GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Engine

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

On the 2.3L and 2.4L engines, the engine mounting bracket bolts are designed to permanently stretch when tightened. Only use the correct replacement.

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 information 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 or transaxle, 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 information guide.
 

  1. Relieve the fuel system pressure.
  2.  


CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turnedOFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Disconnect both battery cables (negative first) and ground straps.
  2.  
  3. Drain the cooling system, then remove the cooling fan.
  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 air cleaner assembly.
  2.  
  3. Detach the ECM connections and feed harness through the bulkhead. Lay the harness across the engine.
  4.  
  5. Label and disconnect the engine wiring harness and all engine-related connectors and lay them across the engine.
  6.  
  7. Tag and detach the radiator hoses and vacuum lines. Disconnect and plug the fuel lines.
  8.  
  9. On models equipped, remove the air conditioning compressor from the engine and lay it aside, DO NOT disconnect the refrigerant lines. Remove the transaxle struts.
  10.  
  11. If equipped with power steering, remove the power steering pump from its mount (with the lines attached) and lay it aside.
  12.  
  13. If equipped with a manual transaxle, disconnect the clutch and transaxle linkage. Remove the throttle cable from the throttle body.
  14.  
  15. If equipped with an automatic transaxle, disconnect the transaxle cooler lines, shifter linkage, downshift cable and throttle cable from the throttle body.
  16.  
  17. Remove any components in the way of engine removal such as the starter, sensors, valves etc. Be sure to label all components lines and wiring.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Remove the power steering line bracket from the engine.
  22.  
  23. Disconnect all wiring from the transaxle.
  24.  
  25. Remove the transaxle strut(s).
  26.  
  27. Disconnect the exhaust pipe from the exhaust manifold and hangers.
  28.  
  29. Disconnect and plug the heater hoses from the heater core tubes.
  30.  
  31. On some models it may be necessary to remove the front wheels and calipers. Wire the calipers up aside and remove the brake rotors. If necessary, matchmark and remove the knuckle-to-strut bolts.
  32.  
  33. On some models it may be necessary to remove the axle shaft from the transaxle and intermediate shaft and position it aside.
  34.  
  35. On some models the engine is removed from under the vehicle as follows:
    1. Using the proper equipment, support the vehicle under the radiator frame support.
    2.  
    3. Position a jack to the rear of the body pan with a 4 in. x 4 in. x 6 ft. (10cm x 10cm x 2m) timber spanning the vehicle.
    4.  
    5. Raise the vehicle enough to remove the support equipment.
    6.  
    7. Position a dolly under the engine/transaxle assembly with 3 blocks of wood for additional support.
    8.  
    9. Lower the vehicle slightly, allowing the engine/transaxle assembly to rest on the dolly.
    10.  
    11. Remove all engine and transaxle mount bolts and brackets. Remove the remaining cradle-to-body bolts.
    12.  
    13. Raise the vehicle, leaving engine and transaxle assembly with the suspension on the dolly.
    14.  

  36.  
  37. On other vehicles the engine/transaxle is removed from above as follows:
    1. Install engine support fixture tool J-28467-A. Remove the right engine mount.
    2.  
    3. Using the proper equipment, support the suspension supports, crossmember and stabilizer shaft. Unfasten the attaching bolts, then remove as an assembly.
    4.  
    5. Position a suitable support below the engine, then carefully lower the car onto the support.
    6.  
    7. Mark the threads on the support fixture hooks so that the setting can be duplicated when reinstalling the engine. Remove the engine support fixture J-hooks.
    8.  
    9. Raise the vehicle slowly off the engine and transaxle assembly. It may be necessary to move the engine/transaxle assembly rearward to clear the intake manifold.
    10.  

  38.  

Many of the bell housing bolts are of different lengths; note their locations before removing. It is imperative that these bolts go back in their original locations when assembling the engine and transaxle or engine damage could result.

  1. Separate the engine from the transaxle.
  2.  

To install:
  1. If the engine has been removed from under the vehicle perform the following:
    1. Assemble the engine and transaxle assembly and position on the dolly.
    2.  
    3. Raise and safely support the vehicle. Roll the assembly to the installation position and lower the vehicle over the assembly.
    4.  
    5. Install all engine, transaxle and suspension mounting bolts. Tighten all cradle mounting bolts to specifications. Connect the wiring to the transaxle.
    6.  

  2.  
  3. On the 2.4L engines, install the engine mounting bracket adapter. Refer to the illustration. these bolts must be replaced with new ones anytime they are removed. Tighten the automatic transaxle bolts to 44 ft. lbs. (60 Nm) plus rotate and additional 90°. Tighten the manual transaxle bolts to 81 ft. lbs. (110 Nm) plus rotate an additional 90°.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Engine mounting bracket bolt locations. Always replace these bolts when removed with new ones-2.3L and 2.4L engines

  1. If the engine has been removed from above the vehicle perform the following:
    1. Assemble the engine and transaxle. If equipped with an automatic transaxle, thoroughly clean and dry the torque converter bolts and bolt holes, apply thread locking compound to the threads and tighten the bolts to specifications. If equipped with a manual transaxle, tighten the clutch cover bolts to specifications.
    2.  
    3. Raise and safely support the vehicle. Position the engine/transaxle assembly and lower the vehicle over the assembly until the transaxle mount is indexed, then install the bolt.
    4.  
    5. Install the engine support fixture and adjust to previously indexed setting. Raise the vehicle off the support fixture.
    6.  

  2.  



Click image to see an enlarged view

Fig. Fig. 2: Engine mounting bolt location and tightening specifications-3.1L engines



Click image to see an enlarged view

Fig. Fig. 3: Bolt locations for the engine mount strut-3.1L engine

  1. Install all engine, transaxle and suspension mounting bolts. Tighten all cradle mounting bolts to specifications and connect the wiring to the transaxle.
  2.  
  3. Install the halfshafts if removed.
  4.  
  5. Install all remaining components in the reverse order of removal.
  6.  
  7. If equipped with a manual transaxle, connect the clutch and transaxle linkage. Connect the throttle cable to the throttle body.
  8.  
  9. If equipped with an automatic transaxle, connect the transaxle cooler lines, shifter linkage, downshift cable and throttle cable to the throttle body.
  10.  
  11. Connect the radiator hoses, vacuum lines and fuel lines.
  12.  
  13. Connect the engine wiring harness and all engine-related connectors. Feed the ECM connections through the bulkhead and connect.
  14.  
  15. Install the air cleaner assembly.
  16.  
  17. Fill all fluids to their proper levels.
  18.  
  19. Start the engine and check for leaks, then check for proper fluid levels and add as necessary.
  20.  

 
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