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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 165 (Engine Mechanical - 4.0L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PRO .
  2. Recover the A/C refrigerant system. Refer to GENERAL MOTORS
  3. Disconnect the vacuum brake booster hose from the vacuum connection and position aside.
    4. Fig 1: Removing Brake Booster Hose
    G01819562Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille.
  5. Disconnect the hose (4) from the evaporative emission canister purge valve (3) and secure to the air inlet grille.
  6. Remove the air cleaner assembly. .
    Fig 2: Disconnecting Evaporative Emission Canister Purge Valve Hose
    G01819563Courtesy of GENERAL MOTORS CORP.
  7. Remove the 2 nuts (2) from the intake manifold sight shield (1).
  8. Remove the sight shield (1) from the engine.
    Fig 3: Removing Intake Manifold Sight Shield
    G01819564Courtesy of GENERAL MOTORS CORP.
  9. Remove the nut (1) securing the battery positive cable to the remote positive terminal and secure to the top of the engine.
    Fig 4: Removing Battery Positive Cable Nut
    G01819565Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the secondary AIR relay (1) from the relay bracket and secure to the top of the engine.
    Fig 5: Disconnecting Secondary AIR Relay
    G01819566Courtesy of GENERAL MOTORS CORP.
  11. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:
    Fig 6: Disconnecting C 101 Wiring Harness Electrical Connector
    G01819567Courtesy of GENERAL MOTORS CORP.
  12. Remove the bolt (1) securing the engine ground cable (2) from the right side body frame rail.
    Fig 7: Removing Engine Ground Cable Bolt
    G01819568Courtesy of GENERAL MOTORS CORP.
    WARNING: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
  13. Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever (1).
  14. Remove the accelerator control cable from the throttle body. Refer to THROTTLE BODY .
    Fig 8: Removing Cruise Control Cable From Throttle Body Bracket & Lever
    G01819569Courtesy of GENERAL MOTORS CORP.
  15. Remove the shift cable (2) from the bracket and manual shift lever (1) and position aside.
  16. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
    Fig 9: Removing Shift Cable From Bracket & Manual Shift Lever
    G01819570Courtesy of GENERAL MOTORS CORP.
  17. Position the J 37097-A  to the clamp in order to remove the radiator inlet hose (1) from the water housing crossover and position aside.
  18. Position the J 38185  to the clamp in order to remove the radiator outlet hose (2) from the thermostat housing and position aside.
    Fig 10: Removing Radiator Inlet & Outlet Hoses
    G01819571Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the surge tank inlet hose (2) from the surge tank (1).
    Fig 11: Disconnecting Surge Tank Inlet Hose
    G01819572Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the heater hoses (1, 2) from the heater pipes.
    Fig 12: Disconnecting Heater Hoses From Heater Pipes
    G01819573Courtesy of GENERAL MOTORS CORP.
    WARNING: Brake fluid may Irritate eyes and skin. In case of contact, take the following actions:
    • Eye contact-rinse thoroughly with water.
    • Skin contact-wash with soap and water.
    • If Ingested-consult a physician immediately.

    Important:  Record the location of the brake pipes to the brake pressure modulator valve (BPMV) for use as an aid during installation.

  21. Remove the 2 master cylinder brake pipes (1) from the BPMV (2).

    Plug the open outlet ports to prevent fluid loss and contamination.

    Fig 13: Removing Master Cylinder Brake Pipes From BPMV
    G01819574Courtesy of GENERAL MOTORS CORP.
  22. Remove the upper transaxle oil cooler pipe retaining bolt from the fan shroud.
  23. Slide the plastic cap off the upper transaxle oil cooler pipe quick connect fitting.
  24. Disconnect the upper transaxle oil cooler pipe from the radiator using the J41623-B. 
  25. Disconnect the lower transaxle oil cooler pipe fitting from the radiator.
    Fig 14: Disconnecting Upper Transaxle Oil Cooler Pipe From Radiator
    G01819575Courtesy of GENERAL MOTORS CORP.
    NOTE: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
  26. Lock the steering column by installing the J 42640  into the underside of the steering column.
    Fig 15: Locking Steering Column
    G01819576Courtesy of GENERAL MOTORS CORP.
  27. Remove the right and left side strut tower bolts.
  28. Raise and support the vehicle.
  29. Remove the rear exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT - REAR (L47) .
  30. Remove the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
    Fig 16: Removing Strut Tower Bolts
    G01819577Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the front wheel speed sensor electrical leads (2) from the body frame rail.
  32. Remove the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT -- FRONT .
  33. Remove the front fascia extensions. Refer to FASCIA EXTENSION REPLACEMENT -- FRONT
    Fig 17: Removing Front Wheel Speed Sensor Electrical Leads
    G01819578Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the secondary AIR inlet hose from the secondary AIR pump.
    Fig 18: Disconnecting Secondary AIR Inlet Hose
    G01819579Courtesy of GENERAL MOTORS CORP.
  35. Loosen the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.
  36. Disconnect the front brake pipes from the retainers at the body frame rails.
  37. Carefully pull the front brake pipes away from the body frame rails.
    Fig 19: Locating Front Brake Pipe Frame Bracket Bolts
    G01819580Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the 2 rear brake pipes at the rear of the engine frame.

    Plug the open outlet ports to prevent fluid loss and contamination.

    Fig 20: Disconnecting Rear Brake Pipes
    G01819581Courtesy of GENERAL MOTORS CORP.
  39. Disconnect the A/C pressure sensor.
  40. Disconnect the A/C discharge hose from the compressor and secure to the cooling fan assembly.
    Fig 21: Disconnecting A/C Discharge Hose
    G01819582Courtesy of GENERAL MOTORS CORP.
  41. Disconnect the A/C suction hose from the compressor and secure to the cooling fan assembly.
    Fig 22: Disconnecting A/C Suction Hose
    G01819583Courtesy of GENERAL MOTORS CORP.
    WARNING: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the Intermediate shaft. This damage may cause loss of steering control which could result in personal injury.
  42. Remove the intermediate shaft pinch bolt.
  43. Remove the steering gear from the intermediate shaft.
  44. Disconnect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS HEAT SHIELD REPLACEMENT .
    Fig 23: Removing Steering Gear From Intermediate Shaft
    G01819584Courtesy of GENERAL MOTORS CORP.
  45. Remove the brace between the engine oil pan and the transaxle case.
    46. Fig 24: Removing Brace Between Engine Oil Pan & Transaxle Case
    G01819585Courtesy of GENERAL MOTORS CORP.
  46. Remove the torque converter cover. Refer to TRANSAXLE (4T80-E) .

    Important:  Mark the flywheel to torque converter relationship prior to removal of the bolts.

  47. Remove the torque converter to the flywheel bolts.
  48. Position the J 39580  powertrain support dolly under the engine frame.
  49. Lower the vehicle on to the J 39580. 
    Fig 25: Identifying J 39580
    G01819586Courtesy of GENERAL MOTORS CORP.
  50. If the powertrain support dolly is unavailable. Support the powertrain with four suitable jackstands.
    Fig 26: Identifying Jackstands
    G01819587Courtesy of GENERAL MOTORS CORP.
  51. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.
  52. Remove the nut securing the right engine mount to the engine mount bracket.
    Fig 27: Removing Right Engine Mount Securing Nut
    G01819588Courtesy of GENERAL MOTORS CORP.
  53. Remove the nut (1) securing the left transaxle mount to the transaxle mount bracket.
    WARNING: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
  54. Secure the front hoist pads to the vehicle.
    Fig 28: Removing Left Transaxle Mount Nut
    G01819589Courtesy of GENERAL MOTORS CORP.
  55. Remove the 6 frame-to-body mounting bolts (3).

    Important:  Ensure clearance is maintained between the engine/transaxle assembly and the following:

    • The A/C accumulator hose
    • The A/C compressor hose
    • The brake pipes
    • The heater hoses
    • The radiator hoses
    • The wheel speed sensor leads
    • The wiring harnesses
    Fig 29: Removing Frame-To-Body Bolts
    G01819590Courtesy of GENERAL MOTORS CORP.
  56. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
  57. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  58. Remove the heater pipes.
  59. Disconnect the intermediate hose from the secondary AIR valve at bank 2.
  60. Remove the nut securing the intermediate hose to the secondary AIR valve at bank 1.
  61. Remove the nut (3) securing the coil cassette ground wire to the right cylinder head.
  62. Disconnect the engine wiring harness from the engine. Refer to COMPONENT LOCATIONS .
    Fig 30: Removing Secondary AIR Valve Hoses & Nuts
    G01819591Courtesy of GENERAL MOTORS CORP.
  63. Disconnect the power steering hose from the power steering pump reservoir.
  64. Remove the power steering return hose retaining bolt from the cylinder head.
    Fig 31: Removing Power Steering Return Hose
    G01819592Courtesy of GENERAL MOTORS CORP.
  65. Remove the power steering pressure hose from the power steering pump.
    Fig 32: Removing Power Steering Pressure Hose
    G01819593Courtesy of GENERAL MOTORS CORP.
  66. Remove the nut (2) securing the power steering pressure hose to the right engine mount bracket (1)
  67. Remove the 4 bolts securing the right engine mount bracket (1) to the engine.
  68. Remove the right engine mount bracket (1).
    Fig 33: Removing Right Engine Mount Bracket
    G01819594Courtesy of GENERAL MOTORS CORP.
  69. Remove the bolt (2) securing the rear transaxle brace (1) to the transaxle.
  70. Remove the nuts (3) securing the rear transaxle brace (1) to the stud located on the right cylinder head.
  71. Remove the rear transaxle brace (1).
    Fig 34: Remove Rear Transaxle Brace
    G01819595Courtesy of GENERAL MOTORS CORP.
  72. Remove the bolts (1,3) securing the front transaxle brace (2) to the transaxle and right cylinder head.
    Fig 35: Removing Front Transaxle Brace
    G01819596Courtesy of GENERAL MOTORS CORP.
  73. Remove the nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.
    Fig 36: Removing Vehicle Speed Sensor Heat Shield
    G01819597Courtesy of GENERAL MOTORS CORP.
  74. Remove the bolts securing the center transaxle brace to the engine and transaxle.
    Fig 37: Removing Center Transaxle Brace
    G01819598Courtesy of GENERAL MOTORS CORP.
  75. Install the J 42504  to the cylinder head.
  76. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.
    Fig 38: Identifying J 42504
    G01819599Courtesy of GENERAL MOTORS CORP.
  77. Remove the nut securing the front engine mount to the engine frame.
    Fig 39: Removing Front Engine Mount
    G01819600Courtesy of GENERAL MOTORS CORP.
  78. Remove the bolts attaching the engine to the transaxle.
  79. Raise the engine from the supported frame and transaxle assembly.
    80. Fig 40: Removing Engine
    G01819601Courtesy of GENERAL MOTORS CORP.
  80. Remove the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front .
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