GM Caprice 1990-1993 Repair Guide

Engine

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REMOVAL AND INSTALLATION



See Figure 1



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Fig. Fig. 1: Engine mounts - 5.0L (VIN Y) engine. Only engine-to-mount through bolt removal is necessary for engine removal

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. If at all possible, remove the component, leaving the wires or hoses connected and place the component on top of the engine assembly. This will help make reassembly easier and less confusing.


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.

4.3L ENGINE
  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the hood from hinges and mark for reassembly.
  4.  
  5. Drain coolant into a suitable container.
  6.  
  7. Raise and safely support vehicle.
  8.  
  9. Disconnect the exhaust crossover pipe at the exhaust manifolds.
  10.  
  11. Remove the flywheel housing cover.
  12.  
  13. Remove the flexplate to torque converter attaching bolts. Scribe chalk mark on the flywheel and converter for reassembly alignment.
  14.  
  15. Disconnect transmission oil cooler lines at the oil pan.
  16.  
  17. Remove right side motor mount through-bolt and loosen left side motor mount through-bolt.
  18.  
  19. Remove transmission to engine attaching bolts.
  20.  
  21. Disconnect wires at the knock sensor.
  22.  
  23. Disconnect the front fuel hoses from front fuel pipes.
  24.  
  25. Remove the lower fan shroud bolts
  26.  
  27. Lower the vehicle.
  28.  
  29. Disconnect the ECM wiring harness at the engine, and other wiring harnesses as necessary.
  30.  
  31. Remove the air cleaner assembly.
  32.  
  33. Remove the upper fan shroud.
  34.  
  35. Disconnect the vacuum supply hoses which supply all non-engine mounted components with engine vacuum. If equipped, the vacuum modulator, load leveler and power brake vacuum hoses should all be disconnected at the engine.
  36.  
  37. Disconnect accelerator and TV cables.
  38.  
  39. Disconnect radiator and heater hoses from engine.
  40.  
  41. Remove the radiator.
  42.  
  43. If equipped with air conditioning, disconnect compressor ground wire from the mounting bracket. Remove the electrical connector from the compressor clutch, remove the compressor to mounting bracket attaching bolts and position the compressor aside.
  44.  
  45. Remove power steering pump to mounting bracket bolts and position pump assembly aside.
  46.  
  47. Disconnect the positive battery cable and wires from the starter motor.
  48.  
  49. Disconnect engine to body ground strap(s) at engine.
  50.  
  51. Remove the AIR hose at the Catalytic converter AIR pipe and the pipe from the exhaust manifold.
  52.  
  53. Remove fan blade, pulleys and, if not removed already, belt(s).
  54.  
  55. Support the transmission.
  56.  
  57. Attach a safe lifting device to the engine and raise the engine enough so the remaining mounting through-bolt can be removed. Ensure the wiring harness, vacuum hoses and other parts are free and clear before lifting engine out of the vehicle.
  58.  
  59. Raise engine far enough to clear engine mounts, raise transmission support accordingly and alternately until engine can be disengaged from the transmission and removed.
  60.  

To install:
  1. With the engine and transmission safely supported, lower engine into position and align with the transmission.
  2.  
  3. Install the motor mount through-bolts.
  4.  
  5. Install the fan blade and pulley assembly.
  6.  
  7. Connect the AIR hose to the catalytic converter AIR pipe and the pipe to the exhaust manifold.
  8.  
  9. Connect the engine ground strap(s) to the engine.
  10.  
  11. Connect the positive battery cable and wires to the starter motor.
  12.  
  13. Attach the power steering pump to mounting bracket bolts.
  14.  
  15. If equipped with air conditioning, connect the compressor and mounting bracket. Connect the compressor ground wire to the mounting bracket and the electrical connector to the compressor clutch.
  16.  
  17. Reconnect belts or serpentine belt.
  18.  
  19. Install radiator and connect radiator and heater hoses.
  20.  
  21. Connect accelerator and TV cables.
  22.  
  23. Reconnect vacuum hoses.
  24.  
  25. Install upper fan shroud.
  26.  
  27. Connect the air cleaner assembly.
  28.  
  29. Reconnect the ECM wiring harness and other engine electrical connectors.
  30.  
  31. Safely raise and support the vehicle.
  32.  
  33. Install the lower fan shroud and bolts.
  34.  
  35. Connect front fuel hoses to fuel pipes.
  36.  
  37. Connect wires to knock sensors.
  38.  
  39. Install the transmission to engine attaching bolts and tighten to 35 ft. lbs. (47 Nm).
  40.  
  41. Connect the transmission oil cooler lines to the pan.
  42.  
  43. Align the flexplate to torque converter chalk marks and install the attaching bolts. Install the flywheel cover.
  44.  
  45. Connect the exhaust crossover pipe to the exhaust manifolds.
  46.  
  47. Lower vehicle. Fill cooling system and check all engine fluids
  48.  
  49. Align hood hinges to marks and install hood.
  50.  
  51. Tighten fuel filler cap and connect the negative battery cable.
  52.  
  53. Check the fluid levels, engine specifications and inspect for leaks and proper operation.
  54.  

5.0L (VIN Y) ENGINE
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hood from hinges and mark for reassembly.
  4.  
  5. Drain coolant into a suitable container.
  6.  
  7. Remove the air cleaner assembly and hot air pipe.
  8.  
  9. Remove the radiator hoses and upper fan shroud.
  10.  
  11. Remove the radiator.
  12.  
  13. Remove the engine cooling fan.
  14.  
  15. Disconnect the heater hoses at the engine.
  16.  
  17. Disconnect the power steering pump, air conditioning compressor and brackets, and position out of the way leaving the hoses attached.
  18.  
  19. Disconnect the accelerator, TV, and cruise control cables.
  20.  
  21. Disconnect all necessary vacuum hoses and the fuel hose from the fuel line.
  22.  
  23. Disconnect the ECM wiring harness, the engine wiring harness at the engine bulkhead, engine to bulkhead ground straps and all other wires between body and engine.
  24.  
  25. Set the engine on TDC and remove the distributor.
  26.  
  27. Remove the battery ground-to-cylinder head cable.
  28.  
  29. Raise and support the vehicle safely.
  30.  
  31. Disconnect the battery positive cable and wires at the starter motor.
  32.  
  33. Disconnect the crossover pipe at the manifolds.
  34.  
  35. Remove the flywheel cover and mark the relationship of the torque converter to the flywheel, remove the torque converter bolts.
  36.  
  37. Remove the engine mount through-bolts.
  38.  
  39. Disconnect the front fuel hoses from the front fuel pipes.
  40.  
  41. Disconnect the transmission converter clutch wiring at the transmission and the transmission oil cooler lines at the clip on the oil pan.
  42.  
  43. Disconnect the catalytic converter AIR pipe at the exhaust manifold.
  44.  
  45. Remove the transmission to engine bolts.
  46.  
  47. Lower the vehicle.
  48.  
  49. Support the transmission and connect a suitable lifting device to the engine.
  50.  
  51. Remove the engine.
  52.  

To install:
  1. With the engine safely supported, lower into position with the lifting device and align with the motor mounts and transmission.
  2.  
  3. Install motor mount through-bolts and the transmission to engine bolts. Tighten the transmission to engine bolts to 35 ft. lbs. (47 Nm).
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Connect the catalytic converter AIR pipe to the exhaust manifold.
  8.  
  9. Connect the transmission converter clutch wiring to the transmission and the transmission oil cooler lines to the clip on the oil pan.
  10.  
  11. Connect the front fuel hoses to the front fuel pipes.
  12.  
  13. Install the torque converter to flywheel bolts and the flywheel housing cover.
  14.  
  15. Connect the crossover pipe to the exhaust manifolds.
  16.  
  17. Connect the battery positive cable and wires to the starter motor.
  18.  
  19. Lower vehicle.
  20.  
  21. Connect the battery ground to cylinder head cable.
  22.  
  23. Set the engine on TDC and install the distributor.
  24.  
  25. Connect the ECM wiring harness, the engine wiring harness at the engine bulkhead, engine to bulkhead ground straps and all other wires between body and engine.
  26.  
  27. Connect all necessary vacuum hoses.
  28.  
  29. Connect the accelerator, TV and cruise control cables.
  30.  
  31. Connect the power steering pump and air conditioning compressor brackets, if equipped.
  32.  
  33. Connect the heater hoses to the engine.
  34.  
  35. Install the engine cooling fan.
  36.  
  37. Install the radiator, hoses and fan shroud.
  38.  
  39. Install the air cleaner assembly.
  40.  
  41. Install the hood, aligning the marks made during removal.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Fill the cooling system to the proper level.
  46.  
  47. Inspect vehicle fluid levels, specifications and verify there are no fluid leaks.
  48.  

5.0L (VIN E) AND 5.7L ENGINES
  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the hood from hinges and mark for reassembly.
  4.  
  5. Drain coolant into a suitable container.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the radiator hoses and upper fan shroud.
  10.  
  11. Remove the radiator.
  12.  
  13. Remove the engine cooling fan.
  14.  
  15. Disconnect the heater hoses at the engine
  16.  
  17. Disconnect the power steering pump and air conditioning compressor brackets, if equipped, and position out of the way.
  18.  
  19. Disconnect the accelerator, TV, and cruise control cables.
  20.  
  21. Disconnect all necessary vacuum hoses.
  22.  
  23. Disconnect the ECM wiring harness, the engine wiring harness at the engine bulkhead, engine to bulkhead ground straps and all other wires between body and engine.
  24.  
  25. Set the engine on TDC and remove the distributor.
  26.  
  27. Remove the wiper motor, MAP sensor and battery negative to cylinder head cable.
  28.  
  29. Raise and support the vehicle safely.
  30.  
  31. Disconnect the battery positive cable and wires at the starter motor.
  32.  
  33. Disconnect the crossover pipe and catalytic converter as an assembly.
  34.  
  35. Remove the flywheel cover and torque converter to flywheel bolts.
  36.  
  37. Remove the engine mount through-bolts.
  38.  
  39. Disconnect the front fuel hoses from the front fuel pipes.
  40.  
  41. Disconnect the transmission converter clutch wiring at the transmission and the transmission oil cooler lines at the clip on the oil pan.
  42.  
  43. Disconnect the catalytic converter AIR pipe at the exhaust manifold.
  44.  
  45. Remove the transmission to engine bolts.
  46.  
  47. Lower the vehicle.
  48.  
  49. Support the transmission and connect a suitable lifting device to the engine.
  50.  
  51. Remove the engine.
  52.  

To install:
  1. With the engine safely supported, lower into position with the lifting device and align with the motor mounts and transmission.
  2.  
  3. Install motor mount through-bolts and the transmission to engine bolts. Tighten the transmission to engine bolts to 35 ft. lbs. (47 Nm).
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Connect the catalytic converter AIR pipe to the exhaust manifold.
  8.  
  9. Connect the transmission converter clutch wiring to the transmission and the transmission oil cooler lines to the clip on the oil pan.
  10.  
  11. Connect the front fuel hoses to the front fuel pipes.
  12.  
  13. Install the torque converter to flywheel bolts and the flywheel housing cover.
  14.  
  15. Connect the crossover pipe and catalytic converter assembly.
  16.  
  17. Connect the battery positive cable and wires to the starter motor.
  18.  
  19. Lower vehicle.
  20.  
  21. Install the wiper motor, MAP sensor and the negative battery to cylinder head cable.
  22.  
  23. Set the engine on TDC and install the distributor.
  24.  
  25. Connect the ECM wiring harness, the engine wiring harness at the engine bulkhead, engine to bulkhead ground straps and all other wires between body and engine.
  26.  
  27. Connect all necessary vacuum hoses.
  28.  
  29. Connect the accelerator, TV and cruise control cables.
  30.  
  31. Connect the power steering pump and air conditioning compressor brackets, if equipped.
  32.  
  33. Connect the heater hoses to the engine.
  34.  
  35. Install the engine cooling fan.
  36.  
  37. Install the radiator, hoses and fan shroud.
  38.  
  39. Install the air cleaner assembly.
  40.  
  41. Install the hood, aligning the marks made during removal.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Fill the cooling system to the proper level.
  46.  
  47. Inspect vehicle fluid levels, specifications and verify there are no fluid leaks.
  48.  

 
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