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Home › Pontiac › 2004 › GTO Automatic › Repair and Diagnosis › Engine Mechanical › Engine Mechanical - 5.7L › Repair Instructions › On-Vehicle Repair Instructions › Engine Replacement › Installation Procedure

Installation Procedure

    IMPORTANT: The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details.
  1. Prepare the engine for installation. Refer to Engine Prelubing .
  2. Install the J 41798  to the engine. See Special Tools and Equipment .
  3. Using an engine hoist and the J 41798  raise the engine slightly. See Special Tools and Equipment .
  4. Remove the engine from the engine stand.
  5. Using an engine hoist and the J 41798  lower the engine onto the crossmember. See Special Tools and Equipment .
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the right and left engine mount to engine bracket nuts.

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

  7. Remove the J 41798  from the engine. See Special Tools and Equipment .
  8. Install the transmission. Refer to Transmission Replacement in Manual Transmission - Tremec 6-Speed and Transmission Replacement in Automatic Transmission - 4L60-E/4L65-E.
  9. Install both exhaust manifolds. Refer to Exhaust Manifold Replacement - Left and Exhaust Manifold Replacement - Right in Engine Exhaust.
  10. Install the power steering high pressure line brackets to the oil pan. Secure with the 2 bolts.

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

  11. Install the tray to the crossmember. Secure with the four bolts.

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

    12. Fig 1: View Of Undertray & Bolts
    GM1302128Courtesy of GENERAL MOTORS CORP.
  12. Connect the brake booster vacuum hose (1) and heater control, vacuum hose to the rear of the intake manifold.
  13. Install the high pressure line flare nut and O-ring to the pump outlet fitting at the rear of the power steering pump.
  14. Install the hose to the reservoir fluid. Secure the hose with the hose clamp.
    15. Fig 2: View Of Brake Booster Vacuum Hose
    GM1366997Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel line (4) to the fuel rail. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
  16. Connect the purge line (1) to the purge valve.
    17. Fig 3: View Of Air Intake Sensor Connector, Hose Clamps, Fuel & Purge Lines
    GM1372163Courtesy of GENERAL MOTORS CORP.
  17. Install the cable to the throttle body cam lever (1) then install the throttle cable (2) to the throttle body mounting bracket.
    18. Fig 4: View Of Throttle Cam Lever & Cable
    GM1358870Courtesy of GENERAL MOTORS CORP.
  18. Install the cable (3) to the retaining clip.
    19. Fig 5: View Of Cable & Retainer Clip
    GM1372120Courtesy of GENERAL MOTORS CORP.
  19. Feed the harness and connectors into the passenger compartment and install the dash panel grommet.
  20. Connect the powertrain to main wiring harness connector.
  21. Install harness straps to retain the wiring harness.
  22. Install the PIM and the TRM. Refer to Throttle Relaxer Assembly Replacement in Antilock Brake System.
  23. Install the engine wiring harness retaining clip to the power steering pipe bracket.
  24. Connect the PCM wiring harness retaining clip.
  25. Connect the connectors (2) to the PCM. Secure with the screws.

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

  26. Install the PCM harness connector cover (1).
    27. Fig 6: View Of PCM Harness Connector & Cover
    GM1372110Courtesy of GENERAL MOTORS CORP.
  27. Install the coolant surge tank. Refer to Surge Tank Replacement in Engine Cooling.
  28. Connect the connector to the theft deterrent horn.
  29. Connect the wiring harness retaining clips to the engine compartment.
  30. Connect the A/C wiring harness connector.
  31. Connect the positive lead terminal to the battery.
  32. Install the nut securing the battery harness ground terminals to the ABS/TCS control module bracket stud.
  33. Install the ground lead screw to the engine block and left hand engine mount.
  34. Install new O-rings (4) onto the A/C compressor hose block fitting (3). Refer to O-Ring Replacement in Heating, Ventilation and Air Conditioning.
  35. Install the A/C compressor and condenser hose to the A/C compressor (5). Secure with the nut (1).

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

    36. Fig 7: View Of A/C Compressor & Components
    GM1376448Courtesy of GENERAL MOTORS CORP.
  36. Install the heater hoses to the water pump. Secure with the clamps.
  37. Install the radiator hoses to the water pump. Secure with the clamps.
  38. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
    39. Fig 8: View Of Heater Hoses & Water Pump
    GM179301Courtesy of GENERAL MOTORS CORP.
  39. Install the intake duct to the vehicle.
  40. Secure the intake duct with the hose clamps (1,3).
  41. Connect the air intake sensor connector (2) to the air intake sensor.
  42. Install the fuel rail covers.
  43. Install the front suspension support brace. Refer to Front Suspension Support Brace Replacement .
  44. Install the hood. Refer to Hood Replacement (Without Hood Scoops) or Hood Replacement (With Hood Scoops) in Body Front End.
  45. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  46. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid andFluid and Lubricant Recommendations in Maintenance and Lubrication.
  47. Connect the negative battery cable.
  48. Disable the ignition system.
  49. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
  50. Enable the ignition system.
  51. Start the engine and listen for unusual noises.
  52. Check the vehicle oil pressure gage and confirm that the engine has acceptable oil pressure.

    If necessary, install an oil pressure gage and measure the engine oil pressure.

  53. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
  54. Listen for sticking lifters and other unusual noises.
  55. Inspect for fuel, oil, and/or other coolant leaks while the engine is running.
  56. Perform a final inspection for the proper engine oil and coolant levels.
    57. Fig 9: Identifying Air Intake Components
    GM1293684Courtesy of GENERAL MOTORS CORP.
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