Roadmaster 1992

Engine

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Removal & Installation



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 disconnecting it, so that it may be reconnected properly during installation. If at all possible, remove the component, leaving the wires or hoses connected and place the component on top of the engine assembly. This will help make reassembly easier and less confusing.


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.


    NOTE
    If working near and/or around the SRS system and components, be sure to properly disable the SRS system. See disarming/arming the SRS system.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the hood from hinges and mark for reassembly.
  8.  
  9. Drain coolant into a suitable container.
  10.  
  11. Remove the air cleaner assembly.
  12.  
  13. Remove the radiator hoses and upper fan shroud.
  14.  
  15. Remove the radiator.
  16.  
  17. Remove the engine cooling fan.
  18.  
  19. Disconnect the heater hoses at the engine
  20.  
  21. Disconnect the power steering pump and air conditioning compressor brackets, if equipped, and position out of the way.
  22.  
  23. Disconnect the accelerator, TV, and cruise control cables.
  24.  
  25. Disconnect all necessary vacuum hoses.
  26.  
  27. Disconnect the ECM wiring harness, the engine wiring harness at the engine bulkhead, engine to bulkhead ground straps and all other wires between body and engine.
  28.  
  29. Set the engine on TDC and remove the distributor.
  30.  
  31. Remove the wiper motor, MAP sensor and battery negative to cylinder head cable.
  32.  
  33. Raise and support the vehicle safely.
  34.  
  35. Disconnect the battery positive cable and wires at the starter motor.
  36.  
  37. Disconnect the crossover pipe and catalytic converter as an assembly.
  38.  
  39. Remove the flywheel cover and torque converter to flywheel bolts.
  40.  
  41. Remove the engine mount through-bolts.
  42.  
  43. Disconnect the front fuel hoses from the front fuel pipes.
  44.  
  45. Disconnect the transmission converter clutch wiring at the transmission and the transmission oil cooler lines at the clip on the oil pan.
  46.  
  47. Disconnect the catalytic converter AIR pipe at the exhaust manifold.
  48.  
  49. Remove the transmission to engine bolts.
  50.  
  51. Lower the vehicle.
  52.  
  53. Support the transmission and connect a suitable lifting device to the engine.
  54.  
  55. Remove the engine.

    Click image to see an enlarged view

    Fig. Engine mounts and related components-1991-1993

  56.  

To install:


NOTE
Be sure to use new fasteners, as required.


NOTE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread sealer are identified. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners.

  1. With the engine safely supported, lower into position with the lifting device and align with the motor mounts and transmission.
  2.  
  3. Install motor mount through-bolts and the transmission to engine bolts. Tighten the transmission to engine bolts to 35 ft. lbs. (47 Nm).
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Connect the catalytic converter AIR pipe to the exhaust manifold.
  8.  
  9. Connect the transmission converter clutch wiring to the transmission and the transmission oil cooler lines to the clip on the oil pan.
  10.  
  11. Connect the front fuel hoses to the front fuel pipes.
  12.  
  13. Install the torque converter to flywheel bolts and the flywheel housing cover.
  14.  
  15. Connect the crossover pipe and catalytic converter assembly.
  16.  
  17. Connect the battery positive cable and wires to the starter motor.
  18.  
  19. Lower vehicle.
  20.  
  21. Install the wiper motor, MAP sensor and the negative battery to cylinder head cable.
  22.  
  23. Set the engine on TDC and install the distributor.
  24.  
  25. Connect the ECM wiring harness, the engine wiring harness at the engine bulkhead, engine to bulkhead ground straps and all other wires between body and engine.
  26.  
  27. Connect all necessary vacuum hoses.
  28.  
  29. Connect the accelerator, TV and cruise control cables.
  30.  
  31. Connect the power steering pump and air conditioning compressor brackets, if equipped.
  32.  
  33. Connect the heater hoses to the engine.
  34.  
  35. Install the engine cooling fan.
  36.  
  37. Install the radiator, hoses and fan shroud.
  38.  
  39. Install the air cleaner assembly.
  40.  
  41. Install the hood, aligning the marks made during removal.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Fill the cooling system to the proper level.
  46.  
  47. Inspect vehicle fluid levels, specifications and verify there are no fluid leaks.
  48.  
  49. Using the GM diagnostic scan tool or aftermarket equivalent reprogram the necessary systems and components. Be sure to follow the scan tool manufacturer-s directions.
  50.  

 
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