Removal (Express, Savana & G-Van)
WARNING: This page is about a different variant/trim than selected.
- Release fuel system pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Remove interior engine cover. Remove coolant recovery bottle, air cleaner assembly and air cleaner intake duct. Remove front bumper, grill, and radiator support. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Drain cooling system. Remove upper and lower fan shroud, accessory belt, and fan.
- Remove upper and lower radiator hoses. Remove radiator and A/C condenser. Disconnect heater hoses from engine. Disconnect engine wiring harness. Disconnect accelerator and cruise control cables. Remove generator and mounting bracket. Remove A/C compressor and mounting bracket. Remove engine ground straps. Remove pulley from power steering pump. Remove power steering pump and mounting bracket. Remove upper intake manifold. See INTAKE MANIFOLD (UPPER).
- Disconnect fuel lines form rear of engine. Remove transmission oil level indicator tube and shift cable connector. Raise and support vehicle. Drain oil from crankcase. Remove exhaust pipes from exhaust manifolds. Remove engine oil cooler lines form retaining brackets and remove from engine. Remove flywheel cover and remove starter. Remove torque converter bolts. Remove transmission cooler lines from engine. Remove all bellhousing bolts. Support transmission with a suitable strap. Lower vehicle.
- Attach engine lifting brackets (J-41427) to right-rear and left-front of intake manifold. Attach engine hoist. Remove engine mount through-bolts. Remove engine mounts from vehicle frame. Remove engine from vehicle.