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Removal & Installation: Engine: Installation

  1. Lay the engine wiring harness on to the engine. Connect the oil level sensor and Crankshaft Position (CKP) sensor engine wiring harness connectors. See Figure.
  2. Install the vacuum hose to the tee on the rear vacuum port. See Figure. Connect the Mass Air Pressure (MAP) sensor harness connector. Install the engine wiring harness clip bolt. Tighten the engine wiring harness clip bolt to specification. See TORQUE SPECIFICATIONS .
  3. Connect the oil pressure sensor and knock sensor engine wiring harness connectors. See Figure.
  4. Tighten the engine wiring harness ground bolts to specification. See TORQUE SPECIFICATIONS .
  5. Connect the fuel injectors and ignition coil engine wiring harness connectors. See Figure. Install the rosebud clips to the right side fuel rail. Connect the right side CPA retainer.
  6. Connect the Idle Air Control (IAC) valve, Throttle Position (TP) sensor, fuel injectors, ignition coil, canister purge valve and Air Injection Reaction (AIR) solenoid engine wiring harness connectors. See Figure and Figure .
  7. Install the rosebud clips to the left side fuel rail. Connect the left side CPA retainer.
  8. Install the right side catalytic converter gasket and converter. See Figure. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to specification. See TORQUE SPECIFICATIONS .
  9. Install the left side catalytic converter gasket and converter. See Figure. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to specification. See TORQUE SPECIFICATIONS .
  10. Install the engine lift bracket to the engine block. See Figure. Install a engine hoist to the engine block. Remove the engine from the engine stand.
  11. Install the flywheel. See Figure. Install the engine flywheel bolts. Tighten the engine flywheel bolts a first, second and final pass in sequence to specification. See TORQUE SPECIFICATIONS .
  12. Install the clutch disc and pressure plate to the flywheel, if equipped. Install the pressure plate bolts until snug, if equipped. Using Clutch Alignment Tool (J-38836), align the clutch disc splines with the pilot bearing. Tighten the pressure plate bolts. Tighten the pressure plate bolts in sequence and evenly over 3 increments with the fourth increment to specification. See TORQUE SPECIFICATIONS . See Figure.
  13. Remove the clutch alignment tool. Remove the converter holding strap from the automatic transmission. Mate the transmission to the engine.
  14. Install the transmission bolts. Tighten the transmission-to-engine bolts to specification. See TORQUE SPECIFICATIONS .
  15. Remove the support from the transmission on the engine support table. With the aide of an assistant, position the engine and transmission over the crossmember. Lower the engine using the engine lift bracket.
  16. Install the left side engine mount and studs. Tighten the engine mount studs to specification. See TORQUE SPECIFICATIONS . Install the engine mount heat shield and nuts. Tighten the engine mount heat shield nuts to specification. Install the right side engine mount and bolts. Tighten the engine mount bolts to specification. Remove the engine hoist from the engine lift bracket.
  17. Install the generator. Install the transmission oil cooler clip and generator bolts until snug. Install the generator rear bracket bolt until snug. See Figure. Tighten the generator rear bracket bolt to specification. See TORQUE SPECIFICATIONS . Tighten the generator bolts to specification.
  18. Install the push-in retainer to the manual transmission tab. See Figure. Connect the skip shift solenoid, reverse lockout solenoid and vehicle speed sensor (VSS) harness connectors to the left side of the manual transmission, if equipped. Install the rosebud clip to the right side of the manual transmission, if equipped. See Figure. Connect the back-up light switch harness connector.
  19. Install the automatic transmission fill tube bolt. Tighten the automatic transmission fill tube bolt to specification. See TORQUE SPECIFICATIONS .
  20. Install the engine wiring harness clip bolt to the automatic transmission, if equipped. See Figure. Tighten bolt to specification. See TORQUE SPECIFICATIONS . Connect the 20-way and VSS harness connectors to the automatic transmission, if equipped.
  21. Install the torque converter bolts. Tighten the torque converter bolts to specification. See TORQUE SPECIFICATIONS .
  22. Install the right side transmission cover and bolt, if equipped. Install the left side transmission cover and bolt, if equipped. Tighten the transmission cover bolts to specification. See TORQUE SPECIFICATIONS .
  23. Install the A/C compressor bracket. Install the A/C compressor bracket bolts. Tighten the A/C compressor bolts to specification. See TORQUE SPECIFICATIONS .
  24. Install the A/C compressor. See Figure. Install the A/C compressor bolts. Tighten the A/C compressor bolts to specification. See TORQUE SPECIFICATIONS .
  25. Connect the A/C compressor harness connector. Install the rosebud clip to the engine bracket.
  26. Install the power steering pump bracket and bolts. Tighten the power steering pump bracket bolts to specification. See TORQUE SPECIFICATIONS .
  27. Position the power steering pump to the engine. Install the power steering pump brace and bolts to the pump. Tighten the power steering pump bolts to specification. See TORQUE SPECIFICATIONS .
  28. Using Power Steering Pump Pulley Installer (J-25033-C), install the power steering pump pulley.
  29. Install the A/C drive belt around the crankshaft balancer. Install a ratchet with hex-head socket to the A/C belt tensioner bolt. Rotate the A/C drive belt tensioner clockwise in order to relieve tension on the drive belt tensioner. Install the A/C drive belt under the idler pulley. Install the A/C drive belt over the A/C compressor pulley. Slowly release tension on the A/C drive belt tensioner. Remove the ratchet and socket from the A/C drive belt tensioner bolt.
  30. Route the accessory drive belt around all the pulleys except the water pump pulley and tensioner. Install a ratchet with hex-head socket to the drive belt tensioner bolt. Rotate the drive belt tensioner clockwise in order to relieve tension on the accessory drive belt tensioner. Install the accessory drive belt under the water pump pulley. Install the accessory drive belt onto the drive belt tensioner. Slowly release the tension. Remove the ratchet and socket from the drive belt tensioner bolt.
  31. Remove the engine lift bracket from the engine. Install the ignition coil(s), (as required). See REMOVAL, OVERHAUL & INSTALLATION - CAMARO & FIREBIRD article in ENGINE PERFORMANCE.
  32. Ensure that the crossmember is still secured to the support table. Carefully lower the vehicle onto the engine and transmission assembly. Install the transmission crossmember bolts. Tighten the transmission support bolts to specification. See TORQUE SPECIFICATIONS . Install the front crossmember bolts. Tighten the 4 upper crossmember bolts to specification. Tighten the 2 lower crossmember bolts to specification.
  33. Remove the security straps from the vehicle. Separate the engine wire harness branches. Raise the vehicle until the crossmember is off the support table, then remove the support table.
  34. Clip the brake lines to the brake pipe clip. Close the fuel pipe clip. Install the front fuel pipe heat shield. Install the front fuel pipe heat shield nuts. Tighten the front fuel pipe heat shield nuts to specification. See TORQUE SPECIFICATIONS .
  35. Insecure both steering knuckles. Install the left and right side upper control arm nuts. Tighten the upper control arm nuts to specification. See TORQUE SPECIFICATIONS . Install NEW cotter pins.
  36. Install the right and left side shock absorber lower bolts. Tighten the shock absorber bolts to specification. See TORQUE SPECIFICATIONS . Install the starter motor. See STARTERS - CAMARO & FIREBIRD article in ENGINE. Tighten starter bolts to specification.
  37. Install the positive lead to the generator. Install the battery positive cable nut to the generator output stud. Tighten the engine wiring harness generator output stud nut to specification. See TORQUE SPECIFICATIONS . Position the generator output terminal boot over the terminal.
  38. Connect the left and right side wheel speed sensor harness connectors. Install the intermediate steering shaft to the power steering rack. Install the intermediate steering shaft bolt. Tighten the intermediate steering shaft bolt to specification. See TORQUE SPECIFICATIONS .
  39. Install the torque arm. See appropriate REAR article in SUSPENSION.
  40. Install the propeller shaft. See PROPELLER SHAFT REPLACEMENT - ONE PIECE and/or PROPELLER SHAFT REPLACEMENT - TWO PIECE .
  41. Connect the master cylinder hose to the clutch actuator hose, if equipped.
  42. Snap the automatic transmission range selector lever cable to the bracket, if equipped. Install the automatic transmission range selector lever cable retainer, if equipped. Snap the automatic transmission range selector lever cable to the range selector lever, if equipped.
  43. Position the Radio Frequency (RF) ground strap and cruise control ground lead to the frame rail. Install the engine wiring harness ground bolt. See Figure. Tighten the engine wiring harness ground bolt to specification. See TORQUE SPECIFICATIONS .
  44. Install the stabilizer bar brackets. Install the stabilizer bar bracket bolts/stud. Tighten the stabilizer bar bracket bolts/stud to specification. See TORQUE SPECIFICATIONS .
  45. Install the drive side front fascia air deflector to the vehicle. Install the deflector bolts to the front fascia and the front bumper fascia lower deflector. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  46. Install the exhaust crossover pipe. See CROSSOVER PIPE . Connect ALL oxygen sensor harness connectors. Install the front wheels.
  47. Install the lower oil cooler line to the radiator. Tighten the lower oil cooler line fitting to specification and lower the vehicle. See TORQUE SPECIFICATIONS .
  48. Pull the engine wiring harness through the front of dash. See Figure. Connect the engine wiring harness to the instrument panel wiring harness. See Figure.
  49. Install the driver side and passenger side hinge pillar trim panel. Slide the hinge pillar trim panels forward and downward in order to install. Install the hinge pillar trim panel bolts/screws. Tighten the hinge pillar trim panel bolts/screws to specification. See TORQUE SPECIFICATIONS .
  50. Install the right side insulator panel. Align the instrument panel sound insulator to the bottom of the instrument panel. Lift the flange on the insulator over the kick panel. Press forward the flange over the boss on the HVAC module. Install the push-in retainers to the insulator. Press the retainer onto the boss on the HVAC module. Ensure that the flat sides of the retainers are facing each other.
  51. Install the PCM to the bracket. Connect the PCM connectors. See POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. Tighten connector bolts to specification. See TORQUE SPECIFICATIONS .
  52. Connect the engine harness vacuum tube to the bottom of the vacuum check valve. See Figure. Connect the forward light harness to the engine harness. Connect the secondary captured locks. Install the front 2 brake lines to the brake pressure modulator valve. Tighten the brake pipe fittings to specification. See TORQUE SPECIFICATIONS . Install the brake booster vacuum hose.
  53. Install the Air Injection Reaction (AIR) hose to the AIR shut-off valve. See Figure.
    54. WARNING: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
    CAUTION: In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. DO NOT pry or lean against the cruise control cable and DO NOT kink the cable. You must replace a damaged cable.
  54. Install and snap the accelerator and cruise control cable to the throttle body bracket. Install the accelerator control cable to the throttle lever. Install the cruise control cable to the throttle lever.
  55. Connect the fuel line to the fuel rail. See Figure. Connect the vapor line to the fuel vapor purge valve.
  56. Install the inlet and outlet heater hoses to the water pump. Install the A/C condenser tube to the condenser. See Figure. Install the A/C condenser tube nut. Install nut to specification. See TORQUE SPECIFICATIONS .
  57. Install the upper oil cooler line to the radiator. Tighten the lower oil cooler line fitting to specification. See TORQUE SPECIFICATIONS .
  58. Install the A/C compressor and condenser hose bolt at the accumulator. See MANUAL A/C-HEATER SYSTEMS article in HVAC.
  59. Install the shift control closeout boot and bolts, if equipped with a manual transmission. Install the control lever handle bolt and handle. Install the front floor console. See FLOOR CONSOLE under REMOVAL & INSTALLATION in SHIFT INTERLOCK SYSTEMS article in TRANSMISSIONS.
  60. Install the lower radiator (outlet) hose. Install the upper radiator (inlet) hose. See RADIATOR HOSES . Install the fan shroud. See FAN SHROUD .
  61. Connect the positive battery cable. Connect the negative battery cable.
  62. Recharge the A/C system. See RECOVERY/EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in HVAC.
  63. Fill the crankcase with the proper quantity and grade of engine oil. See ENGINE LUBRICATION SYSTEM  under ENGINE OILING.
  64. Disable the ignition system. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding. Enable the ignition system.
  65. Start the engine and listen for unusual noises. Check the vehicles oil pressure gauge and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature. Listen for sticking lifters and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running.
  66. Perform the Crankshaft Position (CKP) system variation learn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. Bleed the brake system. See DISC article in BRAKES.
  67. Bleed the power steering system. See appropriate POWER RACK & PINION article in STEERING. Bleed the clutch hydraulic system, if equipped. See CLUTCHES article in TRANSMISSIONS. Perform a final inspection for the proper engine oil and coolant levels.
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