S10 Pickup, Sonoma 2000-2004

Engine

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Removal & Installation



2.2L Engine

NOTE
In certain cases on some models the A/C system will have to be evacuated because the compressor may need to be removed from the vehicle to allow clearance for engine removal. On other models you maybe able to set the compressor and lines to one side and still have enough clearance to remove the engine. In this case the system does not have to be evacuated because the lines do not have to be disconnected from the compressor. To check if your system has to be evacuated, unplug the electrical connectors from the compressor, then unbolt the compressor assembly. Unfasten any brackets holding the refrigerant lines and try to set the components aside so that you will have enough clearance for engine removal. If there is not enough clearance for engine removal you must recover the refrigerant from the A/C system with an approved recovery station before attempting to remove the engine from your vehicle. DO NOT attempt this without the proper equipment. R-134a should NOT be mixed with R-12 refrigerant and, depending on your local laws, attempting to service this system could be illegal.

  1. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. Drain the engine cooling system and the engine oil into separate drain pans.
  4.  
  5. Remove or disconnect the following:
    NOTE
    On some models it may also be necessary to disconnect the catalytic converter from the exhaust pipe.



    Hood
     
    Oxygen Sensor (O 2 S) electrical connection
     
    Exhaust pipe from the manifold
     



    Braces from the engine and the transmission, if equipped
     
    Starter motor
     
    Transmission and separate it from the engine or, if necessary, remove it from the vehicle
     
    Alternator rear brace by unfastening the bolt and nuts
     
    Ground straps from the engine block
     
    Drive belt
     
    A/C compressor and bracket. If possible, set the compressor and bracket to one side without disconnecting the lines.
     
    Hoses and transmission coolant lines engaged to the radiator
     
    Radiator
     
    Power steering pump and cap the power steering lines to avoid contamination
     
    Heater hoses from the heater core
     
    12 volt supply from the mega fuse, if necessary
     
    All electrical connections and wiring harnesses
     
    All vacuum lines
     
    Throttle cable, and if equipped the cruise control cable
     
    Exhaust Gas Recirculation (EGR) pipe and the EGR valve
     
    Fuel lines
     

  6.  
  7. Install a suitable lifting device to the engine.
  8.  
  9. Remove the engine mount bolts and carefully lift the engine from the vehicle. Pause several times while lifting the engine to make sure no wires or hoses have become snagged.
  10.  

To install:

  1. Carefully lower the engine into the vehicle and install the engine mount bolts. Remove the engine lifting device.
  2.  
  3. Install or connect the following:

    Fuel lines
     
    12 volt supply to the mega fuse, if removed
     
    All vacuum lines, electrical connections and wiring harnesses
     
    EGR valve and pipe, if removed
     
    Throttle and if equipped, the cruise control cable
     
    Heater hoses to the heater core
     
    Power steering pump and attach the lines
     
    A/C compressor
     
    Radiator, all hoses and fluid cooler lines
     
    Water pump, if removed
     
    Drive belt
     
    Ground strap to the engine
     
    Alternator rear brace and tighten the bolt and nuts, if removed
     
    Transmission to the engine
     
    Starter motor, if removed
     
    Braces to the engine and the transmission, if equipped
     
    Exhaust pipe to the manifold
     
    Catalytic converter to the exhaust pipe, if removed
     
    O 2 S electrical connection
     
    Battery
     
    Hood
     

  4.  
  5. Check all powertrain fluid levels and add, as necessary. Be sure to properly fill the engine crankcase with clean engine oil.
  6.  
  7. Connect the battery cables and properly fill the engine cooling system.
  8.  
  9. Start and run the engine, then check for leaks.
  10.  

4.3L Engine
  1. Drain the engine cooling system
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel system pressure
     
    Vacuum reservoir and/or the underhood light from the hood, as equipped
     
    Outer cowl vent grilles
     
    Hood
     
    Oxygen Sensor (O 2 S) and/or wiring
     
    Exhaust pipes at the manifolds and loosen the hanger at the catalytic converter. This is necessary to remove the rear catalytic converter cushion mounts for removal of the exhaust assembly.
     
    Skid plate, if equipped
     
    Engine-to-transmission pencil braces
     
    Slave cylinder and position aside, if equipped
     
    Line clamp at the bell housing
     
    Wiring from the starter
     
    Starter
     
    Transfer case
     
    Oil filter
     
    Engine mount through bolts
     
    Rear engine mount crossbar, nut and washer
     
    Bell housing bolts, except the upper left.
     
    Battery ground (negative) cable from the engine
     
    Front drive axle bolts and roll the axle downward, on 4WD vehicles
     
    Air cleaner assembly
     
    Upper radiator shroud
     
    Fan assembly
     
    Drive belt assembly
     
    Water pump pulley
     
    Upper radiator hose
     
    Air conditioning compressor, if equipped, and position aside with the lines intact
     
    Lower radiator hose
     
    Oil cooler and overflow lines from the radiator, plug the openings to prevent system contamination or excessive fluid loss
     
    Radiator and lower radiator shroud
     
    Power steering hoses from the steering gear, then cap the openings to prevent system contamination or excessive fluid loss
     
    Heater hoses from the intake manifold and the water pump
     
    Wiring harness and vacuum lines from the engine
     
    Throttle cables
     
    Remaining bell housing bolt
     
    Fuel lines and the bracket
     
    Ground strap(s) from the rear of the cylinder head
     
    Front body mount bolts, on 4WD vehicles
     

  6.  
  7. Support the transmission.
  8.  
  9. Install a lifting device and lift the engine.
  10.  

To install:

  1. Install or connect the following:

    Engine into the vehicle
     
    Front body mount bolts, on 4WD vehicles
     
    Ground strap(s) to the rear of the cylinder head
     
    Fuel lines and the bracket
     
    Upper left bell-housing bolt
     
    Throttle cables
     
    Vacuum lines and wiring harness connectors
     
    Heater hoses
     
    Power steering hoses
     
    Lower shroud and radiator
     
    Oil cooler lines to the radiator and overflow hose
     
    Lower radiator hose
     
    Air conditioning compressor to the engine, if equipped
     
    Upper radiator hose
     
    Water pump pulley
     
    Drive belt assembly
     
    Fan assembly
     
    Upper radiator shroud
     
    Air cleaner assembly
     
    Front drive axle, for 4WD vehicles
     
    Battery ground strap to the engine block
     
    Remaining bell housing bolts
     
    Engine mount through-bolts. Torque them to 49 ft. lbs. (66 Nm).
     
    Rear engine mount crossbar nut and washer. Tighten the nut to 33 ft. lbs. (45 Nm).
     
    Oil filter
     
    Starter motor
     
    Flywheel cover
     
    Clutch slave cylinder, if equipped
     
    Pencil brace and the skid plate, as equipped
     
    Catalytic converter Y-pipe assembly and hangers
     
    Hood
     
    Outer cowl vent grilles
     
    Vacuum reservoir and/or the underhood light to the hood, as equipped
     
    Negative battery cable
     

  2.  
  3. Check all powertrain fluid levels and add, as necessary.
  4.  
  5. Refill the engine crankcase.
  6.  
  7. Refill the engine cooling system.
  8.  
  9. Start and run the engine, then check for leaks.
  10.  

 
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