GM Cutlass RWD 1970-1987 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7

Refer to the vehicle and engine identification chart at the beginning of General Information & Maintenance to determine the type and manufacturer of the engine used in your vehicle.

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 the section, or in some cases, in another section which deals with the specific component in question.

  1. Scribe marks at the hood hinges and the hinge brackets. Remove the hood.
  2.  



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Fig. Fig. 1: Mark the hood around the hinges to make installation easier later



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Fig. Fig. 2: Remove the hood attaching bolts



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Fig. Fig. 3: Some models may utilize a small attaching bolt on the side. Be sure an assistant holds the hood during removal

  1. Disconnect the battery and drain the coolant.
  2.  


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 air cleaner.
  2.  
  3. On vehicles with air conditioning (A/C), disconnect the compressor ground wire from the bracket. Remove the electrical connector from the compressor. Remove the compressor and position the compressor out of the way. Do not disconnect any hoses.
  4.  


CAUTION
If the compressor refrigerant lines do not have enough slack to position the compressor out of the way without disconnecting the refrigerant lines, the air conditioning system will have to be discharged by a trained air conditioning specialist. Under no conditions should an untrained person attempt to disconnect the air conditioning refrigerant lines. These lines contain pressurized R-12 refrigerant which can be extremely dangerous.



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Fig. Fig. 4: Labelling hoses and wiring before disconnection will make installation much easier

  1. Remove the fan blade, pulley, and belts.
  2.  
  3. Disconnect the radiator and heater hoses. Remove the radiator and shroud assembly.
  4.  
  5. Remove the power steering pump and move it out of the way. Do not disconnect any hoses.
  6.  
  7. Tag and remove the fuel pump hoses and plug them.
  8.  
  9. Disconnect and tag the vapor emission lines, from the carburetor, the vacuum supply hose from the carburetor to the vacuum manifold, and the power brake vacuum hoses, if equipped.
  10.  
  11. Disconnect the throttle linkage at the carburetor.
  12.  
  13. Disconnect the oil and coolant switches.
  14.  
  15. Disconnect the engine-to-body ground strap.
  16.  
  17. Raise the vehicle and support it with jackstands, disconnect the starter wires.
  18.  
  19. Disconnect the pipes from the exhaust manifold and support the exhaust system.
  20.  
  21. On Oldsmobile - built engines:
    1. Remove the torque converter cover and the converter-to-flywheel retaining bolts.
    2.  
    3. Remove the engine mounting bolts.
    4.  
    5. Remove the three engine-to transmission bolts from the right side.
    6.  
    7. Remove the starter motor.
    8.  
    9. Lower the car and support the transmission with a floor jack.
    10.  
    11. Remove the three engine-to-transmission bolts from the left side and remove the engine.
    12.  

  22.  
  23. On Chevrolet and Buick - built engines:
    1. Remove the flywheel and converter cover.
    2.  
    3. On cars with automatic transmission, remove the flywheel to converter attaching bolts. Matchmark the converter to the flywheel. On all automatic transmission models, remove the engine to transmission attaching bolts. On manual transmission models, disconnect the driveshaft, the shaft linkage, the clutch equalizer shaft and the transmission mount.
    4.  
    5. Remove the motor mount fasteners and the cruise control bracket, if so equipped.
    6.  
    7. Lower the car and support the transmission, except for models with manual transmissions.
    8.  
    9. Raise the engine slightly so the engine mount through bolts can be removed. On models with manual transmissions, remove the engine and transmission as a unit.
    10.  

  24.  



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Fig. Fig. 5: Removing the motor mount attaching bolts



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Fig. Fig. 6: Remove the motor mount from the vehicle and inspect for damage

To install:
  1. It may be necessary to alternately raise and lower the transmission to fit the motor mount through-bolts into position. Torque the through-bolt nuts to 35 ft. lbs. (48 Nm). Torque the automatic transmission-to-engine bolts to 35 ft. lbs. (48 Nm).
  2.  
  3. Raise and support the vehicle using jackstands.
  4.  
  5. Support the transmission with a floor jack.
  6.  
  7. Install the motor mount bolts and torque to 55 ft. lbs. (75 Nm).
  8.  
  9. Install the cruise control bracket, if so equipped.
  10.  
  11. Install the transmission-to-engine attaching bolts to the transmission bell housing.
  12.  
  13. Install the flywheel cover pan. Connect the flywheel-to-torque converter bolts at the matchmark of the flywheel-to-torque converter relationship.
  14.  
  15. Connect the exhaust pipes to the exhaust manifolds.
  16.  
  17. Lower the front end of the vehicle. Connect the starter cables and the cable shield to the engine.
  18.  
  19. Connect the engine-to-body ground strap at the engine.
  20.  
  21. Connect the transmission oil cooler lines at the transmission. Install the oil and coolant sending unit switch connections at the engine.
  22.  
  23. Connect the throttle cable, downshift cable and/or throttle valve cable at the carburetor.
  24.  
  25. Install the vacuum lines attached to the engine. Connect the engine wiring harness.
  26.  
  27. Connect the fuel pump hoses.
  28.  
  29. Install the power steering pump-to-mounting bracket bolts.
  30.  
  31. Install the fan shroud assembly.
  32.  
  33. Install the fan blade, pulleys and belts.
  34.  
  35. On air conditioned vehicles, connect the A/C compressor ground wire to the mounting bracket. Install the electrical connector to the compressor clutch, secure the compressor and bracket attaching bolts.
  36.  
  37. Connect the radiator and heater hoses.
  38.  
  39. Install the air cleaner.
  40.  
  41. Refill the coolant into the radiator and reservoir. DON'T FORGET to refill the engine with the specified engine oil.
  42.  
  43. Connect both battery cables.
  44.  
  45. Install the hood around the marks on the hood hinges and hinge bracket.
  46.  
  47. Start the engine and check for vacuum, coolant, oil, fuel and refrigerant leaks. Adjust timing and idle speed to specification.
  48.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of a common engine mount assembly

V8 Including Diesel
  1. Drain the cooling system.
  2.  


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. Scribe the hinge outline on the underside of the hood. Remove the hood attaching bolts and remove the hood.
  2.  
  3. Disconnect the battery cables.
  4.  
  5. Remove the radiator and heater hoses and disconnect the air cleaner.
  6.  
  7. Remove the V-belts to avoid damaging them as the engine is pulled out of the engine compartment.
  8.  
  9. Disconnect the transmission oil cooler lines. Remove the fan shroud, fan belts, and pulleys. On diesels, disconnect the engine oil cooler lines at the radiator. Disconnect the upper radiator support and remove the radiator.
  10.  
  11. Disconnect the battery ground cable from the engine. Remove the radiator.
  12.  
  13. Disconnect the exhaust pipe or pipes or crossover at the exhaust manifolds.
  14.  
  15. Disconnect the vacuum line to the power brake unit.
  16.  
  17. Remove the accelerator to carburetor linkage. On diesels, disconnect the hairpin clip at the bellcrank.
  18.  
  19. Disconnect and label all the engine component wiring that would interfere with the engine removal, such as alternator wires, gauge sending unit wires, primary ignition wires, engine-to-body ground strap, etc.
  20.  
  21. Separate and plug the fuel line at the fuel pump. On diesels, also disconnect fuel pump wiring.
  22.  
  23. Detach the power steering pump and position it to the left. Do not disconnect the hoses.
  24.  
  25. Detach the air conditioner compressor at the bracket and position to the right. DO NOT disconnect the hoses.
  26.  


CAUTION
If the compressor refrigerant lines do not have enough slack to position the compressor out of the way without disconnecting the refrigerant lines, the air conditioning system will have to be discharged by a trained air conditioning specialist with a recovery/recycling station. Under no conditions should an untrained person attempt to disconnect the air conditioning refrigerant lines. These lines contain pressurized R-12 refrigerant which can be extremely dangerous.

  1. Disconnect the starter cable and remove the cable shield.
  2.  
  3. Disconnect the AIR pipe-to-catalytic converter, if there is one.
  4.  
  5. Remove the flywheel cover pan. Unfasten the flywheel-to-torque converter bolts. Matchmark the flywheel and torque converter for reassembly.
  6.  
  7. Separate the engine from the transmission at the bell housing. On 1987 models, remove 5 of the bolts and leave the lower/left bolt in place.
  8.  
  9. Remove the cruise control bracket, if so equipped.
  10.  
  11. Support the transmission with a floor jack.
  12.  
  13. Attach a lifting device to the engine and raise the engine slightly so the engine mount through-bolts can be removed.
  14.  
  15. Check to make sure all of the wiring and hoses have been disconnected. Raise the engine enough to clear the motor mounts.
  16.  
  17. Raise the engine and transmission alternately until the engine can be disengaged and removed. Once both are raised slightly, remove the remaining transmission-to-engine bolt on the 1987 models.
  18.  
  19. Install by reversing the procedure. When installing an engine, the front mounting pad to frame bolts should be the last mounting bolts to be tightened. Note that there are dowel pins in the block that have matching holes in the bellhousing. These pins must be in almost perfect alignment before the engine will go together with the transmission. Torque the through-bolt nuts to 35 ft. lbs. (48 Nm). Torque the automatic transmission-to-engine bolts to 35 ft. lbs. (48 Nm). When tightening the three converter-to-drive plate bolts, first tighten all three finger-tight, and then torque to 46 ft. lbs. (63 Nm), all three. Make sure to retighten and torque the first bolt tightened.
  20.  

To install:
  1. When installing an engine, the front mounting pad to frame bolts should be the last mounting bolts to be tightened.
  2.  

There are dowel pins in the block that have matching holes in the bellhousing. These pins must be in almost perfect alignment before the engine will go together with the transmission.

  1. Torque the through-bolt nuts to 35 ft. lbs. (48 Nm). Torque the automatic transmission-to-engine bolts to 35 ft. lbs. (48 Nm). When tightening the three converter-to-drive plate bolts, first tighten all three finger-tight, and then torque (46 ft. lbs. 63 Nm), all three. Make sure to retighten and torque the first bolt tightened.
  2.  
  3. Lower the engine and transmission alternately until the engine can be engaged. Once both are lowered slightly, install the remaining transmission-to-engine bolts.
  4.  
  5. Check to make sure all of the wiring and hoses have not gotten pinched between the engine and transmission. Lower the engine enough to engage the motor mounts.
  6.  
  7. Using the lifting device, raise the engine slightly so the engine mount through-bolts can be installed.
  8.  
  9. Support the transmission with a floor jack.
  10.  
  11. Install the cruise control bracket, if so equipped.
  12.  
  13. Install and tighten the flywheel-to-torque converter bolts to 50 ft. lbs. (68 Nm). Connect the flywheel cover. Matchmark the flywheel and torque converter.
  14.  
  15. Connect the AIR pipe-to-catalytic converter, if there is one.
  16.  
  17. Connect the starter cable and install the cable shield.
  18.  
  19. Reposition the air conditioner compressor to the bracket.
  20.  
  21. Reinstall the power steering pump. Do not disconnect the hoses.
  22.  
  23. Install the fuel line at the fuel pump. On diesels, also connect the fuel pump wiring.
  24.  
  25. Connect all the engine component wiring that would interfere with the engine installation, such as alternator wires, gauge sending unit wires, primary ignition wires, engine-to-body ground strap, etc.
  26.  
  27. Connect the accelerator to carburetor linkage. On diesels, connect the hairpin clip at the bellcrank.
  28.  
  29. Connect the vacuum line to the power brake unit.
  30.  
  31. Connect the exhaust pipe or pipes or crossover at the exhaust manifolds.
  32.  
  33. Connect the battery ground cable to the engine. Install the radiator.
  34.  
  35. Connect the transmission oil cooler lines. Install the fan shroud, fan belts, and pulleys. On diesels, connect the engine oil cooler lines at the radiator. Install the upper radiator support.
  36.  
  37. Install the V-belts.
  38.  
  39. Install the radiator, heater hoses and the air cleaner.
  40.  
  41. Connect the battery cables.
  42.  
  43. Install the hood and attaching bolts at the scribes on the hinge outline on the underside of the hood.
  44.  
  45. Refill the engine cooling system. DON'T FORGET to refill the engine with the specified engine oil.
  46.  
  47. Start the engine and check for vacuum, coolant, oil, fuel and refrigerant leaks. Adjust timing and idle speed to specification.
  48.  

 
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