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Removal Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.

Important:  The steps in the following procedure are in a specific order. Follow these steps in this order and do not ignore any details or vehicle damage may occur.

  1. Recover the air conditioning (A/C) refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
  2. Remove the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
  3. Remove the break pressure modulator valve (BPMV) bracket. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) BRACKET REPLACEMENT in Antilock Brake System.
  4. Reposition the brake pipes.
  5. Remove the accessory drive belt. Refer to DRIVE BELT REPLACEMENT-ACCESSORY .
  6. Remove the right fuel injection rail cover.
    Fig 1: Removing Right Fuel Injection Rail Cover
    G01970642Courtesy of GENERAL MOTORS CORP.
  7. Relieve the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  8. Disconnect the EVAP emission canister purge hose at the fuel line.
  9. Remove the fuel feed hose. Refer to FUEL LINE DISCONNECT FITTINGS .

    Important:  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.
    Fig 2: Removing Radiator Hoses From Water Pump
    G01970643Courtesy of GENERAL MOTORS CORP.
  11. Remove the heater hoses from the water pump.
    Fig 3: Removing Heater Hoses From Water Pump
    G01970644Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the following electrical connectors from the engine:
    • The fuel injectors (1)
    • The ignition coil main harness connectors
    • The evaporative emission (EVAP) solenoid (2)
    • The electric throttle motor (3)
    • The throttle position (TP) sensor
    • The engine coolant temperature (ECT) sensor
    • The A/C compressor
      • Fig 4: Disconnecting Electrical Connectors From Engine
      G01970645Courtesy of GENERAL MOTORS CORP.
  13. Remove the generator. Refer to GENERATOR in Engine Electrical.
  14. Remove the power brake booster vacuum hose.
    Fig 5: Removing Power Brake Booster Vacuum Hose
    G01970646Courtesy of GENERAL MOTORS CORP.
  15. Remove the intermediate steering shaft bolt (to steering gear).
  16. Remove the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.
    Fig 6: Removing Intermediate Steering Shaft
    G01970647Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the secondary air injection (AIR) pump hose from the AIR pipe.
    Fig 7: Disconnecting Secondary Air Injection Pump Hose From Air Pipe
    G01970648Courtesy of GENERAL MOTORS CORP.
  18. Remove the front tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  19. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  20. Remove the driveline tunnel close-out panel bolts.
    Fig 8: Locating Driveline Tunnel Close-Out Panel Bolts
    G01970649Courtesy of GENERAL MOTORS CORP.
  21. Remove the driveline tunnel close-out panel.
  22. Remove the starter motor. Refer to STARTER MOTOR in Engine Electrical.
  23. Disconnect the crankshaft position (CKP) sensor electrical connector (1).
  24. Disconnect the oil level sensor electrical connector (2).
  25. Disconnect the right heated oxygen sensor (HO2S) electrical connector.
    Fig 9: Disconnecting Electrical Connectors
    G01970650Courtesy of GENERAL MOTORS CORP.
  26. Remove the A/C compressor and condenser hose bolt (at compressor).
  27. Separate the A/C compressor and condenser hose from the A/C compressor.
    Fig 10: Removing A/C Compressor And Condenser Hose Bolt (At Compressor)
    G01970651Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the engine oil temperature sensor (3) electrical connector.
  29. Disconnect the left HO2S electrical connector.
  30. Remove the ground strap bolt.

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

    Fig 11: Locating Electrical Components
    G01970652Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the wheel speed sensor electrical connectors.
    Fig 12: Disconnecting Wheel Speed Sensor Electrical Connectors
    G01970653Courtesy of GENERAL MOTORS CORP.
  32. If equipped with real time damping (RTD) disconnect the following electrical connectors:
    • Shock absorber damper
    • Position sensor pigtail
  33. Unclip the transmission wire harness from the crossmember.
  34. Disconnect the electronic variable orifice (EVO) control connector clips from the crossmember.
  35. Remove the transmission harness clip bolts from the engine block.
    Fig 13: Removing Transmission Harness Clip Bolts From Engine Block
    G01970654Courtesy of GENERAL MOTORS CORP.
  36. Unclip the transmission wire harness from the engine wire harness.
  37. Remove the stabilizer shaft. Refer to STABILIZER SHAFT REPLACEMENT in Front Suspension.
  38. Loosen, do not remove, the steering knuckle nut (2) from the lower control arm ball stud.
  39. Install the J 42188  between the steering knuckle and the lower control arm ball stud.
    Fig 14: Installing SST (J 42188) Between Steering Knuckle And Lower Control Arm Ball Stud
    G01970655Courtesy of GENERAL MOTORS CORP.
  40. Tighten the nut on the J 42188  until the steering knuckle and the lower control arm ball stud separate.
  41. Disconnect the anti-lock brake system (ABS) electrical connector clips from the crossmember (if equipped).
  42. Remove the front transverse leaf spring. Refer to FRONT TRANSVERSE SPRING REPLACEMENT in Front Suspension.
  43. Disconnect the automatic transmission fluid cooler pipe clip from the front of the engine oil pan (if equipped).
    Fig 15: Disconnecting Automatic Transmission Fluid Cooler Pipe Clip From Front Of Engine Oil Pan
    G01970656Courtesy of GENERAL MOTORS CORP.
  44. Disconnect the front automatic transmission fluid cooler pipes from the rear pipes.
    Fig 16: Disconnecting Front Automatic Transmission Fluid Cooler Pipes From Rear Pipes
    G01970657Courtesy of GENERAL MOTORS CORP.
  45. Disconnect the automatic transmission cooler pipe clip at the right transmission cover (if equipped).
    NOTE: Refer to FASTENER NOTICE .

    Important:  Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly.

  46. With automatic transmission vehicles, use the following steps:
    1. 46.1. Remove the 2 driveline support hole plug bolts.
      Fig 17: Removing Driveline Support Hole Plug Bolts
      G01970658Courtesy of GENERAL MOTORS CORP.
    2. 46.2. Install a M10.0-1.5 x 55 mm bolt or longer in each plug location.

      Tighten 

      Tighten the M10 bearing support bolts to 35 N.m (26 lb ft).

  47. If equipped with a automatic transmission, remove the flywheel housing plug.
    Fig 18: Removing Flywheel Housing Plug
    G01970659Courtesy of GENERAL MOTORS CORP.
  48. If equipped with a automatic transmission perform the following:
    1. 48.1. Orientate the prop shaft hub clamp for access to the bolt (1).
    2. 48.2. Position the clamp bolt (1) facing downward.
    3. 48.3. Loosen the prop shaft hub clamp bolt (1).
    Fig 19: Loosening Propeller Shaft Hub Clamp Bolt
    G01970660Courtesy of GENERAL MOTORS CORP.
  49. Remove bolts attaching the transmission wire harness bracket to the flywheel housing.
  50. Remove the transmission wire harness from its mounting location, rearward toward the driveline support.
  51. Lay the harness on the driveline support.

    Secure if necessary.

    Fig 20: Removing Bolts Attaching Transmission Wire Harness Bracket To Flywheel Housing
    G01970661Courtesy of GENERAL MOTORS CORP.

    Important:  The weight of the engine should never be supported by the J 42203  .

  52. Install the J 42203  to the close-out panel flange.
    Fig 21: Installing (J 42203) To Close-Out Panel Flange
    G01970662Courtesy of GENERAL MOTORS CORP.
  53. If equipped with a manual transmission perform the following:
    1. 53.1. Unclip the clutch actuator hose from the clutch actuator hose clip.
    2. 53.2. Using the J 36221  , depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect.
    3. 53.3. Protect both ends from dirt and damage.
      Fig 22: Disconnecting Clutch Actuator Hose From Clutch Actuator Hose Clip
      G01970663Courtesy of GENERAL MOTORS CORP.

    Important:  The weight of the engine should never be supported by the J 42203  .

  54. Install the J 42203  to the close-out panel flange.
    Fig 23: Installing (J 42203) To Close-Out Panel Flange
    G01970664Courtesy of GENERAL MOTORS CORP.
  55. Slowly lower the vehicle onto the J 39580  and the J 39580-500  .
  56. Support the engine and crossmember on the J 39580  and the J 39580-500  .
  57. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts.
    Fig 24: Removing Front And Rear Crossmember Nuts
    G01970665Courtesy of GENERAL MOTORS CORP.
  58. Partially raise the vehicle.
  59. Remove the AIR pipe bolts from the right exhaust manifold.
    Fig 25: Removing AIR Pipe Bolts From Right Exhaust Manifold
    G01970666Courtesy of GENERAL MOTORS CORP.
  60. Remove the AIR pipe bracket bolt (at the rear of the cylinder head).
  61. Remove the AIR pipe (with check valve) and gasket.
    Fig 26: Removing AIR Pipe
    G01970667Courtesy of GENERAL MOTORS CORP.
  62. Remove the ground strap bolt (5).
    Fig 27: Disconnecting Electrical Connectors From Back Of Engine
    G01970668Courtesy of GENERAL MOTORS CORP.
  63. Remove the ground strap (6) from the left rear cylinder head.
  64. Disconnect the following electrical connectors from the back of the engine:
    • The knock sensor wire harness (1)
    • The engine oil pressure sensor (2)
    • The manifold absolute pressure (MAP) sensor (3)
    • The camshaft position (CMP) sensor (4)
  65. Disconnect the vacuum hose from the MAP sensor.
  66. Remove the driveline support bolts.
    Fig 28: Removing Driveline Support Bolts
    G01970669Courtesy of GENERAL MOTORS CORP.

    Important:  Visually inspect the transmission wiring harness to ensure detachment from the engine.

  67. 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.
    Fig 29: Separating Flywheel Housing From Driveline Support
    G01970670Courtesy of GENERAL MOTORS CORP.
  68. Slowly pull the engine away from the propeller shaft.
  69. As soon as the propeller input shaft clears the flywheel housing, slowly raise the vehicle.
  70. Slide the engine and crossmember forward in order to clear the propeller shaft spline.

    Important:  Visually inspect the wiring harness clearances while raising the vehicle.

  71. Raise the vehicle completely off of the engine and crossmember.
  72. Remove the power steering pump pulley hub cap, if necessary.
  73. Using the J 25034-C  remove the power steering pump pulley.
    Fig 30: Removing Power Steering Pump Pulley
    G01970671Courtesy of GENERAL MOTORS CORP.

    Important:  It is not necessary to open the power steering system during the engine removal procedure.

  74. Remove the power steering pump bolts.
    Fig 31: Removing Power Steering Pump
    G01970672Courtesy of GENERAL MOTORS CORP.
  75. Remove the power steering pump brace.
  76. Remove the power steering pump (with reservoir) from the engine and reposition them to the crossmember.
  77. Remove the A/C compressor bracket. Refer to COMPRESSOR MOUNTING BRACKET REPLACEMENT in Heating, Ventilation, and Air Conditioning.
  78. Remove the generator bracket bolts.
  79. Remove the generator bracket and power steering pump bracket.
    Fig 32: Removing Generator Bracket
    G01970673Courtesy of GENERAL MOTORS CORP.
  80. Remove the AIR pipe bolts from the left exhaust manifold.
    Fig 33: Removing AIR Pipe From Left Exhaust Manifold
    G01970674Courtesy of GENERAL MOTORS CORP.
  81. Remove the AIR pipe and gasket.
  82. Install the J 41798  to the engine.
  83. Remove the spark plugs. Refer to SPARK PLUGS .
  84. Remove the engine mount nuts.
  85. Using a engine hoist and the J 41798  slowly raise the engine.
  86. Remove the engine from the crossmember.
    Fig 34: Removing Engine From Crossmember
    G01970675Courtesy of GENERAL MOTORS CORP.
  87. Remove the flywheel housing bolts.
    Fig 35: Removing Flywheel Housing
    G01970676Courtesy of GENERAL MOTORS CORP.
  88. Remove the flywheel housing from the engine block.
  89. Install the engine onto an engine stand and prepare for disassembly. Refer to ENGINE BALANCING  .
  90. Remove the engine hoist.
  91. Remove the J 41798  from the engine.
  92. Remove the engine mount bracket bolts.
  93. Remove the engine mount brackets from the engine block.
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