GM Full Size Vans 1987-1997 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figure 1

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 battery cable, then the positive battery cable, at the battery.
  2.  
  3. Remove the engine cover.
  4.  
  5. Drain the cooling system.
  6.  


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. Remove the radiator coolant reservoir bottle.
  4.  
  5. Remove the upper radiator support.
  6.  
  7. Remove the grille and the lower grille valance.
  8.  
  9. If necessary, remove the front bumper.
  10.  


CAUTION
Please refer toChapter 1before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Discharge the air conditioning system and remove the air conditioning vacuum reservoir.
  2.  
  3. Remove the air conditioning condenser from in front of the radiator.
  4.  
  5. If the van is equipped with an automatic transmission, remove the fluid cooler lines from the radiator.
  6.  
  7. Disconnect the radiator hoses at the radiator.
  8.  
  9. Loosen the radiator support bracket and remove the radiator and the shroud.
  10.  
  11. Disconnect the accelerator and cruise control linkages.
  12.  
  13. Disconnect all hoses and wires at the fuel unit.
  14.  
  15. Remove the fuel supply unit and cap the lines.
  16.  
  17. On 1996-97 models, remove the intake manifold.
  18.  
  19. On turbocharged engines, remove the turbocharger assembly.
  20.  
  21. On diesel engines, remove the lower intake manifold if equipped.
  22.  
  23. On diesel engines, remove the exhaust manifolds if necessary.
  24.  
  25. Disconnect the engine wiring harness from the firewall connection.
  26.  
  27. Tag and disconnect all vacuum lines.
  28.  
  29. Remove the power steering pump. It's not necessary to disconnect the hoses; just lay the pump aside.
  30.  
  31. Disconnect the heater hoses at the engine.
  32.  
  33. On some models it may be necessary to remove the thermostat housing.
  34.  
  35. Remove the oil filler and automatic transmission tubes.
  36.  
  37. Raise and support the van on jackstands.
  38.  
  39. Remove the cruise control servo, servo bracket and transducer.
  40.  
  41. Drain the engine oil.
  42.  
  43. Disconnect the exhaust pipes at the manifolds.
  44.  
  45. Remove the driveshaft and plug the end of the transmission.
  46.  
  47. Disconnect the transmission shift linkage and the speedometer cable.
  48.  
  49. Remove the fuel line from the fuel tank and at the fuel pump.
  50.  
  51. Remove the transmission mounting bolts.
  52.  
  53. Lower the van, support the transmission and engine.
  54.  
  55. On 1996-97 models, install lifting hooks J-41427 as follows:
  56.  



Click image to see an enlarged view

Fig. Fig. 1: Universal lift brackets should be installed in place of the proper intake manifold bolts

Disconnect the spark plug wires and remove the distributor cap.



Remove the two right rear lower intake manifold retainers and install lifting hook J-41427 (the one marked "right"). Tighten the bolts to 11 ft. lbs. (15 Nm).
 
Remove the air conditioning compressor and the accessory drive bracket.
 
Disconnect the EGR tube and the two left lower bolts from the intake manifold.
 
Install the lifting hook J-41427 (the one marked "left") and tighten the bolts to 11 ft. lbs. (15 Nm).
 

  1. Remove the engine mount bracket-to-frame bolts.
  2.  
  3. Remove the engine mount through-bolts.
  4.  
  5. Raise the engine slightly and remove the engine mounts. Support the engine with wood between the oil pan and the crossmember.
  6.  
  7. 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.Support the transmission as the last bolt is being removed to prevent damaging the clutch.
    4.  
    5. Remove the starter and clutch housing rear cover.
    6.  
    7. 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.
    8.  

  8.  
  9. 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 detent cable on the Turbo Hydra-Matic.
    10.  
    11. Remove the transmission-to-engine mounting bolts.
    12.  

  10.  
  11. Attach an engine crane to the engine.
    1. Remove the blocks from the engine only and glide the engine away from the transmission.To install:
    2.  

  12.  
  13. Raise the engine slightly and install the engine mounts. Tighten the bolts to specification.
  14.  
  15. Install the manual transmission and clutch as follows:
    1. Install the clutch disc and the pressure plate. Tighten the clutch mounting bolts a little at a time to prevent distorting the disc.
    2.  
    3. Install the starter and clutch housing rear cover.
    4.  
    5. Install the bolts attaching the clutch housing to the engine and install the transmission and clutch as a unit. Tighten the bolts to specification.
    6.  
    7. Install the clutch housing rear bolts.
    8.  

  16.  
  17. Install the automatic transmission as follows:
    1. Position the transmission.
    2.  
    3. Install the transmission-to-engine mounting bolts.
    4.  
    5. Connect the throttle linkage and detent cable.
    6.  
    7. Install the flywheel-to-converter attaching bolts. Tighten the bolts to specification.
    8.  
    9. Install the starter and converter housing underpan.
    10.  

  18.  
  19. Install the engine mount through-bolts. Tighten the bolts to specification.
  20.  
  21. Install the engine mount bracket-to-frame bolts. Tighten the bolts to specification.
  22.  
  23. Install the clutch cross-shaft.
  24.  
  25. Install the transmission mounting bolts. Tighten the bolts to specification.
  26.  
  27. Connect the transmission shift linkage and the speedometer cable.
  28.  
  29. Install the driveshaft.
  30.  
  31. Remove the lifting hooks and install the compressor, EGR valve tube and intake manifold retaining bolts.
  32.  
  33. Install the condenser.
  34.  
  35. Install the hood latch support.
  36.  
  37. Install the lower fan shroud and filler panel.
  38.  
  39. Install the transmission dipstick tube and the accelerator cable at the tube.
  40.  
  41. Install the coolant hose at the intake manifold and the PCV valve.
  42.  
  43. Install the distributor cap.
  44.  
  45. Install the cruise control servo, servo bracket and transducer.
  46.  
  47. Install the oil filler pipe and automatic transmission filler pipe.
  48.  
  49. Install the engine dipstick tube.
  50.  
  51. If removed, install the thermostat housing.
  52.  
  53. Connect the heater hoses at the engine.
  54.  
  55. Connect the engine wiring harness to the firewall connection.
  56.  
  57. Install the radiator and the shroud.
  58.  
  59. Install the radiator support bracket.
  60.  
  61. On diesel engines, install the exhaust manifolds if removed.
  62.  
  63. On diesel engines, install the lower intake manifold if removed.
  64.  
  65. On 1996-97 models, install the intake manifold.
  66.  
  67. Install the fuel supply unit.
  68.  
  69. Connect the lines to the fuel supply unit.
  70.  
  71. Connect the accelerator and cruise control linkages.
  72.  
  73. Install the windshield wiper jar and bracket.
  74.  
  75. Install the air conditioning condenser.
  76.  
  77. Install the air conditioning vacuum reservoir.
  78.  
  79. Have the air conditioning system charged by a qualified technician using a recovery/recycling station.
  80.  

AIR CONDITIONING WARNING



  1. If the van is equipped with an automatic transmission, install the fluid cooler lines at the radiator.
  2.  
  3. Install the radiator coolant reservoir bottle.
  4.  
  5. Connect the radiator hoses at the radiator.
  6.  
  7. Install the upper radiator support the grille and the lower grille valance.
  8.  
  9. Install the air cleaner.
  10.  
  11. Install the air stove pipe.
  12.  
  13. Install the engine cover.
  14.  
  15. Fill the cooling system.
  16.  
  17. Connect the battery cables.
  18.  

 
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