ORIGINAL: jjohnson

Here it is right out of the GM Book!
Engine Replacement
Removal Procedure
Tools Required

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J 37088-A Fuel Line Quick Connect Separator [/align][align=left]



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J 39580 Universal Engine Support Table [/align][ol]Caution:Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.



Disable the SIR. Refer to Disabling the SIR System in Restraints.
Recover the A/C Refrigerant System. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
Remove the air intake duct.
Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.



Remove the engine cover.



Remove the radiator hose at the crossover.
Remove the upper radiator hose from the engine.



Remove the radiator upper cover.
Remove the cooling fans. Refer to Cooling Fan Motor Replacement - Electric in Engine Cooling.



Remove the transmission cooler lines from the radiator.



Disconnect the coolant overflow hose.
Remove the radiator and A/C condensor assembly.
Remove the cruise control servo connections.
Remove the throttle and cruise control cables from the throttle body. Refer to Accelerator Controls Cable Replacement in Engine Controls.
Remove the brake pressure switch and bracket.
Disconnect the brake master cylinder. Refer to Master Cylinder Replacement in Hydraulic Brakes.



Remove the shift cable from the manual shift lever and the bracket.



Remove the vacuum hose from the brake booster.
Using the J 37088-A fuel line quick connect separator disconnect the fuel inlet and return the lines.
Remove the negative battery cable from the left cylinder head.



Disconnect the A/C suction hose from the compressor.



Disconnect the A/C discharge hose from the compressor.
Disconnect the electrical harness from the underhood relay center.
Disconnect the electrical pass through by the brake booster.
Disconnect the right and left road sensing suspension electrical connectors.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



Remove the lower engine splash shield.
Remove the right and left wheels. Refer to Wheel Removal in Tires and Wheels.



Disconnect the steering gear intermediate shaft.



Disconnect the wheel speed and brake wear sensors.



Disconnect the exhaust downpipe from the exhaust manifold.
Disconnect the brake line at the proportioning valves.
Disconnect the oxygen sensors electrical connectors.
Lower the vehicle.
Remove the right and left road sensing suspension wheel speed harness brackets.



Remove the front and rear engine mount nuts.



Remove the strut to tower bolts at each strut tower.



Position J 39580 powertrain support dolly under engine assembly.



If the powertrain support dolly is unavailable. Support the powertrain with four suitable jackstands.



Remove the six frame mount bolts (3).
Raise the vehicle slowly.



Remove the flywheel inspection cover.



Disconnect the torque converter from the flywheel
Attach an engine lift to the engine.
Disconnect the left engine mount from the frame. Refer to Engine Mount Replacement Engine Mount Replacement.
Remove the engine to transaxle bracket.



Remove the power steering gear heat shield.
Remove the power steering gear and set aside. Refer to Power Steering Gear Replacement in Power Steering System.
Disconnect the right engine mount to frame.
Remove the transaxle to engine bolts.
Raise engine from the frame and transaxle assembly.
Transfer necessary parts as required. [/ol]
Cylinder Head Replacement

Tools Required

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J 28410 Gasket Remover [/align][align=left]



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J 45059 Angle Meter [/align]
Removal Procedure [ol]Remove the engine assembly. Refer to Engine Replacement .
Remove the following subassemblies as described elsewhere in this section: [align=left]



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The intake manifold. Refer to Intake Manifold Replacement . [/align][align=left]



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The left side cam cover. Refer to Camshaft Cover Replacement . [/align][align=left]



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The right side cam cover. Refer to Camshaft Cover Replacement . [/align][align=left]



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The crankshaft balancer. Refer to Crankshaft Balancer Replacement . [/align][align=left]



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The engine front cover. Refer to Engine Front Cover Replacement . [/align]Align the timing marks.
Remove the chain tensioner from the timing chain for the cylinder head being removed.
Remove the cam sprockets from the head being removed. The timing chain remains in the chain case.



Remove the timing chain guides. Access to the retaining screws is through the plugs at the front of the cylinder head.
Remove the water crossover.
Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement .
Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement .
Important:Do not reuse the head bolts after removal. New bolts have a special coating used for bolt retention after installation. This coating remains in the cylinder block threads after removal so proper cleaning of the cylinder block threads is important.

Remove and discard the cylinder head bolts.
Important:With the camshafts remaining in the cylinder head some valves will be open at all times. For this reason the cylinder head cannot rest on a flat surface with the cylinder face down, or valve damage will result.

Remove the cylinder head gasket.
Notice:Carefully clean the aluminum gasket surfaces in order to prevent damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers, such as J28410. Follow the manufacturer's recommendations to dissolve gasket materials with chemical agents.
Clean the gasket surfaces.
Clean the combustion chambers.
Clean the head bolt threads in the cylinder block with a soft brush or the equivalent.
Caution:Wear safety glasses in order to avoid eye damage.
Clean the head bolt bosses in the cylinder head with compressed air. [/ol]
Installation Procedure [ol]



Ensure all the cylinder head locating pins are securely mounted in the cylinder block deck face.
Make sure any old thread sealant material is removed from the cylinder head bolts holes in the cylinder block.
Important:Failure to remove all the old thread sealant material from the cylinder block could cause false torque readings.

Install a new right cylinder head gasket using the deck face locating pins for retention.



Install a new left cylinder head gasket using the deck face locating pins for retention.



Align the cylinder head with the deck face locating pins.
Place the cylinder head in position on the deck face.



Important:DO NOT reuse the old M11 cylinder head bolts.

Install new M11 cylinder head bolts (1) in the cylinder head.
Install the M6 cylinder head bolts (2) at the front of the cylinder head.
Repeat these procedures for the remaining cylinder head.



Notice:Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten the left cylinder head bolts in the sequence shown. [ol]First Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts to 30N·m (22lbft) in the sequence shown.
Second Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts an additional 60degrees in the sequence shown using the J 45059 .
Third Pass

Tighten
Repeat the sequence turning each bolt another 60degrees.
Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60degrees (total 180degrees).[/ol]
Tighten the M6 bolts at the front of the cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12N·m (106lbin).



Tighten the right cylinder head bolts in the sequence shown. [ol]First Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts to 30N·m (22lbft) in the sequence shown.
Second Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts an additional 60degrees in the sequence shown using the J 45059 .
Third Pass

Tighten
Repeat the sequence turning each bolt an another 60degrees.
Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60degrees (total 180degrees).[/ol]
Tighten the M6 bolts at the front of the right cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12N·m (106lbin).
Install the camshaft. Refer to Camshaft Replacement .
Set the camshaft timing. Refer to Setting Camshaft Timing .
Install the camshaft guide bolt access hole plugs in the cylinder heads. The plugs should be seated and snug.
Install the engine front cover. Refer to Engine Front Cover Replacement .
Install the intake manifold. Refer to Intake Manifold Replacement .
Install the left side cam cover. Refer to Camshaft Cover Replacement .
Install the right side cam cover. Refer to Camshaft Cover Replacement .
Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
Install the right exhaust manifold. Refer to Exhaust Manifold Replacement .
Install the left exhaust manifold. Refer to Exhaust Manifold Replacement .
Install the water crossover. Refer to Water Crossover Replacement in Engine Cooling.
Install the powertrain assembly. Refer to Engine Replacement . [/ol]