GM Full Size Vans 1967-1986 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 additions to any repair procedure. Be absolutely sure to tag any wire or hose before it is disconnected, so that you can be assured of proper reconnection during installation.

1967-70 Models

See Figure 1



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Fig. Fig. 1: Engine mount and bolt locations-1967-70 models

The engine and transmission are removed as a unit from below the vehicle.

  1. Disconnect the battery cables.
  2.  
  3. Drain the cooling system. Remove the air cleaner.
  4.  


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 engine splash shield(s).
  2.  
  3. Disconnect the neutral safety switch wire from the automatic transmission.
  4.  
  5. Disconnect the upper and lower radiator hoses from the radiator.
  6.  
  7. Disconnect the wires from the starter solenoid, alternator, temperature switch, oil pressure switch and ignition coil.
  8.  
  9. Disconnect the following components:
    1. Accelerator linkage at the bellcrank on the manifold.
    2.  
    3. Choke cable at the carburetor.
    4.  
    5. Fuel line from the fuel pump.
    6.  
    7. Heater hoses at the engine.
    8.  
    9. Oil pressure gauge line (if used).
    10.  
    11. All vacuum lines at the engine.
    12.  
    13. Power steering lines at the pump.
    14.  
    15. Engine ground straps; and the exhaust pipes at the manifold. Hang the exhaust pipes out of the way from the frame.
    16.  

  10.  
  11. Disconnect the A/C compressor mounting bracket and position the compressor out of the way. Also remove the condenser from in front of the radiator. Position it out of the way. DO NOT DISCONNECT ANY OF THE REFRIGERANT LINES.
  12.  
  13. Remove the fan and pulley.
  14.  
  15. Remove the clutch cross-shaft.
  16.  
  17. Remove the driveshaft. If the plug for the driveshaft opening in the transmission is not easily accessible, drain the transmission.
  18.  
  19. Disconnect the speedometer cable at the transmission.
  20.  
  21. Disconnect the shift linkage at the transmission.
  22.  
  23. Disconnect the clutch linkage.
  24.  
  25. Remove the bolt which holds the starter wire harness clip and the engine ground strap from the flywheel housing.
  26.  
  27. Disconnect the automatic transmission cooler lines at both ends and remove the cooler lines. Plug the openings.
  28.  
  29. Place a jack under the engine and transmission and install safety chains. Take the weight off the engine mounts.
  30.  
  31. Remove the engine mount bolts and the engine mount crossmember. Check to be sure that all necessary components are removed or disconnected.
  32.  
  33. Slowly lower the engine/transmission assembly, pulling it to the rear to clear the front axle.
  34.  
  35. Depending on the service required, separate the engine/transmission and mount the engine on a stand.
  36.  
  37. Installation is the reverse of removal. Be sure to check all fluid capacities and check for leaks.
  38.  

1971-73 Models

See Figures 2, 3, 4 and 5



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Fig. Fig. 2: Six cylinder engine mount locations and retainers



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Fig. Fig. 3: Disconnect the brake lines at the areas indicated-1971-73 models



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Fig. Fig. 4: Crossmember-to-frame attaching bolts-1971-73 models



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Fig. Fig. 5: Suspension-to-frame attaching bolts-1971-73 models

On these vehicles, the engine is removed as a unit with the front suspension.

  1. Remove the engine cover.
  2.  
  3. Disconnect the battery ground strap from the engine, and at the battery.
  4.  
  5. Drain the cooling system and disconnect the heater hoses at the engine. Disconnect the radiator hoses at the radiator.
  6.  

  1. Disconnect the automatic transmission cooler lines at the radiator.
  2.  
  3. Remove the fan guard and radiator.
  4.  
  5. Disconnect the oil pressure gauge.
  6.  
  7. Disconnect the engine wiring harness at the dash panel junction block.
  8.  
  9. Disconnect the alternator wires from the rear of the alternator.
  10.  
  11. Disconnect the TCS system electrical leads at the CEC valve on the carburetor and at the temperature switch. Remove the harness from the clips and position it out of the way.
  12.  
  13. Disconnect the evaporative emission control system lines at the rocker cover and the carburetor. Position these out of the way.
  14.  
  15. Disconnect the accelerator linkage at the bellcrank on the firewall.
  16.  
  17. Disconnect the power brake vacuum line at the intake manifold.
  18.  
  19. Disconnect the A/C compressor mounting bracket and position the compressor out of the way. Also remove the condenser from in front of the radiator. Position it out of the way.
  20.  
  21. Raise and support the vehicle. Disconnect the following items:
    1. Fuel line at the fuel pump.
    2.  
    3. Engine ground straps.
    4.  
    5. Steering idler arm at the frame.
    6.  
    7. Steering Pitman arm at the steering gear.
    8.  
    9. Battery cable from the starter.
    10.  
    11. TCS switch at the transmission (position the wiring harness to one side).
    12.  
    13. Exhaust pipe at the manifold (remove the exhaust system).
    14.  
    15. Transmission at the crossmember.
    16.  
    17. Stabilizer bar at the frame brackets.
    18.  

  22.  
  23. Disconnect the shock absorbers from the frame or lower control arm and position them out of the way.
  24.  
  25. Disconnect the clutch and transmission linkage and remove the clutch crossmember.
  26.  
  27. Remove the driveshaft and install a plug in the transmission extension.
  28.  
  29. Disconnect the front brake line at the equalizer "T" and disconnect the rear brake line at the left frame rail.
  30.  
  31. Disconnect the rear brake line at the right frame rail.
  32.  
  33. Remove the transmission support frame-to-crossmember attaching nuts, but do not remove the bolts.
  34.  
  35. Remove the 6 (3 on each side) frame-to-crossmember attaching bolts.
  36.  
  37. Remove the 4 (2 on each side) frame-to-upper control arm inside attaching bolts.
  38.  
  39. Lower the vehicle on a jack and support it so that the weight is on supports but the wheels and suspension are at curb height.
  40.  
  41. Install wooden blocks between the oil pan and crossmember to stabilize the engine.
  42.  
  43. Position a floor jack under the vehicle so that the jack pad is aligning under the transmission. Use a block of wood between the jack pad and transmission and support the transmission.
  44.  
  45. Remove the transmission support crossmember.
  46.  
  47. Remove the remaining 4 (2 on each side) suspension-to-frame outside retaining bolts.
  48.  
  49. Slowly raise the vehicle, leaving the suspension and power train on the floor until there is sufficient clearance to remove the engine. Check to be sure that all necessary components are disconnected.
  50.  
  51. Roll the power train/suspension assembly to the work area and support the transmission extension with a jackstand. Remove the floor jack.
  52.  
  53. Place a floor jack under the suspension crossmember and raise the assembly until the weight is on the jack.
  54.  
  55. Attach a hoist to the engine at the lifting brackets.
  56.  
  57. Remove the engine mount throughbolts and remove the engine assembly from the crossmember.
  58.  
  59. Remove the manual transmission and clutch as follows:
    1. Remove the clutch housing rear bolts.
    2.  
    3. Remove the bolts attaching the clutch housing to the engine and remove the transmission and clutch as a unit.
    4.  

  60.  

Support the transmission as the last bolt is being removed to prevent damaging the clutch.

  1. Remove the starter and clutch housing rear cover.
  2.  
  3. Loosen the clutch mounting bolts a little at a time to prevent distorting the disc until spring pressure is released. Remove all of the bolts, the clutch disc and the pressure plate.
  4.  

  1. Remove the automatic transmission as follows:
    1. Lower the engine and support it on blocks.
    2.  
    3. Remove the starter and converter housing underpan.
    4.  
    5. Remove the flywheel-to-converter attaching bolts.
    6.  
    7. Support the transmission on blocks.
    8.  
    9. Disconnect the throttle linkage and vacuum modulator on the Powerglide. Disconnect the detent cable on the Turbo Hydra-Matic.
    10.  
    11. Remove the transmission-to-engine mounting bolts.
    12.  
    13. Remove the blocks from the engine only and glide the engine away from the transmission.
    14.  

  2.  
  3. Mount the engine a on a stand.
  4.  
  5. Installation is the reverse of removal. Bleed the front and rear brakes, check all fluid levels, start the engine and check for leaks.
  6.  

1974-76 Models

The engines on these vehicles are removed through the front of the vehicle. A portable boom type hoist is necessary for this job.

  1. Remove the grille. It is attached with screws.
  2.  
  3. Drain the cooling system and disconnect the heater hoses at the engine. Disconnect the radiator hoses at the engine.
  4.  

  1. Disconnect the A/C compressor mounting bracket and position the compressor out of the way. Also remove the condenser from in front of the radiator. Position it out of the way. DO NOT DISCONNECT ANY OF THE REFRIGERANT LINES.
  2.  
  3. Disconnect the automatic transmission cooler lines at the radiator. Remove the fan guard and radiator.
  4.  
  5. Remove the radiator upper tie bar and radiator support.
  6.  
  7. Disconnect the battery cables at the battery and at the radiator support baffle.
  8.  
  9. Disconnect the engine wiring harness at the junction block on the firewall.
  10.  
  11. Disconnect the oil pressure gauge if equipped.
  12.  
  13. Raise and support the van. Disconnect the following items:
    1. Fuel line at the fuel pump.
    2.  
    3. Engine ground straps.
    4.  
    5. Battery cables at the frame mounted clip.
    6.  
    7. Speedometer cable at the transmission.
    8.  
    9. Exhaust pipes from the manifolds (remove the exhaust system).
    10.  
    11. Transmission at the crossmember.
    12.  

  14.  
  15. Disconnect the clutch linkage or the transmission linkage and remove the clutch cross-shaft.
  16.  
  17. Remove the driveshaft. Plug the opening in the extension housing of the transmission.
  18.  
  19. Remove the engine mount through-bolts.
  20.  
  21. Remove the crossmember-to-engine mount bracket (right side only) attaching bolts, but do not remove the bracket.
  22.  
  23. Lower the vehicle and support it approximately 12 in. (305mm) from the floor.
  24.  
  25. Remove the engine access cover.
  26.  
  27. Remove the air cleaner.
  28.  
  29. Disconnect the carburetor throttle linkage. Disconnect and plug the fuel line from the carburetor and remove the carburetor.
  30.  
  31. Disconnect the spark plug wires from the spark plugs and position them out of the way.
  32.  
  33. Remove the ignition coil and rear lifting bracket.
  34.  
  35. Securely attach a boom hoist to the engine.
  36.  
  37. With the aid of an assistant, slowly raise the engine to take the weight off the engine mounts. Remove the right mount frame bracket and mount.
  38.  
  39. Continue raising the engine and move it forward out of the van. Check often to be sure that all necessary components are disconnected.
  40.  
  41. Remove the transmission as outlined in Steps 33 or 34 of the 1971-73 procedure.
  42.  
  43. Installation is the reverse of removal. Check all fluids and check for leaks.
  44.  

1977-78 Models

  1. Scribe matchmarks on the hood hinges for reassembly and remove the hood and the grille. Remove the grille cross brace.
  2.  
  3. Disconnect the negative battery cable, then the positive battery cable, at the battery.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the cooling system and disconnect the heater hoses and radiator hoses at the radiator.
  8.  

  1. Disconnect the A/C compressor mounting bracket and position the compressor out of the way. Also remove the condenser from in front of the radiator. Position it our of the way. DO NOT DISCONNECT ANY OF THE REFRIGERANT LINES.
  2.  
  3. Remove the radiator and the fan shroud.
  4.  
  5. Disconnect and label the wiring at the starter solenoid, alternator, temperature sending switch, oil pressure switch and the coil. Disconnect the engine ground strap.
  6.  
  7. Disconnect:
    1. the accelerator at the intake manifold.
    2.  
    3. the fuel line from the tank at the fuel pump (plug the line).
    4.  
    5. the hoses at the fuel vapor storage canister (if so equipped).
    6.  
    7. the vacuum line to the power brake booster at the manifold (if so equipped).
    8.  

  8.  
  9. Remove the power steering pump mounting bolts and lay the pump aside. Do not disconnect any of the lines.
  10.  
  11. Raise the van on a hoist and drain the crankcase.
  12.  
  13. Disconnect the exhaust pipe at the manifold. If equipped with a catalytic converter, disconnect the converter bracket at the rear transmission mount.
  14.  
  15. Remove the starter motor.
  16.  
  17. Remove the flywheel splash shield or the converter cover, as applicable.
  18.  
  19. On vans with automatic transmissions, remove the converter-to-flywheel attaching bolts.
  20.  
  21. Remove the engine mount through-bolts.
  22.  
  23. Remove the bell housing bolts.
  24.  
  25. Lower the van.
  26.  
  27. Using a floor jack, raise the transmission.
  28.  
  29. Attach a boom hoist to the engine and raise the engine slightly.
  30.  
  31. Remove the engine mount-to-engine brackets.
  32.  
  33. Remove the engine.
  34.  
  35. Reverse the removal procedure to install.
  36.  

1979-86 Models

  1. Have the air conditioning system discharged at a repair facility utilizing a recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable, then the positive battery cable, at the battery. On the V6 remove the glove box.
  4.  
  5. Drain the cooling system.
  6.  

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner. On the V8 remove the air stove pipe. On the V6 remove the outside air duct.
  4.  
  5. On the V6 remove the head light bezels and the grille. On inline six cylinder, remove the grille cross brace and the grille. On the V8, remove the upper radiator support the grille and the lower grille valance.
  6.  
  7. Disconnect the radiator hoses at the radiator.
  8.  
  9. On the V8, remove the radiator coolant reservoir bottle. On the V6, remove the power steering reservoir and the hood release cable.
  10.  
  11. If the van is equipped with an automatic transmission, remove the fluid cooler lines from the radiator.
  12.  
  13. Remove the A/C vacuum reservoir. On the V8, remove the A/C condenser from in front of the radiator. On the six cylinder, remove the A/C compressor.
  14.  
  15. Remove the windshield wiper jar and bracket.
  16.  
  17. Disconnect the accelerator linkage at the carburetor and remove the carburetor.
  18.  
  19. Remove the radiator support bracket and remove the radiator and the shroud.
  20.  
  21. On all six cylinders, remove the A/C compressor mounting bracket and position the compressor out of the way.
  22.  
  23. On the V6 and V8, disconnect the engine wiring harness from the firewall connection. On the inline six cylinder, disconnect the wiring at the alternator, distributor, oil pressure and temperature sending switches and the starter motor.
  24.  
  25. On the V6 and V8:
    1. Disconnect the heater hoses at the engine.
    2.  
    3. Remove the thermostat housing.
    4.  
    5. Remove the oil filler pipe and the engine dipstick tube.
    6.  
    7. Remove the cruise control servo, servo bracket and transducer.
    8.  
    9. Remove the distributor cap.
    10.  
    11. Remove the diverter valve.
    12.  
    13. Remove the coolant hose at the intake manifold and the PCV valve.
    14.  
    15. Remove the transmission dipstick tube and the accelerator cable at the tube.
    16.  
    17. Remove the air conditioning idler pulley.
    18.  
    19. Remove the lower fan shroud and filler panel.
    20.  
    21. Remove the hood latch support.
    22.  
    23. Remove the condenser.
    24.  

  26.  
  27. Raise the vehicle and drain the engine oil.
  28.  
  29. Remove the fuel line from the fuel tank and at the fuel pump.
  30.  
  31. Disconnect the exhaust pipe at the manifold.
  32.  
  33. On the V6 only:
    1. Remove the strut rods at the torque converter or flywheel underpan.
    2.  
    3. Remove the torque converter or flywheel cover.
    4.  
    5. Remove the starter.
    6.  
    7. Remove the flex plate to torque converter bolts (automatic transmissions).
    8.  
    9. Remove the bell housing to engine bolts.
    10.  
    11. Remove the engine mounting through-bolts.
    12.  

  34.  

Lower the van, support the transmission and remove the engine

  1. Remove the driveshaft and plug the end of the transmission.
  2.  
  3. Disconnect the transmission shift linkage and the speedometer cable.
  4.  
  5. Remove the transmission mounting bolts.
  6.  
  7. On the inline six cylinder with manual transmission, disconnect the clutch linkage and remove the clutch cross shaft.
  8.  
  9. On the V8, remove the engine mount bracket-to-frame bolts.
  10.  
  11. Remove the engine mount through-bolts.
  12.  
  13. On the inline six cylinder:
    1. Lower the van and attach a lifting device to the engine.
    2.  
    3. Raise the engine slightly and remove the right hand mount from the engine.
    4.  

  14.  
  15. On the V8: Raise the engine slightly and remove the engine mounts. Support the engine with wood between the oil pan and the crossmember.
  16.  
  17. Remove the engine and transmission as one unit (except the V6). Refer to Steps 33 or 34 of the 1971-73 procedure to remove the transmission.
  18.  
  19. Reverse the removal procedure to install.
  20.  

 
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