The exhaust camshaft actuator (6)
    69. Fig 37: View Of Power Steering Pump & Engine Wiring Harness Retainers
    GM1350723Courtesy of GENERAL MOTORS CORP.
  69. Connect the engine wiring harness retainers (1) to the power steering pump (2).
  70. Connect the engine wiring harness connectors to the following components:
    • The electric motor actuator connector (4WD only)
    • The oil pressure switch
    71. Fig 38: View Of Engine Wiring Harness & Retainers
    GM1350711Courtesy of GENERAL MOTORS CORP.
  71. Connect the engine wiring harness retainers (1) to the wheelhouse (4).
  72. Close the engine wiring harness retainer (5).
  73. Connect the 2 engine wiring harness connectors (2) to the PCM (3).
  74. Install the washer solvent container/coolant recovery reservoir mounting bolts. Refer to Washer Solvent Container Replacement .
    75. Fig 39: View Of Radiator Inlet Hose
    GM1207743Courtesy of GENERAL MOTORS CORP.
  75. Position the J 38185  to the clamp (3) in order to connect the radiator inlet hose (2) to the water outlet housing (4).
  76. Install the generator. Refer to Generator Replacement .
  77. Install the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement .
  78. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  79. Install the cooling fan. Refer to Fan Replacement .
  80. Install the outlet radiator hose. Radiator Outlet Hose Replacement .
  81. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac N Fill) .
  82. Install the battery box. Refer to Battery Box Replacement .
    83. Fig 40: View Of Hood Hinges
    GM1313590Courtesy of GENERAL MOTORS CORP.
  83. Install the hood. Refer to Hood Replacement .
  84. Fill the engine oil, if previously drained. Refer to Engine Oil and Oil Filter Replacement .
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