GM Storm/Spectrum 1985-1993 Repair Guide

Engine Assembly

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REMOVAL & INSTALLATION



Spectrum
  1. Remove the hood, relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. If equipped with carburetor, remove the air cleaner and the throttle cable at the carburetor.
  6.  
  7. Disconnect the heater hoses at the intake manifold, the coolant hose at the thermostat housing and the thermostat housing at the cylinder head.
  8.  
  9. Remove the distributor from the cylinder head.
  10.  
  11. Unplug the oxygen sensor electrical connector.
  12.  
  13. Support the engine using a vertical lift to prevent it from dropping suddenly and remove the right motor mount.
  14.  
  15. Disconnect the necessary electrical connectors and vacuum hoses.
  16.  
  17. Disconnect the flex hose at the exhaust manifold and the lower radiator hose at the block.
  18.  
  19. Remove the upper air conditioning compressor bolt and remove the belt.
  20.  
  21. Disconnect the power steering bracket at the block and remove the belt.
  22.  
  23. Disconnect the fuel lines from the fuel pump and the electrical connectors from under the carburetor, if equipped.
  24.  
  25. Remove the upper starter bolt. Raise and support the vehicle safely.
  26.  
  27. Drain the oil from the crankcase and remove the oil filter.
  28.  
  29. Unplug the oil temperature switch connector.
  30.  
  31. Disconnect the exhaust pipe bracket at the block and the exhaust pipe at the manifold.
  32.  
  33. Remove the air conditioning compressor and move to one side. Do not disconnect the air conditioning refrigerant lines. Remove the alternator wires.
  34.  
  35. Disconnect the starter wires and remove the starter.
  36.  
  37. Remove the flywheel cover and the converter bolts, then install a flywheel holding tool J-35271 or equivalent.
  38.  
  39. Remove the front right wheel and inner splash shield.
  40.  
  41. Lower the engine by lowering the crossmember enough to gain access to the crankshaft pulley bolts, then remove the pulley.
  42.  
  43. Raise the engine and crossmember. Remove the engine support.
  44.  
  45. Lower the vehicle and support the transaxle.
  46.  
  47. Remove the transaxle to engine bolts. Remove the engine. Lift the engine only partly out at first and check to make sure that all wires and hoses are free of the engine or vehicle before proceeding.
  48.  

To install:
  1. Carefully lower the engine into position and secure using the transaxle bolts.
  2.  
  3. Remove the transaxle support, then raise and support the vehicle safely.
  4.  
  5. Install the engine support. If necessary, raise the engine and crossmember slightly for access.
  6.  
  7. Lower the engine sufficiently to install the crankshaft pulley and retaining bolts.
  8.  
  9. Install the right front splash shield and wheel.
  10.  
  11. If installed, remove the flywheel holding tool, then install the converter bolts and flywheel cover.
  12.  
  13. Connect the wiring and install the starter motor.
  14.  
  15. Reconnect the alternator wiring, then reposition the A/C compressor and secure using the fasteners. Make sure the refrigerant lines have not been damaged.
  16.  
  17. Connect the exhaust pipe to the manifold and the bracket to the block.
  18.  
  19. Install the wiring harness connector to the oil temperature switch.
  20.  
  21. Install a new oil filter, then lower the vehicle and immediately fill the engine crankcase. It is too easy to forget the oil at the end of the procedure and risk severe engine damage.
  22.  
  23. If not done already, install the upper starter bolt.
  24.  
  25. If equipped, install the electrical connectors under the carburetor, then connect the fuel lines to the pump.
  26.  
  27. Connect the power steering bracket and install the belt.
  28.  
  29. Install the belt and the upper A/C compressor bolt.
  30.  
  31. Connect the lower radiator hose to the block, then connect the flex hose to the exhaust manifold.
  32.  
  33. Install all electrical connectors and vacuum hoses, as tagged during removal.
  34.  
  35. Install the right motor mount, then remove the engine support.
  36.  
  37. Install the wiring harness connector to the oxygen sensor.
  38.  
  39. Install the distributor to the cylinder head.
  40.  
  41. Install the thermostat housing at the cylinder head, then connect the coolant hose to the thermostat housing and the heater hoses to the intake manifold.
  42.  
  43. For carbureted vehicles, connect the throttle cable to the carburetor, then install the air cleaner.
  44.  
  45. Install the hood to the vehicle, then fill then engine cooling system.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Check and adjust the accessory drive belts.
  50.  
  51. Start the engine and check for leaks. Check all fluids and top-off, as necessary.
  52.  

Storm

See Figures 1 and 2

1.6L ENGINE
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the battery cables, then remove battery and battery tray from vehicle.
  4.  
  5. Scribe match marks between the hood hinge and hood, then remove the hood from the vehicle.
  6.  
  7. Drain cooling system, then disconnect the accelerator cable from the throttle valve.
  8.  
  9. Disconnect the breather hose from the intake air duct, then remove the intake air duct from the throttle valve.
  10.  
  11. Remove the air cleaner cover, filter and the body from the vehicle.
  12.  
  13. Remove the MAP sensor hose from the MAP sensor, then the brake booster vacuum hose.
  14.  
  15. Disconnect the 2 canister hoses from the pipes on the intake manifold (common chamber). If equipped with twincam engine, remove the canister pipe support bracket.
  16.  
  17. Disconnect the 2 cable harness connectors, located near the left shock tower.
  18.  
  19. Disconnect the ignition coil ground cable from the terminal on the thermostat housing flange.
  20.  
  21. Disconnect the ignition coil-to-distributor wire, the 2 primary wires from the ignition coil, then remove the ignition coil and bracket from the vehicle.
  22.  
  23. Disconnect the engine harness ground cable from the left inner fender.
  24.  
  25. Disconnect the harness terminal from the relay and fuse box.
  26.  
  27. Disconnect the cooling fan electrical connector and the 2 battery cable connectors.
  28.  
  29. Disconnect the oxygen sensor electrical connector, then the ground cable terminals from the left front side of the common chamber and/or the rear of the cylinder head cover.
  30.  
  31. If equipped with automatic transaxle, disconnect the electrical connectors from transaxle.
  32.  
  33. If equipped with manual transaxle, loosen the tow adjusting nuts and disconnect the clutch cable. Disconnect the 2 transaxle shaft cables by removing the cotter pin and clip from the shaft cable bracket.
  34.  
  35. If equipped with automatic transaxle, disconnect the shift cable by removing the cotter pin from the shaft cable lever.
  36.  
  37. On all vehicles, remove the 2 heater hoses from the engine.
  38.  
  39. Disconnect the speedometer from the transaxle, then the upper radiator hose from the radiator.
  40.  
  41. Disconnect the fuel feed line and fuel return hose, near the filter, then the coolant recovery tank with bracket.
  42.  
  43. Remove the power steering belt, power steering pump and bracket from the vehicle.
  44.  
  45. Remove the cooling fan and shroud, then raise and support the vehicle safely.
  46.  
  47. Remove the right and left under covers and the lower radiator hose from the engine.
  48.  
  49. If equipped with automatic transaxle, disconnect the oil cooler, lines from the transaxle.
  50.  
  51. Remove the air conditioning compressor bracket bolts and position compressor aside. Be careful not to damage or rupture the compressor lines.
  52.  
  53. Remove the front tire and wheel assemblies, then the halfshafts.
  54.  
  55. Remove the front exhaust pipe from the exhaust manifold.
  56.  
  57. Lower the vehicle and install a suitable engine hoist onto the lifting brackets on the engine.
  58.  
  59. Remove the engine mounts and transaxle mounts, then lift the engine and transaxle assembly out from the vehicle. Lift the assembly only partly out at first and double check to make sure all hoses and wiring are free of the engine or vehicle before proceeding. Separate the transaxle from the engine and place the engine on a suitable stand.
  60.  

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, then the transaxle mounts and engine mounts.
  4.  
  5. Remove the engine hoist from the vehicle, then raise and support vehicle safely.
  6.  
  7. Install the front exhaust pipe to the exhaust manifold, then the install the halfshafts.
  8.  
  9. Install the tire and wheel assemblies, then the 2 air conditioning bracket mounting bolts.
  10.  
  11. If equipped with automatic transaxle, connect the 2 cooler lines to the transaxle.
  12.  
  13. Install the lower radiator hose, then the right and left undercovers. Lower the vehicle.
  14.  
  15. Install the cooling fan and shroud, then the power steering pump and belt onto the engine.
  16.  
  17. Install the coolant recovery tank with bracket, then connect the fuel feed line and fuel return hose.
  18.  
  19. Install the upper radiator hose, then connect the speedometer cable to the transaxle.
  20.  
  21. Connect the 2 heater hoses to the engine, then the transaxle shift cables, if equipped.
  22.  
  23. If equipped with manual transaxle, connect the clutch cable and adjust.
  24.  
  25. If equipped with automatic transaxle, connect the electrical connectors to the transaxle.
  26.  
  27. Connect the ground cable terminal to the rear of the cylinder head cover.
  28.  
  29. Connect the 2 ground terminals to the right side of the intake manifold (common chamber). If equipped with twincam engine, install the canister pipe support bracket.
  30.  
  31. Connect the oxygen sensor electrical connector and the 2 battery cable harness connectors.
  32.  
  33. Connect the cooling fan harness connector, then the chassis harness terminal connector to the relay and fuse box.
  34.  
  35. Connect the engine ground cable to the left inner fender, then install the ignition coil and bracket.
  36.  
  37. Connect the 2 primary wires to the ignition coil and the ignition coil-to-distributor wire.
  38.  
  39. Connect the ignition coil ground wire to the terminal at the thermostat housing.
  40.  
  41. Connect the 2 cable harness connectors, located near the left shock tower.
  42.  
  43. Connect the 2 canister hoses to the intake manifold (common chamber).
  44.  
  45. Connect the brake booster vacuum hose, then the MAP sensor hose to the MAP sensor.
  46.  
  47. Install the air cleaner body, air cleaner filter and the cover.
  48.  
  49. Connect the air intake duct to the throttle body and the breather hose to the air intake duct.
  50.  
  51. Connect the accelerator cable to the throttle valve.
  52.  
  53. Fill the cooling system, engine oil and transaxle with suitable fluids. Install the battery tray and battery.
  54.  
  55. Align the match marks on the hood hinge scribed during removal, and install the hood. Connect the battery cables. Start the engine and check for leaks.
  56.  



Click image to see an enlarged view

Fig. Fig. 1: When removing the engine, the hood must be removed to provide room for the engine hoist, but it also makes engine compartment access easier throughout the procedure



Click image to see an enlarged view

Fig. Fig. 2: Carefully raise the engine and transaxle from the vehicle as an assembly - Storm

1.8L ENGINE
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the battery cables, then remove battery and battery tray from vehicle.
  4.  
  5. Scribe match marks between the hood hinge and hood, disconnect the wiper washer hoses and then remove the hood from the vehicle.
  6.  
  7. Drain cooling system, the crankcase oil and the transaxle fluid/oil, then disconnect the accelerator cable from the throttle valve and common chamber.
  8.  
  9. Remove the intake air duct from the air cleaner and the throttle valve.
  10.  
  11. Remove the air cleaner cover, filter and the body from the vehicle.
  12.  
  13. Disconnect all vacuum hoses from the common chamber.
  14.  
  15. Unplug the engine wiring harness-to-chassis wiring harness electrical connectors.
  16.  
  17. Unplug the secondary (coil) wire from the distributor cap and the ground wire from the ignition coil bracket, then remove the 2 screws and position the coil aside.
  18.  
  19. If equipped with an automatic transaxle, disconnect the shift cable by removing the cotter pin, then removing the cable from the shaft cable lever on the transaxle.
  20.  
  21. If equipped with manual transaxle, loosen the 2 adjusting nuts and disconnect the clutch cable. Disconnect the 2 transaxle shift cables by removing the cotter pin and separating the cables from the transaxle.
  22.  
  23. Remove the ground bolt and negative battery cable from the transaxle.
  24.  
  25. If equipped with an automatic transaxle, unplug the 4 electrical connectors from the transaxle.
  26.  
  27. Loosen the hose clamps, then remove the upper and lower radiator hoses from the radiator and the 2 heater hoses from the engine.
  28.  
  29. Disconnect the fuel feed and return pipes near the fuel filter.
  30.  
  31. Disconnect the speedometer cable from the transaxle, then remove the ground bolts and wires from the common chamber.
  32.  
  33. Remove the upper and lower radiator hoses from the engine.
  34.  
  35. Unplug the oxygen sensor and the alternator electrical connectors.
  36.  
  37. If equipped, unplug the A/C compressor electrical connector.
  38.  
  39. Position a drain pan to catch any escaping fluid, then remove the union bolt and the power steering pressure pipe from the pump. Loosen the hose clamp and remove the return hose from the pump.
  40.  
  41. Remove the serpentine drive belt from the engine.
  42.  
  43. Remove the 5 retaining bolts and the heat shield from the exhaust manifold.
  44.  
  45. Remove the 3 mounting bolts and the power steering pump from the bracket. Remove the alternator from the engine.
  46.  
  47. Remove the ground strap from the front of the engine, then remove the cooling fan.
  48.  
  49. If equipped, remove the A/C compressor upper mounting bolt.
  50.  
  51. Install J-28467-A, or an equivalent engine support fixture using a suitable adapter kit, then raise and safely support the vehicle sufficiently for under vehicle access.
  52.  
  53. Remove the left and right splash shields, then if equipped, loosen the hose clamps and disconnect the automatic transaxle fluid cooler lines from the radiator.
  54.  
  55. Remove the A/C compressor lower mounting bolt, then support the compressor aside. Be careful not to kink or rupture the refrigerant lines. Remove the compressor mounting bracket from the engine.
  56.  
  57. Remove the front wheels, then remove the halfshafts.
  58.  
  59. Remove the attaching nuts, then separate the forward exhaust pipe from the exhaust manifold. Remove the forward exhaust pipe bracket.
  60.  
  61. Unplug the starter motor electrical connectors, then remove 1 bolt, 1 nut and the suspension-to-rear engine brace.
  62.  
  63. Remove the rear engine mount through-bolt. Remove the torque rod-to-center crossmember through bolt and nut. Remove the 4 bolts and the center crossmember from the frame.
  64.  
  65. If necessary, remove the supports and lower the vehicle for underhood access. Support the engine/transaxle assembly using a floor jack.
  66.  
  67. Remove the engine support assembly and attach a suitable engine hoist to the lift brackets on the engine, then unclip the wiring harness from the transaxle and position aside.
  68.  
  69. Remove the left transaxle mount. Remove the bolt and nut from the right engine mount bracket. Remove the through bolt and the right engine mount from the vehicle.
  70.  
  71. Carefully lift the engine and transaxle assembly out of the vehicle. Only lift the assembly part way at first and make sure that all wires or hoses are free of the vehicle or engine before proceeding. Remove the assembly from the vehicle.
  72.  

To install:
  1. Connect the hoist to the engine lifting brackets, raise the engine and carefully lower it into position in the vehicle.
  2.  
  3. Install the right engine mount to the vehicle and secure using the through-bolt, but do not fully tighten at this time.
  4.  
  5. Install the bolt and nut to the right engine mount bracket. Tighten the nut and bolt to 30 ft. lbs. (40 Nm), then tighten the through bolt to 50 ft. lbs. (68 Nm).
  6.  
  7. Install the left transaxle mount, then reposition and secure the transaxle wiring harness to the transaxle.
  8.  
  9. Support the engine and transaxle assembly using a floor jack, then remove the engine hoist and chain. Install the engine support assembly.
  10.  
  11. Remove the floor jack, then raise and safely support the vehicle sufficiently for under vehicle access.
  12.  
  13. Install the center crossmsmber to the frame and tighten the 4 retaining bolts to 45 ft. lbs. (61 Nm). Install the torque rod-to-center crossmember through bolt and nut, tighten the fasteners to 51 ft. lbs. (69 Nm).
  14.  
  15. Install the rear engine mount through bolt and tighten to 37 ft. lbs. (50 Nm). Install the suspension-to-rear engine mount brace, secure using the bolt and nut, then tighten to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the starter motor electrical connections.
  18.  
  19. Install the forward exhaust pipe bracket, then connect the pipe to the exhaust manifold using a new gasket. Tighten the retaining nuts to 29 ft. lbs. (39 Nm).
  20.  
  21. Install the halfshafts, then install the front wheels.
  22.  
  23. If equipped, install the A/C compressor bracket and tighten the retaining bolts to 15 ft. lbs. (20 Nm). Reposition the compressor and tighten the lower mounting bolt to 30 ft. lbs. (40 Nm).
  24.  
  25. If equipped, connect the automatic transaxle fluid cooler lines to the radiator and secure using hose clamps.
  26.  
  27. Install the left and right splash shields, remove the supports and carefully lower the vehicle. Remove the engine support fixture.
  28.  
  29. If equipped, install the A/C compressor upper mounting bolt and tighten to 30 ft. lbs. (40 Nm).
  30.  
  31. Install the cooling fan assembly. Connect the ground strap to the front of the engine.
  32.  
  33. Install the alternator, then install the power steering pump. Tighten the pump mounting bolts to 15 ft. lbs. (20 Nm).
  34.  
  35. Install the heat shield to the exhaust manifold and tighten the retaining bolts to 11 ft. lbs. (15 Nm).
  36.  
  37. Install the serpentine drive belt.
  38.  
  39. Connect the fluid return hose to the power steering pump and secure using a hose clamp. Connect the fluid pressure pipe to the pump and tighten the union bolt to 15 ft. lbs. (20 Nm).
  40.  
  41. If equipped, install the wiring harness to the A/C compressor.
  42.  
  43. Install the alternator and the oxygen sensor electrical connections.
  44.  
  45. Install the upper and lower radiator hoses to the engine using hose clamps.
  46.  
  47. Connect the ground wires to the common chamber and tighten the bolts to 71 inch lbs. (8 Nm).
  48.  
  49. Connect the TP sensor electrical connector, then install the speedometer cable to the transaxle.
  50.  
  51. Connect the fuel feed and return pipes near the fuel filter.
  52.  
  53. Install the 2 heater hoses to the engine and the upper and lower radiator hoses to the radiator. Secure all hoses using clamps.
  54.  
  55. If equipped, install the 4 electrical connectors to the automatic transaxle.
  56.  
  57. Connect the negative battery cable and the transaxle shift cables to the transaxle.
  58.  
  59. If applicable, install and adjust the clutch cable to the manual transaxle.
  60.  
  61. Reposition the ignition coil and secure using the 2 screws. Connect the secondary wire to the distributor cap and the ground wire to the ignition coil bracket.
  62.  
  63. Install the engine wiring harness-to-chassis wiring harness electrical connectors. Connect the vacuum hoses to the common chamber.
  64.  
  65. Install the air cleaner body, filter and element. Connect the air intake duct to the air cleaner and the throttle valve. Connect the accelerator cable to the throttle valve and common chamber.
  66.  
  67. Install the battery tray, then install the battery to the vehicle. Connect only the positive battery cable at this time.
  68.  
  69. Align the marks made earlier and install the hood to the vehicle. Tighten the retaining bolts to 15 ft. lbs. (20 Nm). Connect the washer hoses to the hood.
  70.  
  71. Refill the engine crankcase oil, then connect the negative battery cable.
  72.  
  73. Refill the power steering fluid, the engine coolant and the transaxle fluid/oil.
  74.  
  75. Start the engine and check for leaks.
  76.  

 
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