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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1302 (Engine Mechanical (Repair Instructions 1 Of 3) - 5.7L) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1 >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 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.
    Fig 1: Right Fuel Injection Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  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.
  7. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 5.7 L.
  8. Disconnect the EVAP emission canister purge hose at the fuel line.
  9. Remove the fuel feed hose. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 5.7 L.
    10. Fig 2: Radiator Hoses & Water Pump
    GM179301Courtesy of GENERAL MOTORS CORP.
    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.
    11. Fig 3: Heater Hoses & Water Pump
    GM185256Courtesy of GENERAL MOTORS CORP.
  11. Remove the heater hoses from the water pump.
    12. Fig 4: Electrical Connectors
    GM651871Courtesy 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
  13. Remove the generator. Refer to Generator Replacement in Engine Electrical.
    14. Fig 5: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  14. Remove the power brake booster vacuum hose.
    15. Fig 6: Intermediate Steering Shaft & Bolt
    GM187354Courtesy 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.
    17. Fig 7: AIR Pump Hose & AIR Pipe
    GM651891Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the secondary air injection (AIR) pump hose from the AIR pipe.
  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. Fig 8: View Of Driveline Tunnel Closeout Panel & Bolts
    GM67894Courtesy of GENERAL MOTORS CORP.
  20. Remove the driveline tunnel close-out panel bolts.
  21. Remove the driveline tunnel close-out panel.
  22. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
    23. Fig 9: Engine Oil Level Sensor Electrical Connector & CKP Sensor Electrical Connector
    GM651885Courtesy of GENERAL MOTORS CORP.
  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.
    26. Fig 10: A/C Compressor & Condenser Hose & Bolt
    GM82082Courtesy 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.
    28. Fig 11: Engine Oil Temperature Sensor Electrical Connector & Ground Straps
    GM651886Courtesy 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.

    31. Fig 12: Transmission Wire Harness & Electrical Connectors
    GM652265Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the wheel speed sensor electrical connectors.
  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. Fig 13: Transmission Wire Harness & Engine Wire Harness
    GM652266Courtesy of GENERAL MOTORS CORP.
  35. Remove the transmission harness clip bolts from the engine block.
  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. Fig 14: J 42188, Steering Knuckle & Lower Control Arm Ball Stud
    GM340932Courtesy of GENERAL MOTORS CORP.
  38. Loosen, do not remove, the steering knuckle nut (2) from the lower control arm ball stud.
  39. Install theJ 42188  between the steering knuckle and the lower control arm ball stud.
  40. Tighten the nut on the J 42188  until the steering knuckle and the lower control arm ball stud separate.
  41. Disconnect the antilock 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. Fig 15: Automatic Transmission Fluid Cooler Line & Oil Pan
    GM651883Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the automatic transmission fluid cooler pipe clip from the front of the engine oil pan (if equipped).
    44. Fig 16: Automatic Transmission Fluid Cooler Line Clamp & Bolt
    GM71418Courtesy of GENERAL MOTORS CORP.
  44. Disconnect the front automatic transmission fluid cooler pipes from the rear pipes.
  45. Disconnect the automatic transmission cooler pipe clip at the right transmission cover (if equipped).
    46. Fig 17: Driveline Support Plug & Bolts
    GM173638Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    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. 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.

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

    47. Fig 18: Flywheel Housing Plug
    GM71455Courtesy of GENERAL MOTORS CORP.
  47. If equipped with a automatic transmission, remove the flywheel housing plug.
    48. Fig 19: View Of Propeller Shaft Hub Clamp Bolt
    GM173641Courtesy of GENERAL MOTORS CORP.
  48. If equipped with a automatic transmission perform the following:
    1. Orientate the prop shaft hub clamp for access to the bolt (1).
    2. Position the clamp bolt (1) facing downward.
    3. Loosen the prop shaft hub clamp bolt (1).
    49. Fig 20: Transmission Wire Harness Bracket & Bolts
    GM652267Courtesy 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.

    52. Fig 21: J 42203, Close-Out Panel Flange & Bolts
    GM188853Courtesy 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.
    53. Fig 22: Identifying White Circular Release Ring On The Actuator Hose
    GM71472Courtesy of GENERAL MOTORS CORP.
  53. If equipped with a manual transmission perform the following:
    1. Unclip the clutch actuator hose from the clutch actuator hose clip.
    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. Protect both ends from dirt and damage.
    54. Fig 23: J 42203, Close-Out Panel Flange & Bolts
    GM188853Courtesy 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.
  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. Fig 24: View Of Front & Rear Crossmember Nuts
    GM581372Courtesy of GENERAL MOTORS CORP.
  57. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts.
  58. Partially raise the vehicle.
    59. Fig 25: AIR Pipe & Bolts
    GM651877Courtesy of GENERAL MOTORS CORP.
  59. Remove the AIR pipe bolts from the right exhaust manifold.
    60. Fig 26: AIR Pipe Gasket, Exhaust Manifold & Bolts
    GM651878Courtesy 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.
    62. Fig 27: MAP Sensor Vacuum Hose & MAP Sensor Electrical Connector
    GM651870Courtesy of GENERAL MOTORS CORP.
  62. Remove the ground strap bolt (5).
  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. Fig 28: Driveline Support & Bolts
    GM71466Courtesy of GENERAL MOTORS CORP.
  66. Remove the driveline support bolts.
    67. Fig 29: Inserting Flat Tool Separating Flywheel Housing & Driveline Support
    GM196200Courtesy 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.
  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.
    71. Fig 30: Power Steering Pump Pulley & J 25034-C
    GM65347Courtesy of GENERAL MOTORS CORP.
    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.
    74. Fig 31: Power Steering Pump, Generator Bracket & Bolts
    GM65354Courtesy 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.
  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. Fig 32: Generator Bracket & Bolts
    GM652357Courtesy of GENERAL MOTORS CORP.
  78. Remove the generator bracket bolts.
  79. Remove the generator bracket and power steering pump bracket.
    80. Fig 33: AIR Pipe Bolts, Exhaust Manifold & Bolts
    GM651876Courtesy of GENERAL MOTORS CORP.
  80. Remove the AIR pipe bolts from the left exhaust manifold.
  81. Remove the AIR pipe and gasket.
  82. Install the J 41798  to the engine.
  83. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 5.7 L.
    84. Fig 34: Engine Mount & Nuts
    GM188236Courtesy of GENERAL MOTORS CORP.
  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.
    87. Fig 35: Bottom Flywheel Housing-To-Oil Pan & Bolts
    GM651884Courtesy of GENERAL MOTORS CORP.
  87. Remove the flywheel housing bolts.
  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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