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Home › Hummer › 2009 › H2 4D Utility Pickup › Repair and Diagnosis › Engine Mechanical › Engine Mechanical › Repair Instructions - On Vehicle › Engine Replacement › Installation Procedure

Installation Procedure

    Fig 1: Identifying Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS CORP.
  1. Install the J 41798  to the engine. See Special Tools .

    Tighten: 

    • Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
    • Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).

  2. Install an engine hoist to the J 41798  . See Special Tools .
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
    6. Fig 2: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  6. Install the left and right engine mount-to-engine mount bracket bolts.

    Tighten:  Tighten the engine mount-to-engine mount bracket bolts to 65 N.m (48 lb ft).

  7. Install the upper transmission bolts.

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

  8. Remove the floor jack from under the transmission.
  9. Remove the engine hoist.
    10. Fig 3: Identifying Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS CORP.
  10. Remove the J 41798  . See Special Tools .
    11. Fig 4: View Of Ignition Coils & Spark Plug Wires
    GM339300Courtesy of GENERAL MOTORS CORP.
  11. Install the ignition coils and the spark plug wires. Refer to Ignition Coil Replacement .
  12. Raise the vehicle.
    13. Fig 5: View Of Studs & Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  13. Remove the J 21366  . See Special Tools .
  14. Install the automatic transmission bolt/studs.

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

    15. Fig 6: View Of Transmission Converter Cover Bolt
    GM396795Courtesy of GENERAL MOTORS CORP.
  15. Install the transmission converter cover bolts.

    Tighten:  Tighten transmission converter cover bolts to 12 N.m (106 lb in).

    16. Fig 7: View Of Transmission Stud & Bolt
    GM394448Courtesy of GENERAL MOTORS CORP.
  16. Install the transmission bolt and stud on the right side.

    Tighten:  Tighten the automatic transmission bolts/studs to 50 N.m (37 lb ft).

    17. Fig 8: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  17. Install the automatic transmission oil level indicator tube.
    18. Fig 9: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  18. Install the automatic transmission oil level indicator tube nut.

    Tighten:  Tighten the automatic transmission oil level indicator tube nut to 18 N.m (13 lb ft).

  19. If reusing the torque converter-to-flex plate bolts, clean the bolts and apply LOCTITE™ 242, GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolt threads.
    20. Fig 10: View Of Flywheel-To-Torque Converter Bolt
    GM9096Courtesy of GENERAL MOTORS CORP.
  20. Install the flywheel to torque converter bolts.

    Tighten:  Tighten the bolts to 65 N.m (48 lb ft).

  21. Install exhaust pipes to the exhaust manifolds.
    22. Fig 11: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  22. Install the positive battery cable clip and bolt.

    Tighten:  Tighten the positive battery cable clip bolt to 9 N.m (80 lb in).

  23. Install the starter motor. Refer to Starter Motor Replacement .
  24. Install the engine protection shield. Refer to Engine Protection Shield Replacement .

    Tighten:  Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).

  25. Lower the vehicle.
  26. Install the ground cable to the engine block.

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

    27. Fig 12: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  27. Position the generator bracket to the front of the engine.
  28. Install the generator bracket bolts until snug.
  29. Install the rear power steering pump-to-engine block bolts.

    Tighten: 

    • Tighten the rear power steering pump bolt to 50 N.m (37 lb ft).
    • Tighten the generator bracket bolts to 50 N.m (37 lb ft).

  30. Route the engine wiring harness to the lower engine area.
  31. Raise the vehicle.
    32. Fig 13: View Of Positive Battery Cable, Channel & Bolt
    GM662508Courtesy of GENERAL MOTORS CORP.
  32. Slide the channel pin into the oil pan tab.
  33. Install the battery cable channel bolt.

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

    34. Fig 14: Identifying Electrical Connectors (Right Side Of Engine)
    GM662991Courtesy of GENERAL MOTORS CORP.
  34. Connect the following electrical connectors:
    • The CKP sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
  35. Lower the vehicle.
  36. Connect the fuel pipes.
    37. Fig 15: Identifying EVAP Purge Solenoid Vent Tube Components
    GM372717Courtesy of GENERAL MOTORS CORP.
  37. Install the EVAP purge solenoid vent tube to the solenoid (1).
  38. Install the EVAP tube end (3) to the vapor pipe.
    39. Fig 16: View Of Battery Cable Junction Block
    GM662505Courtesy of GENERAL MOTORS CORP.
  39. Install the battery cable junction block to the junction block bracket.
  40. Clip all of the engine wiring harness clips to their correct location.
    41. Fig 17: Identifying Oil Pressure Sensor & CMP Sensor Connectors
    GM684224Courtesy of GENERAL MOTORS CORP.
  41. Connect the following electrical connectors:
    • Oil pressure sensor (1)
    • CMP sensor (2)
  42. Position the harness ground and the engine ground strap to the block.
  43. Install the harness ground bolt at the left rear of the engine block.
  44. Position the harness ground to the block.
  45. Install the harness ground bolt at the right rear of the engine block.

    Tighten:  Tighten the harness ground bolts at the rear of the block to 16 N.m (12 lb ft).

    46. Fig 18: Identifying Coolant Temperature Sensor & Electronic Variable Orifice Switch Electrical Connectors
    GM684221Courtesy of GENERAL MOTORS CORP.
  46. Connect the following electrical connectors:
    • Coolant temperature sensor (1)
    • Electronic variable orifice switch (2)
  47. Position the harness ground and negative battery cable to the block.
  48. Install the harness ground bolt.

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

    49. Fig 19: Identifying MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  49. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    50. Fig 20: Identifying Right Side Main Electrical Connectors
    GM1235686Courtesy of GENERAL MOTORS CORP.
  50. Connect the following electrical connectors:
    • Main coil harness (4)
    • Fuel injectors (3)
    • ETC (2)
    51. Fig 21: Identifying Main Coil Harness & Fuel Injector Electrical Connectors (Left Side)
    GM679597Courtesy of GENERAL MOTORS CORP.
  51. Connect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    52. Fig 22: View Of Generator Cable & Nut
    GM395686Courtesy of GENERAL MOTORS CORP.
  52. Install the generator cable to the generator, perform the following:
    1. Install the generator cable.
    2. Install the generator cable nut to the terminal stud.

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

    3. Slide the boot over the terminal stud.
    53. Fig 23: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  53. Install the radiator vent inlet hose to the throttle body.
  54. Position the vent inlet hose clamp at the throttle body.
    55. Fig 24: Identifying Purge Solenoid Electrical Connector, Wiring Harness Nut & Generator Electrical Connector
    GM663672Courtesy of GENERAL MOTORS CORP.
  55. Install the engine wiring harness bracket and nut (2).

    Tighten:  Tighten the engine wiring harness bracket nut to 5 N.m (44 lb in).

  56. Connect the following electrical connectors:
    • EVAP canister purge solenoid (1)
    • Generator (3)
  57. Install the engine sight shield retainer and bolts.

    Tighten:  Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in).

    58. Fig 25: View Of Intake Manifold Sight Shield & Bolt
    GM665886Courtesy of GENERAL MOTORS CORP.
  58. Install the engine sight shield to the retainer.
  59. Tighten the engine sight shield bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  60. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
    61. Fig 26: View Of Radiator Outlet Hose
    GM308983Courtesy of GENERAL MOTORS CORP.
  61. Install the radiator outlet hose to the water pump.
  62. Position the radiator outlet hose clamp at the water pump.
    63. Fig 27: View Of Inlet Hose & Water Pump
    GM659418Courtesy of GENERAL MOTORS CORP.
  63. Install the radiator inlet hose to the water pump.
  64. Position the radiator inlet hose clamp at the water pump.
  65. Install the radiator supports. Refer to Radiator Support Replacement .
  66. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  67. Install the hood. Refer to Hood Replacement .
  68. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities or Fluid and Lubricant Recommendations .
  69. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
    NOTE: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
    1. Disable the ignition system.
    2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    3. Enable the ignition system.
    4. Start the engine and listen for unusual noises.
    5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    6. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
    7. Listen for sticking lifter and other unusual noises.
    8. Inspect for fuel, oil and/or coolant leaks while the engine is running.
    9. Perform a final inspection for the proper engine oil and coolant levels.
  70. Close the hood.
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