GM Metro/Sprint 1985-1993 Repair Guide

Engine Assembly

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REMOVAL and INSTALLATION

  1. Relieve the fuel system pressure on fuel injected vehicles.
  2.  
  3. Using a scratch awl, scribe the hood hinge-to-hood outline, then, using an assistant remove the hood.
  4.  
  5. Disconnect the negative battery cable. Drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Remove the radiator assembly along with the cooling fan.
  2.  
  3. Disconnect and tag all necessary electrical connections.
  4.  
  5. Disconnect and tag all necessary vacuum lines.
  6.  
  7. Disconnect, tag and plug all necessary fuel lines.
  8.  
  9. Disconnect the heater inlet and outlet hoses.
  10.  
  11. Disconnect the following cables:
    1. The accelerator cable from the throttle body or carburetor.
    2.  
    3. The clutch cable from the transaxle (for manual transaxle models).
    4.  
    5. The gear select cable and the oil pressure control cable from the transaxle (for automatic transaxle models).
    6.  
    7. The speedometer cable from the transaxle.
    8.  

  12.  
  13. Raise and safely support the vehicle safely.
  14.  
  15. Disconnect the exhaust pipe from the exhaust manifold.
  16.  
  17. Disconnect the gear shift control shaft and the extension to the transaxle for (manual transaxle models).
  18.  
  19. Drain the engine oil and transaxle oil.
  20.  
  21. Remove the drive axles from the differential side gears of the transaxle. For the engine/transaxle removal, it is not necessary to remove the drive axle from the steering knuckle.
  22.  
  23. Remove the engine rear torque rod bracket from the transaxle (for automatic transaxle models).
  24.  
  25. Lower the vehicle.
  26.  
  27. Install a suitable chain hoist to the lifting device on the engine.
  28.  
  29. Remove the right side engine mounting from its bracket.
  30.  
  31. On vehicles equipped with a automatic transaxle, remove the transaxle rear mounting nut.
  32.  
  33. On vehicles equipped with a manual transaxle, remove the transaxle rear mounting from the body.
  34.  
  35. Remove the transaxle left side mounting bracket.
  36.  
  37. Lift the engine and transaxle assembly out from the vehicle. Separate the transaxle from the engine.
  38.  

To install:
  1. Install the transaxle to the engine, then a suitable hoist onto the engine lifting brackets.
  2.  
  3. Install engine and transaxle into vehicle and leave the hoist connected to the lifting device.
  4.  
  5. On vehicles equipped with a automatic transaxle, install the transaxle rear mounting nut.
  6.  
  7. On vehicles equipped with a manual transaxle, install the transaxle rear mounting from the body.
  8.  
  9. Install the transaxle left side mounting bracket.
  10.  
  11. Install the transaxle right side engine mounting to its bracket.
  12.  
  13. Tighten all the bolts and nuts.
  14.  
  15. Remove the lifting device.
  16.  
  17. To complete the installation procedure, reverse the removal procedure.
  18.  
  19. Adjust the clutch pedal free-play.
  20.  
  21. Adjust the gear select cable, and oil pressure control cable.
  22.  
  23. Adjust the accelerator cable play.
  24.  
  25. Refill the transaxle with the recommended fluid. Do the same for the engine oil and engine coolant.
  26.  
  27. Reconnect the negative battery cable. Start the engine and check for leakage of any kind. Make all necessary repairs and adjustments.
  28.  
  29. Torque the transaxle-to-engine bolts and nuts to 37 ft. lbs.. (50 Nm).
  30.  
  31. Torque the engine mounting nuts to 37 ft. lbs.. (50 Nm).
  32.  
  33. Torque the engine mounting left hand bracket bolts to 37 ft. lbs.. (50 Nm).
  34.  
  35. Torque the exhaust pipe to manifold bolts to 37 ft. lbs.. (50 Nm).
  36.  
  37. Torque the flywheel retaining bolts to 47 ft. lbs.. (64 Nm).
  38.  

 
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