Corvette 2005-2008

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  

The following tools will be required in addition to the basic hand tools:



Transverse spring compressor and adapters
 
Ball joint separator
 
Engine support table
 
Driveshaft support strap
 
Fuel pressure gauge
 
Power Steering Pump Pulley Remover/Installer
 

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Cap and plug all openings for the fuel system to prevent contaminants from entering the system.


    CAUTION
    Failure to use the minimum fastener length specified will prevent the proper retention of the propeller shaft during assembly.



    Intake Air Temperature (IAT) sensor electrical connector
     
    Mass Air Flow (MAF) sensor electrical connector
     
    Air intake duct and air cleaner
     
    Upper radiator support
     
    Radiator
     
    Electronic Brake Control Traction Module/Brake Pressure Modulator Valve (EBTCM/BPMV) and bracket
     
    Brake pipes
     
    Accessory drive belt
     
    Fuel line from the connector at the front of the dash
     



    Fuel rail covers
     
    Fuel line at the fuel rail
     
    Radiator hoses from the water pump
     
    Heater hoses from the water pump
     
    Fuel injector electrical connectors
     
    Ignition coil main harness connector
     
    Evaporative Emission (EVAP) solenoid electrical connector
     
    Electric throttle motor electrical connector
     
    Throttle Position Sensor (TPS) electrical connector
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    A/C compressor electrical connector
     
    Alternator electrical connectors
     
    Alternator
     
    Brake booster vacuum hose
     
    Intermediate shaft to steering gear bolt

    Click image to see an enlarged view

    Fig. Remove the intermediate steering shaft bolt to the steering gear

     
    Intermediate shaft from the steering gear
     
    Secondary Air Injection (AIR) hose from the left exhaust manifold
     
    Both front wheels
     
    Heated Oxygen Sensor (HO 2 S) connectors from the intermediate exhaust pipes
     
    Intermediate exhaust pipes
     
    Catalytic converter
     
    Close-out panel
     
    Starter motor electrical connectors
     
    Starter motor
     
    Crankshaft Position (CKP) sensor electrical connector
     
    Oil level sensor connector
     
    Right Heated Oxygen Sensor (HO 2 S)
     
    A/C compressor hose assembly
     
    Engine oil temperature sensor electrical connector
     
    Left Heated Oxygen Sensor (HO 2 S)
     
    Ground straps
     
    Front stabilizer shaft
     
    Connectors from the cooling fans
     
    Cooling fan assembly
     
    Unclip the transmission wire harness from the engine wire harness.
     
    Tie rod ends from the steering knuckles
     
    Antilock Brake System (ABS) electrical connectors from the crossmember, if equipped
     
    Electronic Variable Orifice (EVO) connector clips from the crossmember, if equipped
     
    Real Time Damping (RTD) connector clips from the crossmember, if equipped
     
    Shock absorber lower mounting bolts
     
    Front transverse leaf spring

    Click image to see an enlarged view

    Fig. Use a compressor such as J-33432-A to compress the front transverse spring

     
    Automatic transmission cooler pipes at the flywheel housing junction
     
    Automatic transmission cooler pipe clamps from the engine oil pan
     
    Automatic transmission cooler pipe from the radiator
     



    Click image to see an enlarged view

    Fig. On automatic transmission vehicles, remove the plugs from the driveline support assembly and install 2 M10 x 1.5 bolts into the plug holes

  10.  
  11. For vehicles with an automatic transmission, perform the following steps:
    1. Remove the two plug bolts in the driveline support assembly.
    2.  
    3. Install an M10 x 55 bolt, or longer, in each plug location. Torque the bearing support bolts to 26 ft. lbs. (35 Nm).
    4.  
    5. Remove the bell housing inspection cover, then turn the flywheel hub collar to access the bolt and loosen it.

      Click image to see an enlarged view

      Fig. Loosen the bolt on the flywheel hub collar after turning it for access

    6.  
    7. Remove the engine flywheel housing access plug.
    8.  
    9. Rotate the automatic transmission collar so that the bolt is facing down.
    10.  
    11. Loosen the bolt and unclip the wire harness from the engine and reposition it to the driveline.
    12.  
    13. Install a driveline support tool to the close out panel flange.
      CAUTION
      Never use a driveline support tool to support the weight of the engine assembly.



      Click image to see an enlarged view

      Fig. Install a Driveline Support tool J-42203 to the under cover flange

    14.  

  12.  
  13. If equipped with a manual transmission, perform the following steps:
    1. Unclip the clutch actuator hose from the master cylinder hose.
    2.  
    3. Using a hydraulic clutch line separator tool, depress the white release ring on the actuator hose and pull lightly on the master cylinder hose.
    4.  
    5. Remove the flywheel housing bolts from the driveline support.
    6.  

  14.  
  15. Support the engine and crossmember assembly.
  16.  
  17. Remove or disconnect the following:

    Front crossmember nuts BY HAND and lower the engine assembly slightly
     
    Secondary Air Injection (AIR) tube bracket bolt and reposition the bracket to gain access to the ground strap
     
    Ground strap from the rear of the left cylinder head
     
    Engine oil pressure sensor electrical connector
     
    Camshaft Position (CMP) sensor electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Knock Sensor (KS) electrical connector
     
    Front driveline support assembly bolts
     
    Engine from the driveline, by placing a flat blade tool between edge of the driveline and the flywheel housing

    Click image to see an enlarged view

    Fig. Separate the flywheel housing from the driveline support

     

  18.  
  19. Pull the engine away from the propeller shaft.
  20.  
  21. Raise the vehicle off of the engine and crossmember.
  22.  
  23. Remove the power steering pump (with reservoir) from the engine and reposition them to the crossmember
  24.  
  25. Remove the A/C, alternator and power steering pump brackets
  26.  
  27. Remove the AIR pipe and gasket
  28.  
  29. Remove the spark plugs
  30.  
  31. Remove the engine mount-to-crossmember nuts.
  32.  
  33. Remove the engine from the crossmember.
  34.  

To install:

  1. Install the engine on the crossmember and torque the nuts to 48 ft. lbs. (65 Nm).
  2.  
  3. Lower the vehicle onto the engine/crossmember assembly.
  4.  
  5. Install or connect the following:

    Spark plugs
     
    AIR pipe and gasket
     
    A/C, alternator and power steering pump brackets
     
    Power steering pump and reservoir on the engine and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Ground strap to the rear of the left cylinder head and torque the bolt to 24 ft. lbs. (32 Nm)
     
    Engine oil pressure sensor electrical connector
     
    CMP sensor electrical connector
     
    MAP sensor electrical connector
     
    KS electrical connector
     
    Front driveline support bolts and torque them to 37 ft. lbs. (50 Nm)
     
    Air tube and bracket and torque the bolt to 15 ft. lbs. (20 Nm)
     
    New crossmember nuts and torque them to 81 ft. lbs. (110 Nm)
     
    Flywheel housing bolts and torque them to 37 ft. lbs. (50 Nm)
     
    Clutch actuator hose to the flywheel housing (if equipped)
     
    Master cylinder hose to the clutch actuator hose (if equipped)
     
    Wire harness to the rear of the engine
     

  6.  
  7. Remove the driveline support tool.
  8.  
  9. Remove the M10 x 55mm bolts from the driveline support assembly.
  10.  
  11. Install the following:

    Two plugs in the driveline support assembly after removing the M10 x 55 bolts and torque them to 37 ft. lbs. (50 Nm)
     
    Automatic transmission oil cooler pipes at the flywheel housing junction and torque them to 20 ft. lbs. (27 Nm), if equipped
     
    Automatic transmission cooler pipes to the front and rear of the oil pan
     
    Front transverse spring and torque the bolts to 46 ft. lbs. (62 Nm)
     
    Shock absorber lower mounting nuts and torque them to 21 ft. lbs. (28 Nm)
     
    Front stabilizer shaft and torque the bolts to 53 ft. lbs. (72 Nm)
     
    ABS electrical connector
     
    EVO electrical connector
     
    RTD electrical connector
     
    Tie rods to the steering knuckle and torque the nuts to 33 ft. lbs. (45 Nm).
     
    Radiator
     
    Cooling fan assembly to the radiator and attach the electrical connectors to the fans
     
    Ground wires to the left side of the engine
     
    Left HO 2 S connector
     
    Engine oil temperature sensor connector
     
    A/C compressor hoses to the compressor
     
    A/C compressor line retaining bolt and torque it to 26 ft. lbs. (35 Nm)
     
    Right HO 2 S connector
     
    CKP sensor electrical connector
     
    Oil level sensor electrical connector
     
    Wire harness ground wires to the right side of the engine
     
    Starter motor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Driveline close out panel and torque the bolts to 106 inch lbs. (12 Nm)
     
    Catalytic converters and torque the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Intermediate exhaust pipe and hangers and torque the bolts to 37 ft. lbs. (50 Nm) and the nuts to 15 ft. lbs. (20 Nm)
     
    Front wheels
     
    Automatic transmission cooler pipes to the radiator (if equipped) and torque the fittings to 26 ft. lbs. (35 Nm)
     
    AIR hose to the left exhaust manifold
     
    Intermediate steering shaft to the steering gear and torque the bolt to 35 ft. lbs. (48 Nm)
     
    Brake booster vacuum hose
     
    Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Alternator connectors and torque the nuts to 10 ft. lbs. (13 Nm)
     
    Fuel injector electrical connectors
     
    Ignition coil main electrical connectors
     
    EVAP solenoid electrical connectors
     
    Throttle motor electrical connector
     
    ECT sensor electrical connector
     
    TPS electrical connector
     
    A/C compressor electrical connector
     
    Heater hoses to the water pump
     
    Radiator hoses to the water pump
     
    Fuel line to the fuel rail
     
    Fuel rail covers
     
    Drive belt
     
    EBTCM/BPMV bracket and torque the bolts to 20 ft. lbs. (27 Nm)
     
    EBTCM/BPMV to the bracket and torque the nuts to 89 inch lbs. (10 Nm)
     
    Upper radiator hose
     
    Upper radiator support
     
    Air cleaner and air intake duct
     
    IAT sensor electrical connector
     
    MAF sensor electrical connector
     
    Negative battery cable
     
    Engine flywheel housing inspection plug
     

  12.  
  13. Fill the engine with new oil.
  14.  
  15. Fill the cooling system.
  16.  
  17. Evacuate and recharge the A/C system.
  18.  
  19. On vehicles with an automatic transmission, start the engine and allow it to idle for 10 minutes. Torque the hub collar bolt to 92 ft. lbs. (125 Nm) and install the flywheel inspection plug.
  20.  
  21. A wheel alignment is recommended when the engine and crossmember have been removed from the vehicle.
  22.  
  23. Check the vehicle for leaks and repair if necessary.
  24.  

 
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