Chevrolet Full Size Cars 1979-1989

Engine

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Common engine mounting found on most Chevrolet full size vehicles



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Fig. Fig. 2 The transmission crossmember mount (also known as the rear engine mount) is sometimes shimmed for proper alignment


CAUTION
Please refer to before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result.

Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

Inline 6-Cylinder Gasoline Engine
  1. Scribe alignment marks around the hood hinges and remove the hood.
  2.  
  3. Disconnect the negative battery cable and remove the air cleaner.
  4.  
  5. Drain the cooling system and, if necessary, the crankcase.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the radiator and the heater hoses, then remove the radiator and the fan shroud.
  2.  

When removing the radiator, remember to disconnect and plug the transmission fluid cooler lines at the radiator.

  1. Disconnect and label the wires at the ignition coil, the starter, the alternator, the temperature switch and the oil pressure switch.
  2.  
  3. Disconnect accelerator control cable at the inlet manifold, the fuel inlet line from the fuel pump, the hoses from the vapor canister and (if equipped) the power brake vacuum line from the intake manifold.
  4.  
  5. If equipped with power steering, remove the power steering pump and move it aside.
  6.  
  7. Raise and support the vehicle on jackstands.
  8.  
  9. Disconnect the exhaust pipe from the exhaust manifold and (if equipped) the converter bracket from the rear transmission mount.
  10.  
  11. Remove the starter and the converter housing cover.
  12.  
  13. Remove the converter-to-flexplate bolts.
  14.  
  15. Attach a vertical hoist to the engine and support the transmission with a floor jack, then raise the engine slightly.
  16.  
  17. Remove the engine mount through-bolts and the bell housing-to-engine bolts.
  18.  
  19. Carefully remove the engine from the vehicle. Pause several times while lifting the engine to make sure no components, wires or hoses are caught.
  20.  

To install:

  1. Attach the engine hoist and lower the engine into position.
  2.  

Make sure the torque converter bolts are aligned with the mounting holes on the flexplate, before attaching bell housing to engine.

  1. Support the transmission with a floor jack and install the engine mount through-bolts and the bell housing-to-engine.
  2.  
  3. If equipped with an automatic transmission, install the converter-to-flexplate bolts.
  4.  
  5. Install the starter and the converter housing cover.
  6.  
  7. Connect the exhaust pipe to the exhaust manifold and (if equipped) the converter bracket to the rear transmission.
  8.  
  9. Lower the vehicle.
  10.  
  11. If equipped with power steering, install the power steering pump.
  12.  
  13. Connect accelerator control cable at the inlet manifold, the fuel inlet line to the fuel pump, the hoses to the vapor canister and (if equipped) the power brake vacuum line to the intake manifold.
  14.  
  15. Connect the labeled wires at the ignition coil, the starter, the alternator, the temperature switch and the oil pressure switch.
  16.  
  17. Install the radiator and fan shroud, then connect the heater and radiator hoses.
  18.  
  19. Fill the cooling system and, if applicable, the crankcase.
  20.  
  21. Connect the negative battery cable and install the air cleaner.
  22.  
  23. Install the hood.
  24.  


WARNING
Please refer to before servicing the compressor or damage to the air conditioning system or personal injury could result.

V6 Gasoline Engine
  1. Scribe alignment marks at the hood hinges and remove the hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the exhaust pipe from the exhaust manifold.
  6.  
  7. Remove the bell housing cover and disconnect the transmission oil cooler lines at the oil pan.
  8.  
  9. Remove the left engine mount through-bolt and loosen the right engine mount through-bolt.
  10.  

Before removing the torque converter bolts, scribe a mark to ensure the proper relationship between the torque converter and flex plate during installation.

  1. Remove the torque converter cover, the converter-to-flex plate bolts and the engine-to-transmission bolts.
  2.  
  3. As applicable, disconnect the CCC wiring harness from the transmission and the knock sensor.
  4.  
  5. Disconnect the fuel hoses from the frame and the lower fan shroud, as applicable. Remove the lower fan shroud bolts.
  6.  
  7. Lower the vehicle and, if necessary, remove the windshield washer bottle.
  8.  
  9. Label and disengage the CCC wiring harness, other necessary wiring connectors and the vacuum hoses from the engine.
  10.  
  11. Remove the air cleaner, the upper fan shroud, the accelerator and the T.V. cables.
  12.  
  13. Drain the cooling system, then remove the heater and the radiator hoses.
  14.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. If equipped with air conditioning and power steering, remove the compressor and the power steering pump from the engine, then position them aside.
  2.  
  3. Disconnect the transmission oil cooler lines and the overflow tube from the radiator, then remove the radiator.
  4.  
  5. Remove the air conditioning hose and the adjusting bracket from the alternator.
  6.  
  7. Disconnect the battery cables from the frame and the heater hose from the bracket.
  8.  
  9. Secure a vertical lifting device to the engine and remove the remaining motor mount through-bolt, then remove the engine from the vehicle. Pause several times while lifting the engine to make sure no components, wires or hoses are caught.
  10.  


CAUTION
When removing the engine from the transmission, be careful that the torque converter does not pull out of the transmission.

To install:

  1. Secure a vertical lifting device to the engine and install the engine in the vehicle. Loosely install the right motor mount through-bolt.
  2.  
  3. Connect the battery cables to the frame and the heater hose to the bracket.
  4.  
  5. Secure the air conditioning hose and the adjusting bracket to the alternator.
  6.  
  7. Connect the transmission oil cooler lines and the overflow tube to the radiator, then secure the radiator.
  8.  
  9. As applicable, reposition and secure the compressor and/or the power steering pump.
  10.  
  11. Install the heater and the radiator hoses.
  12.  
  13. Install the air cleaner, the upper fan shroud, the accelerator and the T.V. cables.
  14.  
  15. Engage the CCC wiring harness, other necessary wiring connectors and the vacuum hoses to the engine as tagged or noted during removal.
  16.  
  17. Lower the vehicle and, if removed, install the windshield washer bottle.
  18.  
  19. Connect the fuel hoses to the frame and the lower fan shroud, as applicable. Install the lower fan shroud bolts.
  20.  
  21. As applicable, connect the CCC wiring harness to the transmission and the knock sensor.
  22.  
  23. Align the matchmarks made earlier, then install the converter-to-flex plate bolts and the engine-to-transmission bolts. Install the torque converter cover.
  24.  
  25. Install the left engine mount through-bolt and tighten the right engine mount through-bolt.
  26.  
  27. Connect the transmission oil cooler lines at the oil pan.
  28.  
  29. Connect the exhaust pipe to the exhaust manifold.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Refill the radiator with the proper coolant mixture.
  34.  
  35. Install the hood.
  36.  

V8 Gasoline Engine
  1. Scribe alignment marks on hood and remove hood from hinges.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain cooling system, then remove the heater hoses and the radiator hoses from the engine.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the upper fan shroud and the fan assembly.
  2.  
  3. If equipped with air conditioning and power steering, remove the compressor and the power steering pump from the engine, then position them aside.
  4.  
  5. Disconnect the accelerator and the T.V. cables.
  6.  
  7. Remove the transmission oil cooler lines from the radiator and remove the radiator.
  8.  
  9. Disconnect and label the vacuum hoses and the ECM wiring harness connector(s) from the engine.
  10.  
  11. If equipped, remove the AIR pipe from the converter.
  12.  
  13. If necessary, remove the windshield washer bottle.
  14.  
  15. Tag and disconnect the wiring harness and related engine wiring.
  16.  
  17. Remove the distributor cap and the cruise control cable (if equipped).
  18.  
  19. Disconnect the positive battery cable from the battery and, if equipped, the frame straps. Disconnect the negative battery cable from the air conditioning hose/alternator bracket.
  20.  
  21. Raise and support the vehicle on jackstands.
  22.  
  23. Disconnect the crossover pipe and the catalytic converter as an assembly.
  24.  

Before removing the torque converter bolts, scribe a mark to ensure the relationship between the torque converter and the flex plate.

  1. Remove the torque converter cover and the torque converter bolts.
  2.  
  3. Remove the engine-to-mount bolts.
  4.  
  5. Disconnect and plug the fuel line from the fuel pump.
  6.  
  7. Disconnect the torque converter clutch wiring from the transmission, then disconnect the transmission oil cooler lines from the clip at the engine oil pan.
  8.  
  9. Remove the engine-to-transmission bolts.
  10.  
  11. Lower the vehicle and support the transmission.
  12.  
  13. Secure a vertical lifting device to the engine and remove the engine from the vehicle. Pause several times while lifting the engine to make sure no components, wires or hoses are caught.
  14.  


CAUTION
When removing the engine from the transmission, be careful that the torque converter does not pull out of the transmission.

To install:

Make sure the torque converter bolts are aligned with the mounting holes on the flexplate, before attaching bell housing to engine.

  1. Secure a vertical lifting device to the engine and install the engine to the vehicle, then carefully install the engine-to-transmission bolts.
  2.  
  3. Connect the torque converter clutch wiring to the transmission and the transmission oil cooler lines to the clip at the engine oil pan.
  4.  
  5. Connect the fuel line to the fuel pump.
  6.  
  7. Install the engine-to-mount bolts.
  8.  
  9. Install the torque converter bolts and the torque converter cover.
  10.  
  11. Install the crossover pipe and the catalytic converter as an assembly.
  12.  
  13. Lower the vehicle.
  14.  
  15. Connect the positive battery cable to the battery and, if applicable, to the frame straps. Connect the negative battery cable to the air conditioning hose/alternator bracket.
  16.  
  17. Install the distributor cap and, if equipped, the cruise control cable.
  18.  
  19. Engage the wiring harness and related engine wiring connectors.
  20.  
  21. If removed, install the windshield washer bottle.
  22.  
  23. If equipped, install the AIR pipe to the converter.
  24.  
  25. Connect the vacuum hoses and the ECM wiring harness connector(s) to the engine.
  26.  
  27. Install the transmission oil cooler lines to the radiator and install the radiator.
  28.  
  29. Connect the accelerator and the T.V. cables.
  30.  
  31. As applicable, reposition and secure the compressor and/or the power steering pump.
  32.  
  33. Install the upper fan shroud and the fan assembly.
  34.  
  35. Install the heater hoses and the radiator hoses to the engine, then fill the cooling system.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Install the hood.
  40.  

Diesel Engine
  1. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner assembly.
  2.  
  3. Mark the hood-to-hinge position and remove the hood from the vehicle.
  4.  
  5. Disconnect the ground cables from the batteries.
  6.  
  7. Disconnect the ground wires at the fender panels and the ground strap at the cowl.
  8.  
  9. Disconnect the radiator hoses, cooler lines, heater hoses, vacuum hoses, power steering pump hoses, air conditioning compressor (hoses attached), fuel inlet hose and all attached wiring.
  10.  
  11. Remove the bellcrank clip.
  12.  
  13. Disconnect the throttle and transmission cables.
  14.  
  15. Remove the upper radiator support and the radiator.
  16.  
  17. Raise and support the vehicle safely using jackstands.
  18.  
  19. Disconnect the exhaust pipes at the manifold.
  20.  
  21. Remove the torque converter cover and the three bolts holding the converter to the flywheel.
  22.  
  23. Remove the engine mount bolts and nuts.
  24.  
  25. Remove the three right side transmission-to-engine bolts. Remove the starter.
  26.  
  27. Lower the car and attach a hoist to the engine.
  28.  
  29. Slightly raise the transmission with a jack.
  30.  
  31. Remove the three left side transmission-to-engine bolts and lift out the engine. Pause several times while lifting the engine to make sure no components, wires or hoses are caught.
  32.  

To install:

  1. With a hoist, lower the engine into position and support the transmission with a jack.
  2.  
  3. Install the three left side transmission-to-engine bolts.
  4.  
  5. Install the three right side transmission-to-engine bolts. Install the starter.
  6.  
  7. Install the engine mount bolts or nuts.
  8.  
  9. Install the three bolts holding the converter to the flywheel and tighten to 40 ft. lbs. (54 Nm), then install the torque converter cover.
  10.  
  11. Connect the exhaust pipes at the manifold.
  12.  
  13. Lower the car.
  14.  
  15. Install the upper radiator support and the radiator.
  16.  
  17. Connect the throttle and transmission cables.
  18.  
  19. Install the bellcrank clip.
  20.  
  21. Connect the radiator hoses, cooler lines, heater hoses, vacuum hoses, power steering pump hoses, air conditioning compressor (hoses attached), fuel inlet hose and all attached wiring.
  22.  
  23. Connect the ground wires at the fender panels and the ground strap at the cowl.
  24.  
  25. Connect the ground cables to the batteries.
  26.  
  27. Install the hood.
  28.  
  29. Install the air cleaner.
  30.  
  31. Fill the cooling system.
  32.  

 
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