GM Camaro/Firebird 1993-1998 Repair Guide

Engine

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REMOVAL & INSTALLATION



In the process of removing the engine you will come across a number of steps which call for the removal of a separate component or system, i.e. "disconnect the exhaust system" or "remove the radiator". In all of these instances, a detailed removal procedure can be found elsewhere in this section.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible additions to any repair procedure. Be absolutely sure to tag any wire or hose before disconnecting it, so that it may be reconnected properly during installation.


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. 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.

3.4L Engine
  1. Properly discharge and recover the air conditioning system, using a suitable recovery station. Refer to General Information & Maintenance for procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and suitably support the vehicle.
  6.  
  7. Remove the wheels from the front of the car.
  8.  
  9. Drain the coolant and engine oil.
  10.  
  11. Remove the exhaust crossover pipe assembly from the intermediate pipe.
  12.  
  13. On cars with automatic transmissions, remove the catalytic converter.
  14.  
  15. Remove the front fascia lower deflectors.
  16.  
  17. Remove the stabilizer bar.
  18.  
  19. Remove the drive belt.
  20.  
  21. Disconnect the transmission cooler lines from the radiator, if equipped.
  22.  
  23. Remove the lower radiator hose.
  24.  
  25. Remove the heater hoses from the engine.
  26.  
  27. Disconnect the ground straps from the right side of the engine block.
  28.  
  29. Remove the electrical connections from the starter motor.
  30.  
  31. Unplug the electrical connections from the following sensors:
    1. Knock
    2.  
    3. Oxygen
    4.  
    5. Coolant temperature
    6.  
    7. Camshaft
    8.  
    9. Crankshaft
    10.  
    11. Wheel speed
    12.  

  32.  
  33. Unplug the electrical connectors from the engine oil level switch and fuel pump switch/engine oil pressure gauge sensor assemblies.
  34.  
  35. Disconnect the right front brake line from the caliper brake hose.
  36.  
  37. Unplug the wiring harness from the transmission assembly.
  38.  
  39. Disconnect the shift linkage from the transmission.
  40.  
  41. Remove the driveshaft from the vehicle after matchmarking.
  42.  
  43. Remove the torque arm from the transmission assembly.
  44.  
  45. Remove the intermediate steering shaft from the rack and pinion assembly.
  46.  
  47. Disconnect the ground straps from the left side frame rail.
  48.  
  49. Lower the vehicle.
  50.  
  51. Remove the air intake duct.
  52.  
  53. Disconnect the fuel pipes from the engine.
  54.  
  55. Disconnect the throttle and cruise control cables from the throttle body.
  56.  
  57. Disconnect the upper radiator hose from the intake manifold assembly.
  58.  
  59. Unplug the radiator fan electrical connections.
  60.  
  61. Remove the radiator fan.
  62.  
  63. Disconnect the brake booster vacuum hose.
  64.  
  65. Remove the "Y" brace from the right side exhaust manifold.
  66.  
  67. Remove the alternator and air conditioning compressor bracket, then reposition out of the way.
  68.  
  69. Unplug the engine wiring harness connectors, then reposition out of the way.
  70.  
  71. Remove the brake master cylinder and reposition it out of the way.
  72.  
  73. Remove the upper bolts/screws/nuts from the strut assemblies.
  74.  
  75. Remove the right front brake line from the modulator valve assembly and clips.
  76.  
  77. Raise and suitably support the vehicle.
  78.  
  79. Position a lift table under the engine and engine frame assembly.
  80.  
  81. Remove the engine frame and transmission support screws.
  82.  
  83. Raise the vehicle from the engine, transmission and engine frame assemblies.
  84.  
  85. Secure the strut assemblies to the engine frame.
  86.  
  87. Disconnect the transmission TV cable from the throttle body assembly.
  88.  
  89. Remove the transmission assembly from the engine.
  90.  
  91. Remove the clutch housing and clutch on cars with manual transmissions.
  92.  
  93. Disconnect the lines from the power steering pump.
  94.  
  95. Remove the engine mount through-bolts.
  96.  
  97. Remove the engine assembly from the engine frame.
  98.  

To install:
  1. Install the engine assembly onto the frame. Tighten the through-bolt to 70 ft. lbs. (95 Nm).
  2.  
  3. Connect the lines to the power steering pump.
  4.  
  5. Install the clutch and clutch housing on cars with manual transmissions.
  6.  
  7. Install the transmission assembly.
  8.  
  9. Connect the TV cable to the throttle body.
  10.  
  11. Install the engine, transmission, and frame assembly.
  12.  
  13. Install the frame and transmission support bolts.
  14.  
  15. Remove the engine lift table.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the bolts and nuts to the upper strut assemblies.
  20.  
  21. Connect the right front brake line to the modulator valve assembly and clips.
  22.  
  23. Install the brake master cylinder.
  24.  
  25. Engage the engine wiring harness connectors.
  26.  
  27. Install the alternator and compressor bracket.
  28.  
  29. Install the "Y" brace to the right exhaust manifold assembly.
  30.  
  31. Connect the brake booster vacuum line.
  32.  
  33. Install the radiator fan assembly.
  34.  
  35. Install the lower and upper radiator hoses.
  36.  
  37. Connect the cruise control and accelerator cables to the throttle body.
  38.  
  39. Connect the engine fuel pipes.
  40.  
  41. Raise and suitably support the vehicle.
  42.  
  43. Install the electrical ground straps to the left side frame rail.
  44.  
  45. Install the intermediate steering shaft to the rack and pinion assembly.
  46.  
  47. Install the torque arm to the transmission assembly.
  48.  
  49. Install the driveshaft.
  50.  
  51. Connect the shift linkage to the transmission assembly.
  52.  
  53. Engage the wiring harness to the transmission.
  54.  
  55. Connect the right front brake line to the caliper brake hose.
  56.  
  57. Engage the electrical connectors to the engine oil level switch and fuel pump switch/engine oil pressure gauge sensor assemblies.
  58.  
  59. Engage the sensor electrical connections which were unplugged earlier.
  60.  
  61. Install the electrical connections on the starter motor.
  62.  
  63. Install the electrical ground strap to the right side of the engine block.
  64.  
  65. Connect the heater hoses to the engine.
  66.  
  67. Connect the transmission fluid cooler lines to the radiator.
  68.  
  69. Install the drive belt.
  70.  
  71. Install the stabilizer bar.
  72.  
  73. Install the front fascia lower deflectors.
  74.  
  75. Install the catalytic converter on A/T cars.
  76.  
  77. Install the exhaust crossover assembly to the intermediate pipe.
  78.  
  79. Install the wheels.
  80.  
  81. Lower the vehicle.
  82.  
  83. Refill the engine with motor oil.
  84.  
  85. Refill radiator with coolant.
  86.  
  87. Connect the negative battery cable.
  88.  
  89. Bleed the brake system.
  90.  
  91. Bleed the power steering system.
  92.  
  93. Install the air intake duct.
  94.  
  95. Wheel alignment must be performed.
  96.  

3.8L Engine
  1. Take the vehicle to a reputable repair shop to have the refrigerant discharged and recovered.
  2.  
  3. Disconnect the negative, then the positive battery cables.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the A/C compressor and condenser hose from the accumulator.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the front wheel and tire assemblies.
  12.  
  13. Drain the coolant and engine oil into suitable containers.
  14.  
  15. Remove the 3-way catalytic converter.
  16.  
  17. Remove the front fascia lower deflectors.
  18.  
  19. Remove the stabilizer bar bushing bolts.
  20.  
  21. Disconnect the radiator inlet hose from the radiator.
  22.  
  23. If equipped with an automatic transmission, perform the following:
    1. Remove the transmission converter bolts.
    2.  
    3. Disconnect the transmission oil cooler lines from the radiator.
    4.  
    5. Remove the transmission range selector lever cable from the transmission.
    6.  
    7. Remove the left and right transmission support brackets.
    8.  

  24.  
  25. If equipped with manual transmissions, perform the following:
    1. Remove the transmission control lever handle.
    2.  
    3. Remove the clutch actuator cylinder line from the actuator.
    4.  

  26.  
  27. Remove the propeller (drive) shaft.
  28.  
  29. Remove the torque arm from the transmission.
  30.  
  31. Remove the steering gear coupling shaft from the rack and pinion.
  32.  
  33. Remove the electrical ground strap from the engine block.
  34.  
  35. Remove the starter motor.
  36.  
  37. Remove the A/C compressor and condenser hose from the compressor and from the condenser.
  38.  
  39. Remove the negative battery cable from the rear compressor bracket mounting stud.
  40.  
  41. Remove the engine coolant heater cord from the block.
  42.  
  43. Carefully lower the vehicle.
  44.  
  45. Remove the A/C compressor and condenser hose from the vehicle.
  46.  
  47. Remove the heater hoses from the drive belt tensioner.
  48.  
  49. Remove the air cleaner outlet rear duct. Remove the resonator duct.
  50.  
  51. Disconnect the fuel lines from the fuel rail.
  52.  
  53. Disconnect the cruise control cable from the throttle body. Disconnect the accelerator control cable from the throttle body.
  54.  
  55. Remove the radiator outlet hose from the thermostat housing.
  56.  
  57. Disconnect the brake booster vacuum hose.
  58.  
  59. Remove the bracket lines and the clips from the ABS hydraulic modulator.
  60.  
  61. Remove the right-hand body hinge pillar trim panel.
  62.  
  63. Detach the engine wiring harness connectors.
  64.  
  65. Remove the forward lamp wiring harness connectors.
  66.  
  67. Remove the Powertrain Control Module (PCM) and the wiring harness and place them on top of the engine.
  68.  
  69. Remove the engine wiring harness through the front of the engine, then place on top of the engine.
  70.  
  71. Disconnect the positive lead from the alternator.
  72.  
  73. Remove the lower shock attachment nuts and bolts from the lower control arms.
  74.  
  75. Remove the upper control and ball stud from the steering knuckle. Use the upper control arm in order to secure the struts to the outboard.
  76.  
  77. Remove the wheel speed connectors from the engine frame.
  78.  
  79. Position a suitable engine support table under the engine and frame.
  80.  
  81. Remove the engine frame and transmission support bolts.
  82.  
  83. Raise the vehicle from the engine, the transmission and the engine frame.
  84.  
  85. Remove the transmission.
  86.  
  87. If equipped with a manual transmission, remove the clutch housing and the clutch.
  88.  
  89. Remove the engine mount though bolts.
  90.  
  91. Remove the engine from the engine frame.
  92.  

To install:
  1. Position the engine to the engine frame.
  2.  
  3. Install the engine mount through bolts.
  4.  
  5. Install the transmission.
  6.  
  7. Position the engine lift table. Lower the vehicle to the crossmember in order to install the engine, transmission and engine frame.
  8.  
  9. Install engine frame and transmission support bolts, then remove the engine lift table.
  10.  
  11. Attach the electrical connectors to the wheel speed sensors.
  12.  
  13. Install the upper control arm ball stud to the steering knuckle.
  14.  
  15. Install the lower shock attachment bolts and nuts to the lower control arm.
  16.  
  17. Connect the positive lead to the generator.
  18.  

When routing the engine wiring harness through the front of the dash, the rubber grommet must be installed properly to ensure correct sealing. If the rubber grommet is damaged, replace it.

  1. Install the engine wiring harness through the front of the dash.
  2.  
  3. Install the PCM and PCM harness.
  4.  
  5. Install the forward lamp wiring harness connectors and the engine wiring harness connectors.
  6.  
  7. Install the right-hand body hinge trim panel.
  8.  
  9. Install the brake lines and clips to the ABS hydraulic modulator. Connect the brake booster vacuum hose.
  10.  
  11. Connect the radiator outlet hose from the thermostat.
  12.  
  13. Connect the cruise control and accelerator cables to the throttle body.
  14.  
  15. Attach the fuel lines to the fuel rail.
  16.  
  17. Install the air cleaner outlet rear duct and resonator duct.
  18.  
  19. Connect the heater hoses to the drive belt tensioner.
  20.  
  21. Attach the A/C compressor and condenser hose.
  22.  
  23. Raise and safely support the vehicle.
  24.  
  25. Connect the engine coolant heater cord to the block.
  26.  
  27. Connect the negative battery cable to the rear compressor bracket mounting stud.
  28.  
  29. Install the A/C compressor and condenser hose to their respective components.
  30.  
  31. Install the starter motor.
  32.  
  33. Fasten the electrical ground strap to the engine block.
  34.  
  35. Install the steering gear coupling shaft to the rack and pinion.
  36.  
  37. Connect the power steering inlet and outlet hoses to the steering gear.
  38.  
  39. Install the torque arm to the transmission.
  40.  
  41. Install the propeller shaft.
  42.  
  43. Connect the shift linkage to the transmission.
  44.  
  45. Attach the radiator inlet hose to the radiator.
  46.  
  47. If equipped with a manual transmission, attach the clutch actuator cylinder line to the actuator and install the transmission control lever.
  48.  
  49. If equipped with an automatic transmission, perform the following:
    1. Install the left and right transmission support brackets.
    2.  
    3. Install the transmission range selector lever cable to the transmission.
    4.  
    5. Attach the transmission fluid oil cooler lines to the radiator.
    6.  
    7. Install the transmission converter bolts.
    8.  

  50.  
  51. Install the stabilizer bar bushing bolts.
  52.  
  53. Install the front fascia lower deflectors.
  54.  
  55. Install the 3-way catalytic converter.
  56.  
  57. Install the wheel and tire assemblies.
  58.  
  59. Carefully lower the vehicle.
  60.  
  61. Refill the engine with the proper amounts of coolant and engine oil.
  62.  
  63. Connect the positive, then the negative battery cables.
  64.  
  65. Properly bleed the brake system.
  66.  
  67. Take the vehicle to a reputable repair shop to have the A/C system charged and the wheels aligned.
  68.  

5.7L Engine
  1. Take the vehicle to a reputable repair shop to have the refrigerant discharged and recovered.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air intake duct.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Remove the wheels from the front of the car.
  10.  
  11. Drain the coolant and engine oil.
  12.  
  13. Remove the exhaust crossover pipe assembly from the intermediate pipe.
  14.  
  15. On cars with automatic transmissions, remove the catalytic converter.
  16.  
  17. Remove the front fascia lower deflectors.
  18.  
  19. Remove the stabilizer bar.
  20.  
  21. Remove the drive belt.
  22.  
  23. Remove the secondary air injection pump.
  24.  
  25. Disconnect the air conditioning hoses form the compressor and condenser, cap the openings.
  26.  
  27. Disconnect the transmission cooler lines from the radiator, if equipped.
  28.  
  29. Remove the lower radiator hose.
  30.  
  31. Remove the heater hoses from the engine.
  32.  
  33. Disconnect the ground straps from the right side of the engine block.
  34.  
  35. Remove the electrical connections from the starter motor.
  36.  
  37. Unplug the electrical connections from the knock and oxygen sensors.
  38.  
  39. Unplug the electrical connectors from the engine oil level switch and fuel pump switch/engine oil pressure gauge sensor assemblies.
  40.  
  41. Unplug the coolant temperature and wheel speed sensors.
  42.  
  43. Disconnect the left front brake line from the caliper brake hose.
  44.  
  45. Unplug the wiring harness from the transmission assembly.
  46.  
  47. Disconnect the shift linkage from the transmission.
  48.  
  49. Remove the driveshaft from the vehicle after matchmarking.
  50.  
  51. Remove the torque arm from the transmission assembly.
  52.  
  53. Remove the intermediate steering shaft from the rack and pinion assembly.
  54.  
  55. Disconnect the ground straps from the left side frame rail.
  56.  
  57. Lower the vehicle.
  58.  
  59. Disconnect the fuel pipes from the engine.
  60.  
  61. Disconnect the throttle and cruise control cables from the throttle body.
  62.  
  63. Disconnect the upper radiator hose from the intake manifold assembly.
  64.  
  65. Disconnect the brake booster vacuum hose.
  66.  
  67. Remove the alternator.
  68.  
  69. Unplug the engine wiring harness connectors, then reposition out of the way.
  70.  
  71. Remove the power steering reservoir and reposition out of the way.
  72.  
  73. Remove the brake master cylinder and reposition it out of the way.
  74.  
  75. Remove the upper bolts/screws/nuts from the strut assemblies.
  76.  
  77. Remove the right front brake line from the modulator valve assembly and clips.
  78.  
  79. Raise and suitably support the vehicle.
  80.  
  81. Position a lift table under the engine and engine frame assembly.
  82.  
  83. Remove the engine frame and transmission support screws.
  84.  
  85. Raise the vehicle from the engine, transmission and engine frame assemblies.
  86.  
  87. Secure the strut assemblies to the engine frame.
  88.  
  89. Disconnect the transmission TV cable from the throttle body assembly.
  90.  
  91. Remove the transmission assembly from the engine.
  92.  
  93. Remove the clutch housing and clutch on cars with manual transmissions.
  94.  
  95. Disconnect the lines from the power steering pump.
  96.  
  97. Remove the engine mount through-bolts.
  98.  
  99. Remove the engine assembly from the engine frame.
  100.  

To install:
  1. Install the engine assembly onto the frame. Tighten the through-bolt to 70 ft. lbs. (95 Nm).
  2.  
  3. Connect the lines to the power steering pump.
  4.  
  5. Install the clutch and clutch housing on cars with manual transmissions.
  6.  
  7. Install the transmission assembly.
  8.  
  9. Connect the TV cable to the throttle body.
  10.  
  11. Install the engine, transmission, and frame assembly.
  12.  
  13. Install the frame and transmission support bolts.
  14.  
  15. Remove the engine lift table.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the bolts and nuts to the upper strut assemblies.
  20.  
  21. Connect the right front brake line to the modulator valve assembly and clips.
  22.  
  23. Install the brake master cylinder.
  24.  
  25. Install the power steering reservoir.
  26.  
  27. Engage the engine wiring harness connectors.
  28.  
  29. Install the alternator.
  30.  
  31. Connect the brake booster vacuum line.
  32.  
  33. Install the lower and upper radiator hoses.
  34.  
  35. Connect the cruise control and accelerator cables to the throttle body.
  36.  
  37. Connect the engine fuel pipes.
  38.  
  39. Raise and suitably support the vehicle.
  40.  
  41. Install the electrical ground straps to the left side frame rail.
  42.  
  43. Install the intermediate steering shaft to the rack and pinion assembly.
  44.  
  45. Install the torque arm to the transmission assembly.
  46.  
  47. Install the driveshaft.
  48.  
  49. Connect the shift linkage to the transmission assembly.
  50.  
  51. Engage the wiring harness to the transmission.
  52.  
  53. Engage the electrical connectors to the engine oil level switch and fuel pump switch/engine oil pressure gauge sensor assemblies.
  54.  
  55. Engage the sensor electrical connections which were unplugged earlier.
  56.  
  57. Install the electrical connections on the starter motor.
  58.  
  59. Install the electrical ground straps to the right side of the engine block.
  60.  
  61. Connect the heater hoses to the engine.
  62.  
  63. Connect the transmiss