GM Astro/Safari 1985-1996 Repair Guide

Engine

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REMOVAL & INSTALLATION



2.5L Engine

CAUTION
Before removing any component of the fuel system, be sure to reduce the fuel pressure in the system.

  1. From inside the vehicle, remove the engine cover. For details, please refer to General Information & Maintenance of this information.
  2.  
  3. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  4.  
  5. Place a drain pan under the radiator, open the drain cock and drain the cooling system; be sure to save the cooling fluid for reuse.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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 headlight bezel and grille.
  2.  
  3. Remove the lower radiator close out panel and the radiator support brace.
  4.  
  5. Remove the lower tie bar, the cross braces and the hood latch assembly.
  6.  
  7. If equipped, remove the upper radiator core support.
  8.  
  9. Remove the radiator hoses, then disconnect and plug the transmission-to-radiator oil cooler lines (if equipped).
  10.  
  11. Remove the radiator filler panels, then the radiator and the fan shroud as an assembly.
  12.  
  13. At the bulkhead connector, disconnect the engine electrical harness. Disconnect the electrical harness from the Electronic Control Module (ECM) and pull it through the bulkhead.
  14.  
  15. Remove the heater hoses from the heater core.
  16.  
  17. Disconnect the accelerator, the cruise control and the detent (if equipped) cables. Disconnect the ground cable from the cylinder head.
  18.  
  19. Remove the oil filler neck and the thermostat housing from the engine.
  20.  
  21. Remove the purge hose from the charcoal canister, then the air cleaner and adapter from throttle body. Disconnect the fuel hoses from the throttle body.
  22.  
  23. Raise and support the front of the vehicle on jackstands.
  24.  
  25. Disconnect the exhaust pipe from the exhaust manifold. Remove the flywheel cover from the bellhousing.
  26.  
  27. Disconnect the electrical harness from the transmission and the frame, then the electrical connectors from the starter.
  28.  
  29. Remove the starter-to-engine bolts and the starter from the engine.
  30.  
  31. Remove the through-bolts from the engine mounts and install an engine lifting device to the engine.
  32.  
  33. Remove the bellhousing-to-engine bolts, then lower the vehicle. Using a floor jack, support the transmission.
  34.  
  35. Using an engine lifting device, lift the engine, separate it from the transmission and remove it from the vehicle.
  36.  

To install:
  1. Using an engine lifting device, lift the engine, connect it to the transmission and install it in the vehicle.
  2.  
  3. Install the bellhousing-to-engine bolts, torque to 32 ft. lbs. (44 Nm) then lower the vehicle. Using a floor jack, support the transmission.
  4.  
  5. Install the through-bolts to the engine mounts and remove the engine lifting device from the engine.
  6.  
  7. Install the starter and starter-to-engine bolts.
  8.  
  9. Connect the electrical harness to the transmission and the frame, then the electrical connectors to the starter.
  10.  
  11. Connect the exhaust pipe to the exhaust manifold. Install the flywheel cover to the bellhousing.
  12.  
  13. Raise and support the front of the vehicle on jackstands.
  14.  
  15. Install the purge hose to the charcoal canister, then the air cleaner and adapter to the throttle body. Connect the fuel hoses to the throttle body.
  16.  
  17. Install the oil filler neck and the thermostat housing to the engine.
  18.  
  19. Connect the accelerator, the cruise control and the detent (if equipped) cables. Connect the ground cable to the cylinder head.
  20.  
  21. Install the heater hoses to the heater core.
  22.  
  23. At the bulkhead connector, connect the engine electrical harness. Connect the electrical harness to the Electronic Control Module (ECM).
  24.  
  25. Install the radiator, filler panels and the fan shroud as an assembly.
  26.  
  27. Install the radiator hoses, then connect the transmission-to-radiator oil cooler lines (if equipped).
  28.  
  29. If equipped, install the upper radiator core support.
  30.  
  31. Install the lower tie bar, the cross braces and the hood latch assembly.
  32.  
  33. Install the lower radiator close out panel and the radiator support brace.
  34.  
  35. Install the headlight grille and bezel.
  36.  
  37. Refill the cooling system.
  38.  
  39. From inside the vehicle, install the engine cover.
  40.  
  41. Connect the negative battery cable to the battery.
  42.  
  43. Start the engine and check for fluid leaks and proper operation.
  44.  

All engine fasteners are important parts that may affect the performance of the components and systems. If replacement becomes necessary, they MUST BE replaced with the same part number or equivalent part. Use specific torque values when assembling the parts, to assure proper retention.

4.3L Engine

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Typical 4.3L engine mounting on All Wheel Drive (AWD) and rear wheel drive Astro and Safari vans


CAUTION
To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing any fuel system component. If this procedure is not performed, fuel may be sprayed out of the connection under pressure. Always keep a dry chemical (Class B) fire extinguisher near the work area. Relieve the pressure on the fuel system before disconnecting any fuel line connection.

1985-90 MODELS
  1. If equipped, properly discharge and recover the air conditioning refrigerant. If you do not have access to a recovery/recycling station, take the vehicle to a reputable repair facility that has the proper and have them recover the refrigerant.
  2.  
  3. Properly relieve the fuel system pressure and disconnect the negative battery cable.
  4.  
  5. Place a pan under the radiator, open the drain cock and drain the engine coolant.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by 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. Raise and support the front of the vehicle on jackstands.
  2.  
  3. Disconnect the exhaust pipes from the exhaust manifolds.
  4.  
  5. At the flywheel cover, remove the strut rods, then the flywheel cover from the bellhousing. If equipped with an automatic transmission, mark the torque converter-to-flywheel position, then disconnect the torque converter from the flywheel.
  6.  
  7. Disengage the electrical connectors from the starter, then remove the starter from the engine. Disconnect the electrical harness and connectors from the transmission and the frame.
  8.  
  9. Remove the oil filter and the lower fan shroud bolts. Disconnect the fuel hoses from the frame.
  10.  
  11. From the radiator, disconnect the lower transmission oil cooler line (if used) and the lower engine oil cooler line (if used).
  12.  
  13. Remove the through-bolts of the engine-to-frame mounts, then remove the jackstands and lower the vehicle.
  14.  
  15. Remove the headlight bezels and the grille. At the radiator, remove the lower close-out panel, the support brace and the core support cross brace, then remove the lower tie-bar and the hood latch mechanism.
  16.  
  17. At the firewall, remove the master cylinder.
  18.  
  19. From the radiator, remove the upper fan shroud, the upper radiator core support, the filler panels and the radiator.
  20.  

Before removing the radiator, be sure to discharge the air conditioning system (if equipped).

  1. From inside the vehicle, remove the engine cover (for details, please refer to General Information & Maintenance of this information) and the right side kick panel.
  2.  
  3. From the air conditioning system, remove the rear compressor brace, the hose from the accumulator, then the compressor (with the bracket) and the accumulator.
  4.  
  5. Remove the power steering pump (DO NOT disconnect the pressure hoses) and move it aside.
  6.  
  7. Disconnect the vacuum hoses from the intake manifold. Disconnect the electrical harness connector from the bulkhead and the Electronic Control Module (ECM); push the electrical harness connector through the bulkhead.
  8.  
  9. Remove the distributor cap, the fuel line(s) from the carburetor or throttle body and the diverter valve (if equipped).
  10.  
  11. Remove the transmission dipstick tube, the heater hose(s) from the heater core, the horn and the Air Injector Reactor (AIR) check valves.
  12.  
  13. Using and engine lifting device, attach it to the engine.
  14.  
  15. Using a floor jack, raise and support the transmission, then remove the bellhousing-to-engine bolts.
  16.  
  17. Raise the engine, disconnect it from the bellhousing and remove it from the vehicle.
  18.  

To install:

All engine fasteners are important parts that may affect the performance of the components and systems. If replacement becomes necessary, they MUST BE replaced with the same part number or equivalent part. Use specific torque values when assembling the parts, to assure proper retention.

  1. Place the engine on a lifting device and lower the engine into the vehicle. Connect it to the bellhousing.
  2.  
  3. Using a floor jack, raise and support the transmission, then install the bellhousing-to-engine bolts.
  4.  
  5. Remove the engine lifting device.
  6.  
  7. Install the transmission dipstick tube. Connect the heater hose(s) to the heater core.
  8.  
  9. Install the horn and the Air Injector Reactor (AIR) check valves.
  10.  
  11. Install the distributor cap. Connect the fuel line(s) to the carburetor or throttle body and install the diverter valve (if equipped).
  12.  
  13. Connect the vacuum hoses to the intake manifold. Connect the electrical harness connector to the bulkhead and the Electronic Control Module (ECM).
  14.  
  15. Install the power steering pump.
  16.  
  17. To the air conditioning system, install the rear compressor brace, the hose to the accumulator, then the compressor (with the bracket) and the accumulator.
  18.  
  19. From inside the vehicle, install the engine cover and the right side kick panel.
  20.  
  21. To the radiator, install the upper fan shroud, the upper radiator core support, the filler panels and the radiator.
  22.  
  23. At the firewall, install the master cylinder.
  24.  
  25. Install the grille and the headlight bezels. At the radiator, install the lower close-out panel, the support brace and the core support cross brace, then install the lower tie-bar and the hood latch mechanism.
  26.  
  27. Install the through-bolts to the engine-to-frame mounts, then and lower the vehicle.
  28.  
  29. To the radiator, connect the lower transmission oil cooler line (if used) and the lower engine oil cooler line (if used).
  30.  
  31. Install a new oil filter and the lower fan shroud bolts. Connect the fuel hoses to the frame.
  32.  
  33. Engage the electrical connectors to the starter after installing the starter to the engine. Connect the electrical harness and connectors to the transmission and the frame.
  34.  
  35. If equipped with an automatic transmission, note the torque converter-to-flywheel position, then connect the torque converter to the flywheel at the marked position. At the flywheel cover, install the strut rods, then the flywheel cover to the bellhousing.
  36.  
  37. Connect the exhaust pipes to the exhaust manifolds.
  38.  
  39. Refill the engine with coolant and oil.
  40.  
  41. Connect the negative battery cable to the battery.
  42.  
  43. Start the engine and check for leaks and proper operation.
  44.  
  45. If the A/C system was discharged, take the van to a reputable repair facility to have the system evacuated, recharged and leak tested. DO NOT WAIT LONG to do this or moisture which entered the system while it was discharged will cause corrosion and internal system damage. ALSO, DO NOT run the compressor until the system has been properly recharged. Depending on how your model is equipped this may mean you CANNOT use the defogger (this automatically turns the compressor on in some vehicles).
  46.  

1991-95 MODELS

See Figures 2, 3 and 4



Click image to see an enlarged view

Fig. Fig. 2: Scribing marks for cutting the tie bar-1995 models



Click image to see an enlarged view

Fig. Fig. 3: Drilling out holes for tie bar replacement brackets-1995 models



Click image to see an enlarged view

Fig. Fig. 4: Tie bar bracket positioning-1995 models

  1. If equipped, properly discharge and recover the air conditioning refrigerant. If you do not have access to a recovery/recycling station, take the vehicle to a reputable repair facility that has the proper equipment and have them recover the refrigerant.
  2.  
  3. Properly relieve the fuel system pressure and disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Raise and safely support the vehicle. Disconnect the exhaust pipes at the manifolds.
  8.  
  9. If applicable, disconnect the strut rods at the flywheel housing.
  10.  
  11. Remove the torque converter cover, then remove the torque converter bolts.
  12.  
  13. Remove the starter assembly, then drain the oil and remove the and oil filter. Disconnect the wires at the transmission. Disconnect the fuel lines.
  14.  
  15. Tag and disengage the wires at the engine and frame. Disconnect the fuel lines at the frame.
  16.  
  17. Disconnect the transmission and engine oil cooler lines at the radiator.
  18.  
  19. Remove the lower fan shroud retainers, then remove the motor mount bolts.
  20.  
  21. Lower the vehicle. Remove the headlight bezels and/or grille, as necessary. On 1994-95 vehicles, remove the horns.
  22.  
  23. Remove the radiator close out panel and the radiator support brace.
  24.  
  25. Remove the hood latch mechanism. If necessary on vehicles through 1992, remove the master cylinder.
  26.  
  27. Remove the air cleaner assembly and ducts.
  28.  
  29. Remove the upper fan shroud.
  30.  
  31. For 1991-93 vehicles:
    1. Remove the upper radiator core support, then if equipped, remove the A/C condenser.
    2.  
    3. Remove the radiator filler panels, then remove the radiator.
    4.  
    5. Remove the lower radiator shroud, then remove the engine cover (for details, please refer to General Information & Maintenance of this information).
    6.  
    7. If equipped, disconnect the A/C hose at the accumulator.
    8.  
    9. Remove the multi-ribbed accessory drive belt, then remove the fan.
    10.  

  32.  
  33. For 1994-95 vehicles:
    1. If equipped, remove the A/C condenser.
    2.  
    3. Remove the fan and clutch assembly, then remove the lower fan shroud.
    4.  
    5. If not done already, disconnect the remaining oil cooler-to-radiator lines.
    6.  
    7. Remove the radiator.
    8.  
    9. Remove the engine cover (for details, please refer to General Information & Maintenance of this information).
    10.  
    11. If equipped, remove the A/C accumulator.
    12.  
    13. If not done already, remove the multi-ribbed engine accessory drive belt.
    14.  

  34.  
  35. Disconnect the power steering pump lines at the gearbox (1991-93) or from the hydro-boost, oil cooler and reservoir (1994-95).
  36.  
  37. If equipped, remove the A/C compressor pencil braces at the engine block.
  38.  
  39. Remove the power steering pump, bracket and A/C compressor as an assembly.
  40.  
  41. Disengage the alternator wiring, then remove the alternator and bracket assembly.
  42.  
  43. Disengage the wiring harness at the bulkhead. Except for 1995 vehicles, remove the right kick panel.
  44.  
  45. Disengage the wiring from the knock sensor module.
  46.  
  47. Disconnect the upper and lower radiator hoses, then disconnect the heater hose from the water pump.
  48.  
  49. Remove the oil filler tube, then remove the transmission filler tube (top bolt only).
  50.  
  51. Tag and disconnect the vacuum hoses at the intake manifold.
  52.  
  53. If equipped, remove the cruise control servo and bracket.
  54.  
  55. Matchmark and remove the distributor assembly or the High Voltage Switch (HVS) assembly, as applicable.
  56.  
  57. If equipped with the 4.3L (VIN W) engine, remove the upper intake manifold assembly, then disconnect the fuel lines and remove the lower intake manifold.
  58.  
  59. If equipped with the 4.3L (VIN B or Z) engine, disconnect the fuel lines from the TBI unit, tag and disengage all cables, wiring and hoses, then remove the TBI unit from the engine. Remove the MAP sensor bracket, then disconnect the heater hose from the engine block with bracket from the exhaust manifold.
  60.  
  61. Raise and support the vehicle safely, then If equipped, remove the transfer case brace.
  62.  
  63. For 1994-95 vehicles, remove the fuel line bracket and ground wire from the back of the left cylinder head.
  64.  
  65. Remove the transmission oil level indicator tube.
  66.  
  67. Disengage the necessary wiring from the transmission.
  68.  
  69. Remove the bellhousing bolts, then lower the vehicle.
  70.  
  71. For 1995 vehicles the tie bar must be cut from the vehicle in order to create sufficient clearance for engine removal:
    1. Remove the master cylinder retaining nuts, then reposition the cylinder assembly out of the way.
    2.  
    3. Scribe marks for cutting the tie bar assembly. The marks should be made at the centerline between the indentations on the right and left side of the bar assembly.
    4.  
    5. Using the replacement brackets from the service kit as a template over the indentations, center punch the holes for drilling.
    6.  
    7. Drill out 8mm holes for the brace bolts.
    8.  
    9. Carefully cut the tie bar cross section using a reciprocating power saw or hack saw.
    10.  

  72.  

Extreme care must be taken when cutting out the tie bar cross section. The tie bar will be attached using brackets from the service kit. The cut out portion of the bar and the brackets must be treated with anti-corrosion materials and painted. Care taken during cutting will help save time on surface preparation and installation.

  1. Attach a suitable lifting device to the engine and support the transmission, then carefully remove the engine.
  2.  

To install:
  1. Carefully lower the engine into position and engage it to the transmission assembly. If possible, thread the bellhousing bolts to secure the engine to the transmission.
  2.  
  3. Remove the engine lifting device, then raise and support the vehicle safely. Install any remaining bellhousing bolts, then tighten the bolts and remove the transmission support.
  4.  
  5. Engage the wiring to the transmission assembly.
  6.  
  7. Install the transmission oil level indicator tube.
  8.  
  9. On 1994-95 vehicles install the fuel line bracket and ground wire to the back of the left cylinder head.
  10.  
  11. If equipped, install the transfer case brace.
  12.  
  13. Lower the vehicle.
  14.  
  15. If equipped with the 4.3L (VIN B or Z) engine, connect the heater hose to the engine block with the exhaust manifold bracket, then install the MAP sensor bracket. Install the TBI unit, connecting all wiring, cables and hoses. Connect the fuel lines.
  16.  
  17. If equipped with the 4.3L (VIN W) engine, install the lower intake manifold assembly, then connect the fuel lines and install the upper intake manifold assembly.
  18.  
  19. Align and install the distributor or the HVS assembly, as equipped.
  20.  
  21. If equipped, install the cruise control servo and bracket.
  22.  
  23. Connect the vacuum hoses to the intake manifold.
  24.  
  25. Install the transmission filler tube (upper bolt) and the oil filler tube.
  26.  
  27. If removed and applicable, install the ignition coil.
  28.  
  29. Except for 1995 vehicles, the air cleaner and ducts may be installed at this time.
  30.  
  31. Connect the heater and radiator hoses.
  32.  
  33. Connect the wiring harness to the knock sensor module, then for vehicles 1991-94 install the kick panel.
  34.  
  35. Engage the wiring harness at the bulkhead.
  36.  
  37. Install the alternator and bracket as an assembly, then engage the wiring.
  38.  
  39. Install the power steering pump, bracket and A/C compressor assembly. Connect the compressor pencil braces to the block and connect the hoses to the power steering pump, oil cooler and reservoir. Make sure all components are secure.
  40.  
  41. For 1991-93 vehicles, install the fan.
  42.  
  43. Position the multi-ribbed drive belt.
  44.  
  45. Install the accumulator and/or connect the refrigerant hoses to the accumulator assembly, as applicable.
  46.  
  47. Install the lower radiator shroud, then for 1994-95 vehicles, install the fan and clutch.
  48.  
  49. For 1995 vehicles install the tie bar assembly:
    1. File the rough edges of the tie bar and removed cross section.
    2.  
    3. Clean the assembly, cross section and brackets using a wax and grease remover.
    4.  
    5. Treat all bare metal surfaces with an anticorrosion primer.
    6.  
    7. Apply primer surfaces to the tie bar assembly, cross section and brackets.
    8.  
    9. Paint the components and allow to dry.
    10.  
    11. Install the front brackets to the tie bar cross section and to the bar assembly using the 2 bolts and nuts facing the front of the vehicle.
    12.  
    13. Install the U-nuts to the rear tie bar cross section and tie bar assembly.
    14.  
    15. Install the rear bracket and remaining nuts and bolts, then tighten to 24 ft. lbs. (31 Nm)
    16.  
    17. Reposition and secure the master cylinder assembly. If necessary, cut out indication hole in the air cleaner snorkel.
    18.  

  50.  
  51. Install the radiator and connect the hoses.
  52.  
  53. If equipped, install the A/C condenser.
  54.  
  55. Install the upper fan shroud and, if applicable, the upper radiator core support.
  56.  
  57. Install the hood latch mechanism, then install the core support brace.
  58.  
  59. On vehicles 1991-94 install the radiator lower close out panel.
  60.  
  61. On 1994-95 vehicles, install the horns.
  62.  
  63. Install the grille and, if applicable, the headlight bezels.
  64.  
  65. If not done earlier, install the air cleaner and intake ducts at this time.
  66.  
  67. If not done earlier, connect the fuel lines at the engine.
  68.  
  69. Raise and support the vehicle safely, then install the motor mount fasteners.
  70.  
  71. If not done earlier, install the lower fan shroud retainers.
  72.  
  73. Connect the engine and transmission oil cooler lines.
  74.  
  75. Secure the fuel line bracket at the frame.
  76.  
  77. Engage the wiring to the engine and frame, as necessary.
  78.  
  79. Install the oil filter, then install the starter assembly.
  80.  
  81. Install the torque converter bolts, then install the cover.
  82.  
  83. Connect the exhaust pipes, then lower the vehicle.
  84.  
  85. Refill the engine crankcase with engine oil, then connect the negative battery cable.
  86.  
  87. Properly refill the engine cooling system.
  88.  
  89. If the A/C system was discharged, take the van to a reputable repair facility to have the system evacuated, recharged and leak tested. DO NOT WAIT LONG to do this or moisture which entered the system while it was discharged will cause corrosion and internal system damage. ALSO, DO NOT run the compressor until the system has been properly recharged. Depending on how your model is equipped this may mean you CANNOT use the defogger (this automatically turns the compressor on in some vehicles).
  90.  

1996 MODELS

See Figures 5, 6, 7 and 8



Click image to see an enlarged view

Fig. Fig. 5: A body protection hoist adapter set must be used to spread the weight evenly and prevent damage-1996 models



Click image to see an enlarged view

Fig. Fig. 6: A twin post hoist frame assembly support bar is necessary unless you are using a side lift hoist



Click image to see an enlarged view

Fig. Fig. 7: Universal lift brackets should be installed in place of the proper intake manifold bolts



Click image to see an enlarged view

Fig. Fig. 8: The proper frame bolt tightening sequence MUST BE OBSERVED to assure proper chassis-to-frame alignment

For the 1996 model year, the manufacturer determined that lifting the engine from the van's engine compartment was no longer a viable option (especially if it involved cutting pieces of the

radiator support in order to providesufficient clearance). Although it still may be possible to remove the engine as outlined for similar late-model vehicles (under the 1991-95 procedures), IT IS NOT recommended.

Because there is insufficient clearance to remove the engine from the van through the engine compartment, the body must be lifted off the frame assembly for access. This requires great care and patience to prevent

unnecessary damage to the vehicle's body. ALSO, this procedure requires the use of a side lift or twin post hoist. If a suitable hoist is not available, it is recommended that you do NOT attempt this procedure, but instead have the work done by a reputable repair facility.

  1. If equipped, properly discharge and recover the air conditioning refrigerant. If you do not have access to a recovery/recycling station, take the vehicle to a reputable repair facility that has the proper and have them recover the refrigerant.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Disconnect the negative battery, followed by the positive cable, then remove the battery from the engine compartment.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Disconnect the throttle cable, and cruise control cable (if equipped), from the throttle body bracket.
  12.  
  13. If equipped, disengage the cruise control stepper motor wiring.
  14.  
  15. If equipped, disconnect the air conditioning lines at the accumulator and condenser. Immediately plug all openings to prevent system contamination.
  16.  
  17. Remove the radiator assembly.
  18.  
  19. Remove the power steering reservoir and drain the fluid.
  20.  
  21. If equipped, disconnect the lines from the brake hydro-boost unit.
  22.  
  23. Remove the master cylinder from the hydro-boost unit, then tie it to the oil fill tube for support.
  24.  
  25. Matchmark, then disconnect the steering shaft from the gear. Make sure the steering wheel is locked in position and remains so to prevent possible damage to the Supplemental Inflatable Restraint (SIR or air bag) coil in the steering column).
  26.  
  27. Disconnect the heater hoses from the engine.
  28.  
  29. Disconnect the vacuum line from the vacuum tank.
  30.  
  31. Disengage the fuse box and wiring harness from the bulkhead connector and all related electrical connectors. Position the wiring harness over the engine.
  32.  
  33. Drain the engine crankcase.
  34.  
  35. Matchmark and remove the rear driveshaft.
  36.  
  37. Remove the starter and starter opening shield.
  38.  
  39. Matchmark the torque converter to the flywheel (flexplate), then remove the torque converter bolts through the starter opening.
  40.  
  41. Disconnect the shift linkage from the transmission.
  42.  
  43. Disconnect the exhaust system at the main flange behind the catalytic converter.
  44.  
  45. Disconnect the parking brake bracket from the frame.
  46.  
  47. Disconnect the brake line from the BMPV assembly.
  48.  
  49. Remove the front bumper.
  50.  
  51. Remove the power steering cooler from the front air deflector.
  52.  
  53. Disengage the SIR (air bag) sensor connector.
  54.  
  55. Remove the wheel housing splash shield's chassis-to-frame retainers.
  56.  
  57. If equipped, disconnect the rear air conditioning lines at the rear crossmember. Leave the A/C lines attached to the powertrain assembly.
  58.  
  59. Disconnect the fuel lines at the fuel filter. Carefully pull the lines through the crossmember (forward) and position them on the transmission.
  60.  
  61. Disengage the fuel tank electrical connector.
  62.  

Make sure that there are no connections between the chassis and frame.

  1. On All Wheel Drive (AWD) vehicles, remove the transfer case vent hose.
  2.  


CAUTION
When working on a vehicle that is supported by a hoist, add extra support to the opposite end of the vehicle, from where the work is occurring to prevent the possibility of the vehicle falling from the lift. A sudden jarring motion that causes the vehicle to fall could also cause SEVERE personal injury or even death.

  1. If a side lift hoist is being used:
    1. Install a body protection hoist adapter set such as J-41602, or equivalent, to the pinch weld area on both sides of the vehicle. A suitable replacement for this tool may be fabricated from blocks of wood, but be sure that they spread the weight across a sufficiently large area of the body around the weld point.
    2.  
    3. If raised, lower the vehicle.
    4.  
    5. Position the front hoist arms under the body protection adapter set, making sure the rear of the vehicle is slightly higher than the front.
    6.  
    7. Support the rear crossmember with jackstands.
    8.  
    9. Remove the 6 frame bolts.
    10.  
    11. Raise the hoise to separate the body from the frame assembly.
    12.  
    13. Install supports under the rear axle.
    14.  

  2.  
  3. If a twin post hoist is being used:
    1. Install a body protection hoist adapter set such as J-41602, or equivalent, to the pinch weld area on both sides of the vehicle. A suitable replacement for this tool may be fabricated from blocks of wood, but be sure that they spread the weight across a sufficiently large area of the body around the weld point.
    2.  
    3. Install jackstands under the body protection set and under the rear of the van to support the vehicle.
    4.  
    5. Lower the front post of the hoist, then install J-41617 or an equivalent twin post hoist frame assembly support bar to the hoist. Raise the front part of the hoist with the tool attached.
    6.  
    7. Remove the 6 frame bolts.
    8.  
    9. CAREFULLY lower the powertrain/frame assembly from the vehicle.
    10.  

  4.  
  5. Install J-41427, or equivalent universal lift brackets, to the engine:
    1. Tag and disconnect the spark plug wires, then remove the distributor cap from the top of the HVS assembly.
    2.  
    3. Remove the 2 rear right lower intake manifold bolts, then install the engine lift bracket marked RIGHT REAR.Tighten the bracket retaining bolts to 11 ft. lbs. (15 Nm).
    4.  
    5. Remove the air conditioning compressor and accessory drive bracket.
    6.  
    7. Disconnect the EGR tube from the intake manifold.
    8.  
    9. Remove the 2 left front lower intake manifold bolts, then install the engine lift bracket marked LEFT FRONT, with the arrow pointing to the front of the engine. Tighten the retaining bolts to 11 ft. lbs. (15 Nm).
    10.  

  6.  
  7. Remove the engine mount through-bolts.
  8.  
  9. Disconnect the fuel line bracket from the rear of the left cylinder head.
  10.  
  11. Disconnect the fuel lines from the fuel rail.
  12.  
  13. Disengage the electrical harness at the transmission connectors and ALL of the emission sensors.
  14.  
  15. On All Wheel Drive (AWD) vehicles, remove the transfer case-to-engine support brace. Raise the engine slightly and support the transmission with jackstands and a block of wood. DO NOT support the transmission under the oil pan.
  16.  
  17. Disconnect the exhaust "Y'' pipe from the manifolds.
  18.  
  19. Disconnect the engine from the transmission, then remove the engine from the frame.
  20.  

To install:

If you are installing a new motor, make sure that any remaining components, brackets or accessories are transferred from the old engine.

  1. Carefully position the engine to the frame, then install it to the transmission and tighten the retaining bolts. Remove the transmission jack, then lower the assembly onto the engine mountings.
  2.  
  3. Install and tighten the engine mount through-bolts.
  4.  
  5. Connect the exhaust pipe to the manifolds.
  6.  
  7. Install the fuel line bracket to the rear of the left cylinder head, then connect the fuel lines to the rail.
  8.  
  9. Engage the wiring harness to the transmission connectors and to the emission sensors.
  10.  
  11. If equipped, install the transfer case-to-engine block support brace.
  12.  
  13. Remove the universal lift brackets from the engine.
  14.  
  15. Install the intake manifold bolts where the lift hooks were installed.
  16.  
  17. Install the A/C compressor and accessory drive bracket.
  18.  
  19. Connect the EGR pipe to the intake manifold.
  20.  
  21. CAREFULLY lower the vehicle onto the frame (if using a side post hoist) OR raise the engine/frame assembly up and into the vehicle (if using a twin post hoist). As the body is assembled to the frame, use a prybar or dowel pin to properly align the components using the 2 alignment holes provided in each.
  22.  
  23. Loosely install the 6 frame mounting bolts, then tighten the bolts to specification using THE PROPER SEQUENCE:
    1. First, tighten the right center bolt to 114 ft. lbs. (155 Nm).
    2.  
    3. Then, tighten the left center bolt to 114 ft. lbs. (155 Nm).
    4.  
    5. Next, tighten the right front bolt, followed by the left rear bolt each to 66 ft. lbs. (90 Nm).
    6.  
    7. Finally, tighten left front bolt, followed by the right rear bolt each to 66 ft. lbs. (90 Nm).
    8.  

  24.  
  25. Remove the body protection hoist adapters and, if raised, lower the vehicle.
  26.  
  27. Engage the engine wiring harness connectors.
  28.  
  29. Secure the wheel housing splash shields.
  30.  
  31. Align and install the steering shaft to the gear.
  32.  
  33. Install the cooler line to the power steering pump and to the gear.
  34.  
  35. Connect the lines to the hydro-boost unit.
  36.  
  37. Connect the hose to the power steering reservoir.
  38.  
  39. Connect the heater hoses to the engine.
  40.  
  41. Engage the SIR (air bag) sensor connector.
  42.  
  43. If equipped, engage the wiring to the cruise control stepper motor.
  44.  
  45. Connect the throttle and, if equipped, cruise control cables.
  46.  
  47. If equipped, remove the plugs, then connect the A/C lines to the accumulator and condenser.
  48.  
  49. Install the distributor cap and plug wires to the HVS assembly, as tagged during removal.
  50.  
  51. Install the radiator assembly. Connect the transmission and engine oil cooler lines, replacing the retaining clips.
  52.  
  53. Install the air cleaner.
  54.  
  55. Reposition and secure the master cylinder.
  56.  
  57. Raise and support the vehicle safely for access.
  58.  
  59. Connect the rear brake line to the BMPV.
  60.  
  61. Install the parking brake bracket to the frame.
  62.  
  63. Connect the fuel lines at the fuel filter.
  64.  
  65. If equipped, secure the rear A/C lines to the rear crossmember.
  66.  
  67. On All Wheel Drive (AWD) vehicles, install the transfer case vent tube.
  68.  
  69. Install the power steering cooler.
  70.  
  71. Install the front bumper.
  72.  
  73. Connect the shift linkage to the transmission.
  74.  
  75. Align the torque converter and flexplate matchmarks made earlier, then install and tighten the converter bolts. Tighten the bolts evenly to specification. For details, please refer to Drive Train .
  76.  
  77. Install the starter shield and the starter motor assembly.
  78.  
  79. Align and install the rear driveshaft.
  80.  
  81. Connect the exhaust system at the center flange, behind the catalytic converter.
  82.  
  83. Remove the jackstands and carefully lower the vehicle.
  84.  
  85. Refill the engine crankcase, then install and connect the battery (negative cable last).
  86.  
  87. Fill and bleed the hydraulic brake system.
  88.  
  89. Check and fill the transmission assembly, as necessary.
  90.  
  91. Refill the power steering system.
  92.  
  93. Fill and bleed the engine cooling system.
  94.  
  95. Properly refill the engine cooling system, then check for leaks.
  96.  
  97. Once the engine has cooled sufficiently, install the engine cover to the passenger compartment.
  98.  
  99. If the A/C system was discharged, take the van to a reputable repair facility to have the system evacuated, recharged and leak tested. DO NOT WAIT LONG to do this or moisture which entered the system while it was discharged will cause corrosion and internal system damage. ALSO DO NOT run the compressor until the system has been properly recharged, depending on how your model is equipped this may mean you CANNOT use the defogger (this automatically turns the compressor on in some vehicles).
  100.  

 
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