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Home >> Chevrolet >> 2011 >> Corvette ZR-1 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 6.2L Or 7.0L - Repair Instructions - On Vehicle (2 Of 2) >> Engine Replacement (Except LS9) >> Removal Procedure

Removal Procedure

NOTE: The steps in the following procedure are in a specific order. Follow these steps in this order and do not ignore any details.
    Fig 1: Fuel Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  1. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) .
  2. Remove the radiator. Refer to Radiator Replacement (LS3, LS7) .
  3. Remove the break pressure modulator valve (BPMV) bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement .
  4. Reposition the brake pipes.
  5. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (w/o LS9) .
  6. Remove the right fuel injection rail cover.
  7. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) or Fuel Pressure Relief (CH 48027) .
  8. Disconnect the evaporative emission (EVAP) canister purge hose at the fuel line.
  9. Remove the fuel feed hose. Refer to Fuel Line Replacement - Engine .
    10. Fig 2: Water Pump Inlet & Outlet Hoses
    GM179301Courtesy of GENERAL MOTORS CORP.
    NOTE: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.
  10. Remove the radiator hoses from the water pump.
    11. Fig 3: Heater Hoses & Water Pump
    GM185256Courtesy of GENERAL MOTORS CORP.
  11. Remove the heater hoses from the water pump.
  12. Disconnect the following electrical connectors from the engine:
    • The fuel injectors
    • The ignition coil main harness connectors
    • The EVAP solenoid
    • The electric throttle motor
    • The engine coolant temperature (ECT) sensor
    • The A/C compressor
  13. Remove the generator. Refer to Generator Replacement (LS3 or LS7) .
    14. Fig 4: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  14. Remove the power brake booster vacuum hose.
    15. Fig 5: Intermediate Steering Shaft & Bolt
    GM187354Courtesy of GENERAL MOTORS CORP.
  15. Remove the intermediate steering shaft bolt to the steering gear.
  16. Remove the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.
  17. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
  18. Remove the intermediate pipe. Refer to Intermediate Pipe Replacement .
    19. Fig 6: View Of Driveline Tunnel Closeout Panel & Bolts
    GM67894Courtesy of GENERAL MOTORS CORP.
  19. Remove the driveline tunnel close-out panel bolts.
  20. Remove the driveline tunnel close-out panel.
  21. Remove the starter motor. Refer to Starter Replacement .
    22. Fig 7: Oil Tank Inlet Hose, Bolt & Oil Seal
    GM1705736Courtesy of GENERAL MOTORS CORP.
  22. On 7.0L engine, remove the oil inlet hose to oil pan bolt (3) and disconnect the hose (2) from the oil pan.

    Discard the oil seal (1).

  23. If the engine failed and debris was created, remove the oil tank inlet hose and discard. Refer to Oil Tank Inlet Hose Replacement .
    24. Fig 8: Oil Tank Outlet Hose, Bolt & Oil Seal
    GM1708415Courtesy of GENERAL MOTORS CORP.
  24. Remove the oil tank outlet hose to oil pan bolt (2) and disconnect the hose (3) from the oil pan.

    Discard the oil seal (1).

  25. If the engine failed and debris was created, remove the oil tank outlet hose and discard. Refer to Oil Tank Outlet Hose Replacement .
    26. Fig 9: Transmission Lines - Oil Pan Rear
    GM1478613Courtesy of GENERAL MOTORS CORP.
  26. Remove the transmission lines from the rear of the oil pan.
    27. Fig 10: Transmission Lines - Oil Pan Front
    GM1478646Courtesy of GENERAL MOTORS CORP.
  27. Remove the transmission lines from the front of the oil pan.
    28. Fig 11: View Of Oil Cooler, Seal & Bolts
    GM1708343Courtesy of GENERAL MOTORS CORP.
  28. Remove the 2 oil cooler bolts (1) and separate the oil cooler (2) from the pan.

    Discard the oil cooler seal (3).

  29. If the engine failed and debris was created, remove the oil cooler hoses and discard. Refer to Engine Oil Cooler Hose/Pipe Replacement (LS9 and LS7) .
    30. Fig 12: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector
    GM651885Courtesy of GENERAL MOTORS CORP.
  30. On all engines, disconnect the crankshaft position (CKP) sensor electrical connector (1).
  31. Disconnect the oil level sensor electrical connector (2).
  32. Disconnect the right heated oxygen sensor (HO2S) electrical connector.
    33. Fig 13: Compressor Hose Assembly & Retaining Bolt
    GM82082Courtesy of GENERAL MOTORS CORP.
  33. Remove the A/C compressor and condenser hose bolt at the compressor.
  34. Separate the A/C compressor and condenser hose from the A/C compressor.
    35. Fig 14: View Of Engine Oil Temperature Sensor Electrical Connector
    GM651886Courtesy of GENERAL MOTORS CORP.
  35. If equipped, disconnect the engine oil temperature sensor (3) electrical connector.
  36. Disconnect the left HO2S electrical connector.
  37. Remove the ground strap bolt.

    Remove the ground straps (1 and 2) from the engine block.

    38. Fig 15: Transmission Wire Harness & Electrical Connectors
    GM652265Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the wheel speed sensor electrical connectors.
  39. If equipped with real time damping (RTD) disconnect the following electrical connectors:
    • Shock absorber damper
    • Position sensor pigtail
  40. Unclip the transmission wire harness from the crossmember.
  41. Disconnect the electronic variable orifice (EVO) control connector clips from the crossmember.
    42. Fig 16: Transmission Wire Harness & Engine Wire Harness
    GM652266Courtesy of GENERAL MOTORS CORP.
  42. Remove the transmission harness clip bolts from the engine block.
  43. Unclip the transmission wire harness from the engine wire harness.
  44. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    45. Fig 17: Lower Control Arm Ball Joint Stud & Steering Knuckle
    GM168544Courtesy of GENERAL MOTORS CORP.
  45. Loosen, do not remove, the steering knuckle nut (2) from the lower control arm ball stud.
  46. Install the J 42188  between the steering knuckle and the lower control arm ball stud. See Special Tools .
  47. Tighten the nut on the J 42188  until the steering knuckle and the lower control arm ball stud separate. See Special Tools .
  48. Disconnect the antilock brake system (ABS) electrical connector clips from the crossmember, if equipped.
  49. Remove the front transverse leaf spring. Refer to Front Transverse Spring Replacement .
    50. Fig 18: Transmission Lines - Oil Pan Front
    GM1478646Courtesy of GENERAL MOTORS CORP.
  50. Disconnect the automatic transmission fluid cooler pipe clip from the front of the engine oil pan, if equipped.
  51. Disconnect the front automatic transmission fluid cooler pipes from the rear pipes.
  52. Disconnect the automatic transmission cooler pipe clip at the right transmission cover, if equipped.
    53. Fig 19: Driveline Support Hole Plug Bolts
    GM173638Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
    NOTE: Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly.
  53. With automatic transmission vehicles, use the following steps:
    1. Remove the 2 driveline support hole plug bolts.
    2. Install a M10.0-1.5 x 55 mm bolt or longer in each plug location and tighten to 35 N.m (26 lb ft).
    54. Fig 20: View Of Engine Flywheel Housing Access Plug
    GM71455Courtesy of GENERAL MOTORS CORP.
  54. If equipped with an automatic transmission, remove the flywheel housing plug.
  55. If equipped with an automatic transmission perform the following:
    1. Orientate the prop shaft hub clamp for access to the bolt.
    2. Position the clamp bolt facing downward.
    3. Loosen the prop shaft hub clamp bolt.
  56. Remove bolts attaching the transmission wire harness bracket to the flywheel housing.
  57. Remove the transmission wire harness from its mounting location, rearward toward the driveline support.
  58. Lay the harness on the driveline support.

    Secure if necessary.

    59. NOTE: The weight of the engine should never be supported by the J 42203  . See Special Tools .
  59. Install the J 42203  to the close-out panel flange. See Special Tools .
  60. If equipped with a manual transmission, disconnect the clutch actuator hose from the master cylinder hose.
    61. Fig 21: Driveline Support Strap, Close-Out Panel Flange & Bolts
    GM188853Courtesy of GENERAL MOTORS CORP.
    NOTE: The weight of the engine should never be supported by the J 42203  . See Special Tools .
  61. Install the J 42203  to the close-out panel flange. See Special Tools .
  62. Slowly lower the vehicle onto the J 39580  and the J 39580-500  . See Special Tools .
  63. Support the engine and crossmember on the J 39580  and the J 39580-500  . See Special Tools .
    64. Fig 22: View Of Front & Rear Crossmember Nuts
    GM581372Courtesy of GENERAL MOTORS CORP.
  64. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts.
  65. Partially raise the vehicle.
  66. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  67. Disconnect the camshaft position (CMP) sensor electrical connector.
  68. Remove the ground strap bolt.
  69. Remove the ground strap from the left rear cylinder head.
  70. Disconnect the engine oil pressure sensor electrical connector from the back of the engine.
    71. Fig 23: Knock Sensor Electrical Connector -- Left Side
    GM1480894Courtesy of GENERAL MOTORS CORP.
  71. Disconnect the electrical connector (2) for the knock sensor, left side.
    72. Fig 24: Knock Sensor Electrical Connector -- Right Side
    GM1480896Courtesy of GENERAL MOTORS CORP.
  72. Disconnect the electrical connector (2) for the knock sensor, right side.
    73. Fig 25: View Of Driveline & Bolts
    GM71466Courtesy of GENERAL MOTORS CORP.
  73. Remove the driveline support bolts.
    74. Fig 26: Driveline Support Assembly & Engine Flywheel Housing
    GM196200Courtesy of GENERAL MOTORS CORP.
    NOTE: Visually inspect the transmission wiring harness to ensure detachment from the engine.
  74. Insert a flat-bladed screwdriver, or similar tool, between the edge of the driveline support and the flywheel housing, then separate the flywheel housing from the driveline support.
  75. Slowly pull the engine away from the propeller shaft.
  76. As soon as the propeller input shaft clears the flywheel housing, slowly raise the vehicle.
  77. Slide the engine and crossmember forward in order to clear the propeller shaft spline.
  78. Remove the electronic brake control module (EBCM). Refer to Electronic Brake Control Module Replacement .
    79. Fig 27: Power Steering Pump Pulley & Special Tool
    GM65347Courtesy of GENERAL MOTORS CORP.
    NOTE: Visually inspect the wiring harness clearances while raising the vehicle.
  79. Raise the vehicle completely off of the engine and crossmember.
  80. Remove the power steering pump pulley hub cap, if necessary.
  81. Using the J 25034-C  remove the power steering pump pulley. See Special Tools .
    82. Fig 28: Power Steering Pump, Generator Bracket & Bolts
    GM65354Courtesy of GENERAL MOTORS CORP.
    NOTE: It is not necessary to open the power steering system during the engine removal procedure.
  82. Remove the power steering pump bolts.
  83. Remove the power steering pump brace.
  84. Remove the power steering pump, with reservoir, from the engine, and reposition them to the crossmember.
  85. Remove the power steering pump assembly. Refer to Power Steering Pump Replacement (LS3, LS7) .
    86. Fig 29: Generator Bracket & Bolts
    GM652357Courtesy of GENERAL MOTORS CORP.
  86. Remove the generator bracket bolts.
  87. Remove the generator bracket and power steering pump bracket.
  88. Install the J 41798  to the engine. See Special Tools .
  89. Remove the spark plugs. Refer to Spark Plug Replacement .
    90. Fig 30: Engine Mount & Nuts
    GM188236Courtesy of GENERAL MOTORS CORP.
  90. Remove the engine mount nuts.
  91. Using a engine hoist and the J 41798  slowly raise the engine. See Special Tools .
  92. Remove the engine from the crossmember.
  93. Remove the flywheel housing bolts.
  94. Remove the flywheel housing from the engine block.
  95. Install the engine onto an engine stand and prepare for disassembly.
  96. Remove the engine hoist.
  97. Remove the J 41798  from the engine. See Special Tools .
  98. Remove the engine mount bracket bolts.
  99. Remove the engine mount brackets from the engine block.
    100. CAUTION: Avoid engine damage. Debris in the engine oil tank, oil tank hoses and engine oil cooler may be pulled back into the engine causing severe engine damage. You must clean the engine oil tank, and replace the engine oil hoses and engine oil cooler.
  100. On 7.0L engine, if the engine failed and debris was created, the engine oil tank must be cleaned and the oil tank hoses and engine oil cooler must be replaced:
    1. Remove the engine oil tank. Refer to Oil Tank Replacement (w/o LS9) .
    2. Disassemble the engine oil tank. Refer to Oil Tank Disassemble .
    3. Clean and inspect the engine oil tank. Refer to Oil Tank Cleaning and Inspection .
    4. Assemble the engine oil tank. Refer to Oil Tank Assemble .
    5. Replace the engine oil cooler. Refer to Auxiliary Engine Oil Cooler Replacement (Export) or Auxiliary Engine Oil Cooler Replacement (Z52) .
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