GM Corvette 1984-1996 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, such as "disconnect the exhaust system" or "remove the radiator." In most instances, a detailed removal procedure can be found elsewhere in this guide.

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 approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

  1. Disconnect the negative, then the positive battery cables.
  2.  
  3. Drain the engine coolant into a suitable container.
  4.  
  5. Properly relieve the fuel system pressure, as outlined in Fuel System of this repair guide.
  6.  
  7. Disconnect the throttle, TV and cruise control cables at the engine.
  8.  
  9. Tag and disconnect he spark plugs wires from the plugs, then remove the cap and wires as an assembly.
  10.  
  11. If necessary for clearance, remove the distributor.
  12.  
  13. Remove the cowl screen.
  14.  
  15. Remove the nut from the wiper motor arm. Disconnect the wiper motor wires, then remove the wiper motor cover.
  16.  
  17. Remove the air intake duct with the Mass Air Flow (MAF) sensor.
  18.  
  19. Disconnect the brake booster vacuum hose.
  20.  
  21. Detach the canister hose at the PCV pipe.
  22.  
  23. Tag and detach the necessary wires and vacuum hoses from the engine.
  24.  
  25. Disconnect the injector harness at the intake manifold.
  26.  
  27. Disconnect the heater hose from the pipe.
  28.  
  29. Disconnect the upper radiator hose from the housing.
  30.  
  31. Remove the serpentine drive belt.
  32.  
  33. Remove the AIR control valve at the A/C compressor.
  34.  
  35. Disconnect the fuel lines from the fuel rail.
  36.  
  37. Remove the catalytic converter AIR pipe.
  38.  
  39. Remove the A/C brace from the exhaust manifold.
  40.  
  41. Remove the A/C compressor mounting bracket.
  42.  
  43. Remove the accumulator from the fan shroud and brace.
  44.  
  45. Disconnect the fuel lines from the block.
  46.  
  47. Disconnect the lower radiator hose and the heater hose from the water pump.
  48.  
  49. Remove the alternator, as outlined in Engine Electrical of this repair guide.
  50.  
  51. Remove the AIR pump and bracket assembly.
  52.  
  53. Remove the power steering pump reservoir from the fan shroud and crossmember.
  54.  
  55. Unbolt the power steering pump and wire it aside.
  56.  
  57. Remove the water pump pulley.
  58.  
  59. Remove the crankshaft pulley (balancer/damper).
  60.  
  61. Raise and safely support the vehicle.
  62.  
  63. Detach the wiring from the oxygen, ESC and temperature sensors.
  64.  
  65. Remove the temperature sensor wire retainer from the block.
  66.  
  67. Disconnect the ground wires from the block.
  68.  
  69. Remove the catalytic converter AIR pipe from the manifold.
  70.  
  71. Disconnect and plug the transmission cooler lines from the flywheel cover.
  72.  
  73. Remove the starter motor.
  74.  
  75. Disconnect the front crossover pipe from the exhaust manifolds.
  76.  
  77. Drain the engine oil into a suitable container, then remove the oil filter.
  78.  
  79. Remove the oil cooler adapter from the engine block.
  80.  
  81. Remove the flywheel cover.
  82.  
  83. Disconnect and plug the oil cooler line from the oil pan.
  84.  
  85. Remove the exhaust from the converter hanger.
  86.  
  87. If equipped with a manual transmission, remove the clutch assembly.
  88.  
  89. Remove the engine mount through bolts and nuts.
  90.  
  91. If equipped with an automatic transmission, remove the transmission-to-engine bolts.
  92.  
  93. Carefully lower the vehicle.
  94.  
  95. Support the transmission assembly with a jack, then install a suitable engine lifting device.
  96.  
  97. Make sure that all retainers, wiring and vacuum lines are disconnected, then carefully lift the engine out of the vehicle. Mount the engine on a suitable stand.
  98.  
  99. Installation is the reverse of the removal procedure.
  100.  

 
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