LEMON Manuals: Even more car manuals for everyone
Home >> Cadillac >> 2021 >> CT4 Sport, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 92 (Engine Mechanical - 2.0L (LSY) - Repair Instructions (3 Of 3)) >> Repair Instructions >> Engine Replacement (AWD) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2022 Cadillac CT4. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant. Refrigerant Recovery and Recharging
  2. Relieve the fuel system pressure. Fuel Pressure Relief
  3. Drain the coolant. Cooling System Draining and Filling (LSY GE 47716) , or Cooling System Draining and Filling (LSY Static Fill) , or Cooling System Draining and Filling (LSY with V03 Static Fill) , or Cooling System Draining and Filling (LSY with V03 GE 47716)
  4. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
  5. Remove the oil fill cap.
  6. Drain the engine oil. Engine Oil and Oil Filter Replacement (RWD) , or Engine Oil and Oil Filter Replacement (AWD) 
  7. Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation
  8. GM5427523

    Air Cleaner Bolt (1) - Remove

  9. Air Cleaner Outlet Duct Clamp (2) - Loosen
  10. GM5427515

    Wiring Harness Retainer (1) @ Air Cleaner Assembly - Remove [4x]

  11. Positive Crankcase Ventilation Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
  12. Electrical Connector (4) - Disconnect [2x]
  13. Remove the ground wire on the frame support.
  14. GM5427525

    Remove the air cleaner (1) and air cleaner outlet duct (2) as an assembly.

  15. GM5335087

    Lift up on the front of the intake manifold cover (1).

  16. GM5335089

    Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove

  17. GM5334198

    Positive Crankcase Ventilation Tube (1) - Disconnect [2x] - Plastic Collar Quick Connect Fitting Service

  18. Unclip and remove the retainer (2) from the engine.
  19. GM5080707

    Disconnect the quick disconnects and remove from the retainers (3). Plastic Collar Quick Connect Fitting Service

  20. Evaporative Emission Canister Purge Tube (2) - Remove
  21. GM5312713

    Heater Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type

  22. Heater Outlet Hose (2) @ Auxiliary Water Pump Inlet Pipe - Remove
  23. GM5312791

    Heater Inlet Hose Retainer (1) - Disengage

  24. Heater Inlet Hose (2) @ Engine Coolant Thermostat Housing Pipe (3) - Remove
  25. GM5323484

    Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type

  26. Engine Coolant Air Bleed Hose (3) @ Engine Coolant Heater Exhaust Pipe - Remove
  27. GM5420763

    Radiator Surge Tank Inlet Hose Clamp (1) @ Radiator Surge Tank Outlet Pipe (3) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type

  28. Radiator Surge Tank Inlet Hose (2) @ Radiator Surge Tank Outlet Pipe (3) - Remove [2x]
  29. GM5312607

    Radiator Surge Tank Inlet Hose Clip (1) @ Positive Crankcase Ventilation Hose - Remove

  30. Radiator Surge Tank Inlet Hose Clip (3) @ Fuel Pump Cover - Remove
  31. Radiator Surge Tank Inlet Hose Clip (2) @ Engine Wiring Harness - Remove
  32. GM5312610

    Radiator Surge Tank Inlet Hose Clip (1) @ Radiator Surge Tank Inlet Pipe Bracket - Remove

  33. Radiator Surge Tank Inlet Hose Clip (2) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
  34. Radiator Surge Tank Outlet Pipe (3) - Remove
  35. GM5420297
    NOTE:

    The radiator, condenser and charge air cooler will be removed together with the engine and cradle.

    Remove the front 3 radiator air upper baffle retainers (1).

  36. Radiator Air Upper Baffle (2) - Reposition
  37. GM5427430

    Wiring Harness Retainer (1) - Remove

  38. Radiator Upper Bracket Bolt (3) - Remove [4x]
  39. Radiator Upper Bracket (2) - Remove [2x]
  40. GM5137012

    Electrical Connector (1) - Disconnect [3x]

  41. Retainer (2) @ Upper Intake Manifold Bracket (3) - Unclip
  42. Wiring Harness (4) - Reposition
  43. GM5137013

    Upper Intake Manifold Cover Bracket Bolt (1) @ Upper Intake Manifold Bracket (2) - Remove [2x]

  44. GM5137016

    Upper Intake Manifold Cover Nut (1) - Remove [2x]

  45. Upper Intake Manifold Bracket (2) - Remove
  46. GM5471127

    Air Conditioning Compressor Hose Nut (1) - Remove

  47. Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (2) @ Air Conditioning Refrigerant Heat Exchanger - Remove
  48. Air Conditioning Evaporator Thermal Expansion Valve Seal (3) - Remove and DISCARD
  49. Air Conditioning Evaporator Tube Clip Bracket Bolt (4) - Remove
  50. Position the air conditioning refrigerant heat exchanger out of the way.
  51. GM5315482

    Air Conditioning Condenser Hose Nut (1) @ Air Conditioning Condenser - Remove

  52. Air Conditioning Condenser Tube Clip (2) - Remove
  53. GM5471158

    Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (1) @ Air Conditioning Condenser - Remove

  54. Air Conditioning Compressor and Condenser Hose Seal (2) - Remove and DISCARD
  55. GM5471160

    Air Conditioning Refrigerant Heat Exchanger (1) @ Air Conditioning Condenser - Remove

    56. CAUTION:

    Refer to Air Conditioning Sealing Washers Oil or Lubricant Exposure Caution .

  56. Air Conditioning Condenser Hose Seal (2) - Remove and DISCARD
  57. GM5471834

    Unfasten the radiator inlet hose clip (1), and position the radiator inlet hose (2) out of the way.

  58. GM5472013

    Disconnect the electrical connector. (1)

  59. GM5315475

    Air Conditioning Compressor Hose Nut (1) @ Air Conditioning Compressor - Remove

  60. GM5460376

    Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (1) @ Air Conditioning Compressor - Remove

  61. Air Conditioning Evaporator Thermal Expansion Valve Seal (2) - Remove and DISCARD
  62. Air Conditioning Compressor Hose Seal (3) - Remove and DISCARD
  63. Maneuver the air conditioning evaporative connector hose/tube and compressor hose out of the engine compartment.
  64. GM5403825

    Fuel Feed Pipe (1) @ Fuel Pump - Disconnect - Metal Collar Quick Connect Fitting Service

  65. GM5439477

    Disconnect the electrical connector at the evaporative emission canister purge pump (1).

  66. Evaporative Emission Pipe (1) @ Evaporative Emission Canister Purge Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
  67. Evaporative Emission Front Pipe (1) - Reposition away
  68. GM5314604
    NOTE:

    Nuts are captured with the wires.

    Battery Distribution Engine Compartment Fuse Block Cover (1) - Remove

  69. Battery Positive Cable Nut (6) - Remove
  70. Battery Positive Cable (7) - Remove
  71. Auxiliary Generator Battery Jumper Cable Nut (5) - Remove
  72. Auxiliary Generator Battery Jumper Cable (8) - Remove
  73. Engine Wiring Harness Conduit Nut (4) - Remove
  74. Engine Wiring Harness Conduit Nut (3) - Remove
  75. Engine Wiring Harness (9) - Remove [2x]
  76. Engine Wiring Harness Conduit Nut (2) - Remove [2x]
  77. Forward Lamp Wiring Harness (10) - Remove [2x]
  78. GM5314636

    Retaining Tab (1) - Disengage [2x]

  79. Battery Distribution Engine Compartment Fuse Block (2) - Remove
  80. GM5315620
    NOTE:

    Nut is captured with the wire.

    Battery Positive Cable Nut (1) - Remove

  81. Auxiliary Generator Battery Jumper Cable (2) - Remove
  82. Battery Positive Cable (3) - Remove
  83. GM5311887

    Retainer (1) - Disengage [2x]

  84. Engine Wiring Harness Fuse Block Cover (2) - Remove
  85. GM5314788

    Engine Wiring Harness Junction Block Bolt (1) - Remove

  86. Engine Wiring Harness Junction Block (3) - Remove
  87. GM5315623

    Disengage the 2 retaining covers (2), and remove the 2 electrical connectors (1).

  88. GM5315648

    Disengage the 3 retaining tabs (1) from the body wiring harness junction block bracket (3) and remove the engine wiring harness fuse block bracket (2).

  89. GM5315881

    Body Wiring Harness Fuse Block Bracket Bolt (1) - Remove [2x]

  90. Remove harness retainers as needed.
  91. Body Wiring Harness Junction Block Bracket (2) - Remove
  92. GM5415995

    Disconnect the 3 electrical connectors (1) from the engine control module.

  93. Remove and disconnect the remaining engine harness from body harness as needed, and secure the engine harness to the engine.
  94. Raise and support the vehicle. Lifting and Jacking the Vehicle
  95. GM5407645

    Front Bumper Fascia Center Air Deflector Screws (1) - Remove [10x]

  96. GM5468709

    Front Bumper Fascia Center Air Deflector Screws (1) - Remove [3x]

  97. GM5407644

    Front Bumper Fascia Center Air Deflector Screw (1) - Remove [6x]

  98. Front Bumper Fascia Center Air Deflector Bolt (2) - Remove [5x]
  99. Front Bumper Fascia Center Air Deflector Retainer (3) - Remove [2x]
  100. GM5407648

    Pull the front bumper fascia center air deflector (1) rearward and down from the front bumper fascia.

  101. GM5396438

    Front Bumper Fascia Center Air Deflector Bolt (1) - Remove [5x]

  102. Front Bumper Fascia Air Deflector Retainer (2) - Remove [2x]
  103. GM5396453

    Front Wheelhouse Liner Bolt (1) - Remove

  104. Engine Front Splash Shield Retainer (2) - Remove [2x]
  105. Engine Front Splash Shield Bolt (3) - Remove
  106. GM5396496

    Front Wheelhouse Liner Bolt (3) - Remove

  107. Engine Front Splash Shield Retainer (2) - Remove [2x]
  108. Engine Front Splash Shield Bolt (1) - Remove
  109. GM5420502

    Front Compartment Air Deflector Bolt (1) - Remove [4x]

  110. Front Compartment Air Deflector (2) - Remove
  111. GM5423335

    Radiator Air Front Lower Baffle Retainer (1) - Remove [3x]

  112. GM5423336

    Radiator Air Front Lower Baffle (1) - Remove

  113. GM5424015

    Rear Tire Front Air Deflector Bolt (1) - Remove [2x]

  114. Rear Tire Front Air Deflector- Left Side (2) - Remove
  115. GM5400553

    Rear Wheelhouse Liner Screw (1) - Remove

  116. Underbody Rear Air Deflector Nut (2) - Remove [3x]
  117. Underbody Rear Air Deflector Bolt (3) - Remove [3x]
  118. Underbody Rear Air Deflector Nut (4) - Remove [2x]
  119. Underbody Rear Air Deflector- Left Side (5) - Remove
  120. GM5424018

    Rear Tire Front Air Deflector Bolt (1) - Remove [2x]

  121. Rear Tire Front Air Deflector- Right Side (2) - Remove
  122. GM5400642

    Rear Wheelhouse Liner Screw (1) - Remove

  123. Underbody Rear Air Deflector Bolt (2) - Remove [3x]
  124. Underbody Rear Air Deflector Nut (3) - Remove [3x]
  125. Underbody Rear Air Deflector Nut (4) - Remove [2x]
  126. Underbody Rear Air Deflector- Right Side (5) - Remove
  127. GM5400756

    Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Remove [6x]

  128. Floor Panel Reinforcement (2) - Remove
  129. GM5309188

    Catalytic Converter Nut (1) - Remove [2x]

  130. GM5309202

    Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator- Left Side (2) - Separate

  131. Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator- Left Side (3) - Separate
  132. GM5309211

    Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator- Right Side (2) - Separate

  133. Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator- Right Side (3) - Separate
  134. { If equipped } Electrical Connector @ Exhaust Control Valve Actuator - Disconnect
  135. GM5309214
    NOTE:

    With the aid of an assistant.

    Exhaust Muffler (1) - Remove

  136. Catalytic Converter Gasket (2) - Remove and DISCARD
  137. GM5334107

    Front Axle Propeller Shaft Heat Shield Bolt (1) - Remove

  138. Front Axle Propeller Shaft Heat Shield Stud (2) - Remove
  139. Front Axle Propeller Shaft Heat Shield (3) - Remove
  140. GM5309833

    Exhaust Heat Shield Bolt (1) - Remove [6x]

  141. Exhaust Intermediate Underbody Heat Shield (2) - Remove
  142. GM5334717

    Floor Panel Number 2 Cross Bar Reinforcement Bolt (1) - Remove [4x]

  143. Floor Panel Reinforcement (2) - Remove
  144. Support the transmission with an appropriate jack.
  145. GM5326445

    Transmission Mount Bracket Bolt (1) - Remove [4x]

  146. GM5326444
    NOTE:

    The transmission mount bolt is retained in the mount, loosen the bolt to disengage the threads and remove the mount and bolt as an assembly.

    Transmission Mount Bolt (1) - Remove

  147. Transmission Mount (2) - Remove
  148. GM5481383

    Transfer Case Front Output Shaft Boot Clamp (1) @ Transfer Case Front Output Shaft - Remove and DISCARD

  149. Release the transfer case front output shaft boot (2) from the groove in the transfer case front output shaft.
  150. GM5339603

    Mark the relationship between the front axle propeller shaft (2) and the front differential carrier flange with a grease pencil.

  151. Front Axle Propeller Shaft Bolt (1) - Remove [6x]
  152. Front Axle Propeller Shaft Washer (3) - Remove [3x]
  153. GM5339604

    Front Axle Propeller Shaft (1) - Remove

  154. GM5339605

    Inspect the transfer case front output shaft boot (1), if damage is found, remove and DISCARD the transfer case front output shaft boot clamp (2) and the transfer case front output shaft boot (1).

  155. GM5411943

    Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose Clamp (1) @ Automatic Transmission Fluid Cooling Exchanger - Remove [2x] - Hose Clamp Replacement Guidelines - Spring Type

  156. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) - Remove
  157. GM5411944

    Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose Clamp (1) @ Automatic Transmission Fluid Cooling Exchanger - Remove [2x] - Hose Clamp Replacement Guidelines - Spring Type

  158. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (2) - Remove
  159. GM5412364

    Transmission Fluid Auxiliary Cooler Bolt (1) - Remove [2x]

  160. GM5415576

    Transmission Fluid Auxiliary Cooler Bracket Nut (1) - Remove

  161. Automatic Transmission Fluid Cooling Exchanger (2) - Reposition
    162. WARNING:

    Provide additional support when a vehicle is on a hoist in the following ways:

    • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. 
    • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. 

    Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

  162. Using suitable straps or chains, secure the vehicle to the hoist arms.
  163. GM5394612
    NOTE:

    Left side shown, right side similar.

    Front Tire Front Air Deflector Bolt (1) - Remove [8x]

  164. Front Tire Front Air Deflector (2) - Remove [2x]
  165. GM5421515
    NOTE:

    Left side shown, right side similar.

    Engine Front Splash Shield Bolt (1) - Remove [10x]

  166. Engine Front Splash Shield Retainer (2) - Remove [4x]
  167. Engine Front Splash Shield (3) - Remove [2x]
  168. GM5312762
    NOTE:

    Left side shown, right side similar.

    Front Bumper Fascia Bolt (1) - Remove [6x]

  169. Front Wheelhouse Liner Bolt (2) - Remove [10x]
  170. Front Wheelhouse Liner Retainer (3) - Remove [2x]
  171. GM5312788
    NOTE:

    Left side shown, right side similar.

    Front Wheelhouse Liner Bolt (1) - Remove [4x]

  172. Front Wheelhouse Liner Retainer (2) - Remove [6x]
  173. Front Wheelhouse Liner (3) - Remove [2x]
  174. GM5399464

    { If equipped } Front Crossmember Brace Nut (1) - Remove [4x]

  175. { If equipped } Front Crossmember Brace (2) - Remove
  176. GM5318200

    Front Crossmember Brace Bolt- Right Side (1) - Remove [4x]

  177. Front Crossmember Brace Nut- Right Side (2) - Remove
  178. Front Crossmember Brace- Right Side (3) - Remove
  179. GM5317837

    Front Crossmember Brace Bolt- Left Side (1) - Remove [4x]

  180. Front Crossmember Brace Nut- Left Side (2) - Remove
  181. Front Crossmember Brace- Left Side (3) - Remove
  182. GM5326435
    NOTE:

    Left side shown, right side similar.

    Front Stabilizer Shaft Link Nut- Lower (1) - Remove [2x]

  183. GM5326436
    NOTE:

    Left side shown, right side similar.

    Front Stabilizer Shaft Link (1) @ Stabilizer Shaft - Remove [2x]

  184. GM5472805
    NOTE:

    Left side shown, right side similar.

    Front Wheel Speed Sensor Bolt (1) - Remove [2x]

  185. Front Wheel Speed Sensor (2) - Remove [2x]
  186. GM5430376
    NOTE:

    Left side shown, right side similar.

    Front Brake Caliper Bolt (2) - Remove [4x]

    187. CAUTION:

    Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  187. Remove the brake caliper and support with heavy mechanics wire. (1) [2x]
  188. GM5448424
    NOTE:

    Left side shown, right side similar.

    Steering Knuckle Nut (1) - Remove [4x]

  189. Steering Knuckle Bolt (2) - Remove [4x]
  190. GM5335427

    Wiring Harness Retainer (1) - Disengage [6X]

  191. Turn the wheels of the vehicle back to the straight ahead position.
  192. GM5330305

    Turn the steering wheel so the mid lower intermediate steering shaft bolt (2) is accessible from the engine compartment.

  193. Mid Intermediate Steering Shaft Bolt (2) - Remove
  194. Turn the wheels of the vehicle back to the straight ahead position.
    195. CAUTION:

    With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:

    • The steering column
    • The intermediate shaft (s)
    • The steering gear

    After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has become un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

  195. With the wheels of the vehicle in the straight ahead position, LOCK the steering column.
  196. Separate the mid lower intermediate steering shaft (1) from the intermediate steering shaft by pushing the lower portion of the mid lower intermediate shaft upward and rearward along the axis of the upper portion of the mid lower intermediate steering shaft.
  197. GM5330303

    Intermediate Steering Shaft Lower Bolt (1) - Remove

  198. GM5330297

    Intermediate Steering Shaft (1) @ Electric Belt Drive Rack and Pinion Steering Gear - Separate

  199. GM5471853

    Automatic Transmission Range Selector Lever Cable Bolt (1) - Remove

  200. Remove the automatic transmission range selector lever cable (2) from the automatic transmission range selector lever cable bracket.
  201. GM5471847

    Slide the automatic transmission range selector locking ring (1) in the direction of the arrow to access the automatic transmission range selector cable retainer (2).

  202. Using a flat bladed tool, release the automatic transmission range selector cable retainer (2) then remove the automatic transmission range selector cable (3) from the automatic transmission range selector lever (4).
  203. GM5333497

    Disconnect the electrical connector. (1)

  204. Release the retainers. (2)
  205. Disconnect the transmission vent hose from the engine.
  206. Position the powertrain support table underneath the vehicle.
  207. GM5541631

    Lower the vehicle until the powertrain (1) rests lightly on the GE-52200  Powertrain and Battery Lifter (2).

  208. Secure the powertrain to the GE-52200  Powertrain and Battery Lifter (2) using straps and binders around the transmission and cradle.
  209. GM5538431

    Drivetrain and Front Suspension Cradle Front Bolt (1) - Remove [4x]

  210. Drivetrain and Front Suspension Cradle Rear Bolt (2) - Remove [2x]
  211. GM5504544
    CAUTION:

    DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.

    Front Wheel Drive Shaft Nut (1) - Remove and DISCARD

  212. GM5492444
    NOTE:

    Support the front steering knuckle assembly to prevent over-articulation of the ball joints.

    Steering Knuckle Nut (1) - Remove [2x]

  213. Steering Knuckle Bolt (2) - Remove [2x]
  214. Front Suspension Strut @ Steering Knuckle - Separate
  215. GM5504560

    Steering Linkage Outer Tie Rod Nut (2) - Loosen

  216. Using CH-42188-B  Ball Joint Separator (1) separate the steering linkage outer tie rod (3) from the steering knuckle.
  217. CH-42188-B  Ball Joint Separator (1) - Remove
  218. Steering Linkage Outer Tie Rod Nut (2) - Remove
  219. GM5341099

    Install the DT-45341  Rear Wheel Drive Shaft Removal Tool (1), GE-47829  Slide Hammer Extension (3) and GE-02619-A  Slide Hammer (4) to the front wheel drive half shaft (2).

  220. Release the front wheel drive half shaft (2) from the front wheel drive intermediate shaft.
  221. Remove the GE-02619-A  Slide Hammer (4), GE-47829  Slide Hammer Extension (3) and DT-45341  Rear Wheel Drive Shaft Removal Tool (1) from the front wheel drive half shaft (2).
  222. GM5341102

    Front Wheel Drive Half Shaft (1) - Remove

  223. GM5504525

    Front Wheel Drive Intermediate Shaft Retaining Ring (2) - Remove and DISCARD

  224. Front Wheel Drive Intermediate Shaft Seal (1) - Remove and DISCARD
  225. GM5344068

    Front Wheel Drive Intermediate Shaft Bracket Bolt (2) - Remove [3x]

    226. NOTE:

    Insert suitable flat edge tool into gaps between bracket and mounting surface and apply alternate and even pressure to gently rock bracket out of mating recess.

  226. Front Wheel Drive Intermediate Shaft Bracket (1) - Remove
    227. NOTE:

    The front wheel drive intermediate shaft bracket bearing is not serviced separately. If the bearing is worn or damaged, replace the front wheel drive intermediate shaft bracket assembly.

  227. Thoroughly clean and inspect the front wheel drive intermediate shaft bracket for damage.
  228. If damaged, replace the front wheel drive intermediate shaft bracket.
  229. GM5502694

    Attach the DT - 44467  Output Shaft Assembly Remover/Installer (1) to the shaft.

  230. Attach the GE-6125-1B  Slide Hammer (2) to the DT-44467  Output Shaft Assembly Remover/Installer (1).
  231. Use the tools to remove the Front Wheel Drive Intermediate Shaft (3) from the front differential carrier.
  232. Front Wheel Drive Intermediate Shaft (3) - Remove
  233. Front Wheel Drive Intermediate Shaft Retaining Ring (4) - Remove and DISCARD
  234. GM5507500
    CAUTION:

    DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.

    Front Wheel Drive Shaft Nut (1) - Remove and DISCARD

  235. GM5341517

    Install the DT-45859  Axle Remover (1) to the front wheel hub and secure with 3 wheel nuts (2) hand tightened.

  236. Using the DT-45859  Axle Remover (1), release the front wheel drive half shaft from the front wheel hub.
  237. Remove the 3 wheel nuts (2) and the DT-45859  Axle Remover (1) from the front wheel hub.
  238. GM5507502
    NOTE:

    Support the front steering knuckle assembly to prevent over-articulation of the ball joints.

    Steering Knuckle Nut (2) - Remove [2x]

  239. Steering Knuckle Bolt (1) - Remove [2x]
  240. Front Suspension Strut @ Steering Knuckle - Separate
  241. GM5507512

    Steering Linkage Outer Tie Rod Nut (1) - Loosen

  242. Using CH-42188-B  Ball Joint Separator (2) separate the steering linkage outer tie rod (3) from the steering knuckle.
  243. CH-42188-B  Ball Joint Separator (2) - Remove
  244. Steering Linkage Outer Tie Rod Nut (1) - Remove
  245. Steering Linkage Outer Tie Rod @ Steering Knuckle - Separate
  246. GM5341518

    Install the DT-45341  Rear Wheel Drive Shaft Removal Tool (1), GE-47829  Slide Hammer Extension (3) and GE-02619-A  Slide Hammer (4) to the front wheel drive half shaft (2).

  247. Release the front wheel drive half shaft (2) from the front wheel drive intermediate shaft.
  248. Remove the GE-02619-A  Slide Hammer (4), GE-47829  Slide Hammer Extension (3) and DT-45341  Rear Wheel Drive Shaft Removal Tool (1) from the front wheel drive half shaft (2).
  249. GM5341521

    Partially remove the front wheel drive half shaft (1) from the front differential carrier.

    250. CAUTION:

    DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal

  250. Install the DT-51504  Seal Protector (2) into the front axle shaft seal.
  251. GM5341523

    Front Wheel Drive Half Shaft (1) - Remove

  252. GM5507536

    Front Wheel Drive Shaft Retaining Ring (2) @ Front Wheel Drive Half Shaft (1) - Remove and DISCARD

  253. GM5458092

    Front Axle Vent Hose (1) - Remove

  254. GM5525793

    Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Remove and DISCARD

  255. Apply a small amount of lubricant to the front wheel drive intermediate shaft (2) splines. Adhesives, Fluids, Lubricants, and Sealers
  256. Install the front wheel drive intermediate shaft (2) into the front differential carrier (3).
  257. GM5344077

    Front Differential Carrier Bolt (1) - Remove [2x]

  258. Front Differential Carrier Bolt (2) - Remove
  259. GM5344075

    Front Differential Carrier Bolt (1) - Remove

  260. GM5525786

    Front Differential Carrier (2) - Remove

  261. GM5310876

    Catalytic Converter Brace Bolt (1) - Remove

  262. GM5310881

    Catalytic Converter Brace Bolt (1) - Remove

  263. GM5310863

    Exhaust Pipe Clamp (1) - Remove and DISCARD

  264. GM5525783

    Warm Up Three-Way Catalytic Converter (1) - Remove

  265. Catalytic Converter Gasket (2) - Remove and DISCARD
  266. GM5311061

    Catalytic Converter Brace Bracket Nut (1) - Remove [2x]

  267. Catalytic Converter Brace Bracket (2) - Remove
  268. GM5311076

    Catalytic Converter Brace Bracket Bolt (1) - Remove [2x]

  269. Catalytic Converter Brace Bracket (2) - Remove
  270. Remove the engine harness from the engine so it can be transferred to the new engine.
  271. GM5071195

    Retainer Spring (1) - Release

  272. Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Remove
  273. GM5314511

    Retainer Spring (1) - Release

  274. Charge Air Cooler Inlet Air Tube (2) @ Compressor Air Intake Turbocharger (3) - Remove
  275. GM5313262

    Radiator Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type

  276. Radiator Inlet Hose (2) @ Engine Coolant Flow Control Valve - Remove
  277. GM5313295

    Radiator Outlet Hose Clamp (1) @ Engine - Disengage - Hose Clamp Replacement Guidelines - Spring Type

  278. Radiator Outlet Hose (2) @ Engine - Remove
  279. GM5129599

    Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise and hold.

  280. GM5129786

    Accessory Drive Primary Belt (1) - Remove

  281. Slowly release tension on the drive belt tensioner.
  282. GM5395328

    Remove the generator (1) and transfer the generator lower mounting bolt (2) to the NEW generator, if necessary.

  283. GM5335764

    Oil Level Indicator (1) - Remove

  284. GM5136547

    Oil Level Indicator Tube Bracket Bolt (2) - Remove

  285. GM5068106

    Oil Level Indicator Tube (1) - Remove

  286. Oil Level Indicator Tube Seal (2) - Remove and DISCARD
  287. GM5319715

    Starter Stud (1) - Remove

  288. Starter Bolt (2) - Remove [2x]
  289. Starter (3) - Remove
  290. Mark the torque converter to flex plate orientation to ensure proper realignment.
  291. GM5342773

    Repeat the following steps for all torque converter bolts (1):

    1. Rotate the harmonic balancer center bolt clockwise ONLY, to align the torque converter bolt with the starter opening.
    2. Torque Converter Bolt (1) - Remove [6x]
  292. Disconnect the transmission vent hose from the transmission.
  293. GM5334105

    Disconnect the electrical connectors. (1)

  294. Wiring Harness Retainer (2) - Remove
  295. GM5508846

    Transmission Bolt (2) - Remove [2x]

  296. Transmission Stud (1) - Remove
  297. GM5129535

    Remove the 2 left side thermostat bypass pipe bolt (2).

  298. GM5508848

    Transmission Bolt (2) - Remove [3x]

  299. Transmission Stud (1) - Remove [2x]
  300. GM5323001

    Remove harness bolt prior to installing the lift bracket in this location.

  301. EN-36857  Engine Lift Bracket Set (1) - Install
  302. EN-51768  Engine Support Fixture Adapter Bolts - M8 (2) - Install and tighten 65 N.m (48 lb ft)
  303. GM5598887

    EN-36857  Engine Lift Bracket Set (1) - Install

  304. EN-51768  Engine Support Fixture Adapter Bolts - M8 (2) - Install and tighten 65 N.m (48 lb ft)
  305. Install a suitable lifting chain and lifting hoist to the EN-36857  Engine Lift Bracket Set (1) just enough to take tension off the Engine Mounts.
  306. Using the GE-52200  Powertrain and Battery Lifter, unlock the table slide and separate the engine and transmission.
  307. Install the J-21366  Converter Holding Strap onto the transmission bell housing to retain the torque converter.
  308. GM5335541

    Engine Mount Nut- Left Side (1) - Remove

  309. GM5335537

    Engine Mount Nut- Right Side (1) - Remove

  310. Remove the engine from the GE-52200  Powertrain and Battery Lifter using a suitable engine hoist.
  311. GM5090647

    Transfer the engine (1) to a J-36854  Engine Stand (2) or approved shipping container.

  312. GM5336818

    Engine Mount Bracket Bolt (1) - Remove and DISCARD [3x]

  313. Engine Mount Bracket- Left Side (2) - Remove
  314. GM5541638

    Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]

  315. Engine Mount Bracket- Right Side (2) - Remove
  316. GM4961570

    Ignition Coil Bolt (1) - Remove [8x]

  317. Ignition Coil (2) - Remove [4x]
  318. GM5049385

    Clamp (1) - Remove - Hose Clamp Replacement Guidelines - Spring Type

  319. Turbocharger Coolant Feed Pipe Bracket Bolt (3) - Remove
  320. Turbocharger Coolant Feed and Return Pipe (4) @ Engine Coolant Thermostat Housing Inlet Pipe (2) - Remove
  321. GM5049386

    Clamp (2) - Remove - Hose Clamp Replacement Guidelines - Spring Type

  322. Turbocharger Coolant Feed Pipe Bracket Bolt (3) - Remove
  323. Turbocharger Coolant Feed and Return Pipe Bolt (5) - Remove [2x]
  324. Turbocharger Coolant Feed and Return Pipe (4) @ Engine Coolant Heater Exhaust Pipe (1) - Remove
  325. Turbocharger Coolant Feed and Return Pipe (4) - Remove
  326. Turbocharger Coolant Feed and Return Pipe Gasket (6) - Remove and DISCARD
  327. GM5541642

    Remove the compressor air intake turbocharger and lines as an assembly.

  328. Remove the 2 oil feed pipe bolts (4).
  329. Remove the oil feed pipe bolt (5).
  330. Remove and DISCARD the 4 turbocharger bolt (2).
  331. Remove the compressor air intake turbocharger (3).
  332. Remove and DISCARD the turbocharger heat shield (1).
  333. Remove and DISCARD the turbocharger oil feed pipe gasket (7).
  334. Remove and DISCARD the turbocharger oil return pipe seal (6).
  335. GM5067948

    Water Pump Inlet Pipe Bolt (5, 6) - Remove [2x]

  336. Clamp (1, 3) - Remove [2x] - Hose Clamp Replacement Guidelines - Spring Type
  337. Water Pump Inlet Pipe (2) @ Water Pump (4) - Remove
  338. Water Pump Inlet Pipe (2) @ Engine Coolant Air Bleed Pipe (7) - Remove
  339. Water Pump Inlet Pipe (2) - Remove
  340. GM5541652

    Clamp (1, 2) Remove [2x] - Hose Clamp Replacement Guidelines - Spring Type

  341. Water Pump Bolt (4) - Remove [3x]
  342. Water Pump (3) - Remove
  343. GM5129570

    Engine Coolant Thermostat Housing Inlet Pipe Bolt (1) - Remove [3x]

  344. GM5129572

    Engine Coolant Thermostat Housing Inlet Pipe (2) - Remove

  345. Water Inlet Gasket (1) - Remove and DISCARD
  346. GM5068210

    Wiring Harness Clip (4) @ Evaporative Emission Canister Purge Pump Bracket - Unclip

  347. Evaporative Emission Canister Purge Pump Bolt (1, 3) - Remove [3x]
  348. Evaporative Emission Canister Purge Pump (2) - Remove
  349. GM5541656

    Intake Manifold Bolt (3) - Remove [7x]

  350. Remove the intake manifold and throttle body as and assembly (2).
  351. Intake Manifold Seal (1) - Remove and DISCARD
  352. GM5541662

    Clamp (1) - Remove [3x] - Hose Clamp Replacement Guidelines - Spring Type

  353. Engine Oil Cooler Bolt (3) - Remove [4x]
  354. Engine Oil Cooler Seal (2) - Remove and DISCARD [2x]
  355. Engine Oil Cooler (4) - Remove
  356. GM5402881

    Engine Coolant Air Bleed Pipe Bolt (1) - Remove [2x]

  357. GM5318618

    Engine Coolant Air Bleed Pipe (1) - Remove

  358. GM4962310

    Engine Coolant Heater Exhaust Pipe Bracket Bolt (2) - Remove

  359. Clamp (1) - Remove - Hose Clamp Replacement Guidelines - Spring Type
  360. GM5323487

    Engine Coolant Heater Exhaust Pipe Bolt (1) - Remove

  361. GM5323492

    Engine Coolant Heater Exhaust Pipe Bolt (1) - Remove [3x]

  362. Engine Coolant Heater Exhaust Pipe (2) - Remove
  363. Engine Coolant Manifold Gasket (3) - Remove and DISCARD
  364. GM5323488

    Engine Coolant Air Bleed Pipe Bolt (1) - Remove

  365. Hose Clamp (2) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
  366. Engine Coolant Heater Exhaust Pipe (3) @ Engine Coolant Flow Control Valve - Remove
  367. GM5125429

    Engine Coolant Air Bleed Pipe Bolt (1) - Remove [2x]

  368. GM5125430

    Engine Coolant Air Bleed Pipe (1) - Remove

  369. Engine Coolant Manifold Gasket (2) - Remove and DISCARD
  370. GM5541666

    Air Conditioning Compressor Bolt (1) - Remove

  371. Air Conditioning Compressor Nut (2) - Remove
  372. Air Conditioning Compressor Bolt (3) - Remove
  373. Air Conditioning Compressor (4) - Remove
  374. Air Conditioning Compressor Stud (5) - Remove
  375. GM5541821

    Drive Belt Tensioner Bolt (1) - Remove

    376. NOTE:

    Twist out toward where the air conditioning compressor sits.

  376. Drive Belt Tensioner (2) - Remove
  377. GM4966906

    Engine Coolant Flow Control Valve Bolt (1) - Remove [4x]

  378. GM4966911

    Engine Coolant Flow Control Valve (1) - Remove

  379. Water Outlet Seal (2) - Remove and DISCARD
  380. GM5422918

    Fuel Pump Shield Bolt (1) - Remove [3x]

  381. Fuel Pump Cover (2) - Remove
  382. GM4967233
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Fuel Pump Insulator (1) - Remove

  383. GM5314508

    Fuel Injection Fuel Feed Pipe Bolt (1) - Remove

  384. Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
  385. GM4967228
    CAUTION:

    Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage

    Fuel Pump Bolt (4) - Remove [2x]

  386. Fuel Pump (1) - Remove
  387. Fuel Pump Seal (3) - Remove and DISCARD
  388. Valve Lifter Follower (2) - Remove
  389. GM4995197

    Wiring Harness (2) @ Fuel Injection Fuel Rail Insulator (1) - Remove

    390. WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

  390. Fuel Injection Fuel Rail Insulator (1) - Remove
  391. GM4995278

    Electrical Connector (2, 3) - Disconnect [2x]

  392. Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
  393. GM4995383
    NOTE:

    Use care to avoid contact with the fuel rail harness during special tool installation and fuel rail removal.

    Install the 2 studs (2) from EN-49248  remover to the fuel injection fuel rail bolt holes and hand tighten.

  394. Install the EN-49248  remover 4) onto each stud (2) and engage the hooks to the fuel injection fuel rail.
  395. Install and tighten the 2 nuts (1, 3).
  396. GM4995505
    NOTE:
    • Turn BOTH handles simultaneously, in small, even increments.
    • Do NOT twist the fuel injector fuel rail while removing.

    Rotate the handles (1) from the EN-49248  remover and remove the fuel injection fuel rail (2).

  397. EN-49248  Remover, Injector Rail Assembly - Remove
  398. Fuel Injector Nozzle Housing Seal - Remove and DISCARD [8x]
  399. GM5299624

    Remove the knock sensor bolt (1).

  400. Remove the knock sensor (2).
  401. GM5299629

    Remove the knock sensor bolt (1).

  402. Remove the knock sensor (2).
  403. GM5521720

    Positive Crankcase Ventilation Oil Separator Cover Bolt (1) - Remove [11x]

  404. GM5020637

    Positive Crankcase Ventilation Oil Separator Cover (1) - Remove

scientia non olet · About LEMON Manuals