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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1629 (Engine Mechanical - 2.4L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. For the LAT engine, disconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
  3. Remove the hood. Refer to Hood Replacement .
  4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (With HP5) or Refrigerant Recovery and Recharging (Without HP5) .
    5. Fig 1: View Of Fuel Feed Pipe Retainer & Fuel Pipe Bracket
    GM1683133Courtesy of GENERAL MOTORS CORP.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027-100) or Fuel Pressure Relief (Without CH 48027-100) .
  6. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  7. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  8. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  9. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Remove the fuel feed pipe clip (2) from the fuel line bracket.
    11. Fig 2: Transaxle Shift Cable Clip
    GM1834359Courtesy of GENERAL MOTORS CORP.
  11. Remove the transaxle shift cable clip (1) from the fuel line bracket.
  12. Remove the bolts from the engine control module and position aside. Refer to Engine Control Module Replacement .
  13. For the LE5, remove the battery box. Refer to Battery Box Replacement .
  14. For the LAT, remove the battery tray. Refer to Battery Tray Replacement (HP7) .
  15. On the LAT engine, remove the generator starter. Refer to Generator with Starter Replacement .
  16. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LAT or LE5) .
  17. Remove the oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Sensor 1 and Heated Oxygen Sensor Replacement - Sensor 2 .
  18. Remove the throttle body. Refer to Throttle Body Assembly Replacement .
  19. Remove the engine oil level indicator.
  20. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  21. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
  22. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) or Cooling System Draining and Filling (Static Fill Without HP5) or Cooling System Draining and Filling (GE 47716 Fill With HP5) or Cooling System Draining and Filling (GE 47716 Fill Without HP5) .
  23. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  24. Lower the vehicle.
    25. Fig 3: Vacuum Brake Booster Hose And Clamp
    GM1810786Courtesy of GENERAL MOTORS CORP.
  25. On all engines, reposition the vacuum brake booster hose clamp (1) at the intake manifold.
  26. Remove the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.
    27. Fig 4: Coolant Recovery Inlet Hose And Clamp
    GM1812505Courtesy of GENERAL MOTORS CORP.
  27. Remove the coolant recovery inlet hose clamp (2) at the cylinder head.
  28. Remove the coolant recovery inlet pipe clip from the fuel rail.
  29. Remove the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.
    30. Fig 5: View Of Radiator Inlet Hose To Engine
    GM1656126Courtesy of GENERAL MOTORS CORP.
  30. Reposition the radiator inlet hose clamp using the J 38185  . See Special Tools .
  31. Remove the radiator inlet hose from the cylinder head.
  32. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LAT) or Radiator Outlet Hose Replacement (LE5) or Radiator Outlet Hose Replacement (HP5) .
    33. Fig 6: Generator Control Module Coolant Hose And Clamp
    GM1816290Courtesy of GENERAL MOTORS CORP.
  33. On LAT engine, reposition the generator control module coolant hose clamp (1) at the generator control module.
  34. Remove the generator control module coolant hose from the generator control module.
    35. Fig 7: Locating Engine Wiring Harness Electrical Connector
    GM1816297Courtesy of GENERAL MOTORS CORP.
  35. Disconnect the engine wiring harness electrical connector (1) from the transaxle auxiliary pump module.
    36. Fig 8: View Of Auxiliary Heater Water Pump & Heater Hoses
    GM1812209Courtesy of GENERAL MOTORS CORP.
  36. Remove the auxiliary heater water pump hose clip (1) from the heater outlet hose.
  37. On all engines, reposition the heater inlet hose clamp at the thermostat housing.
  38. Remove the heater inlet hose (3) from the thermostat housing.
  39. Reposition the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.
  40. Remove the coolant recovery reservoir/heater inlet hose (2) from the thermostat housing.
  41. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    42. Fig 9: Engine Wiring Harness Electrical Connector
    GM1811958Courtesy of GENERAL MOTORS CORP.
  42. On LAT engine, disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump.
  43. On all engines, disconnect the engine wiring harness electrical connector (2) from the air conditioning (A/C) compressor.
    44. Fig 10: Generator Control Module Coolant Pump
    GM1811960Courtesy of GENERAL MOTORS CORP.
  44. On LAT engine, remove the generator control module coolant pump bolt and pump.
    45. Fig 11: Compressor Bolts
    GM1811970Courtesy of GENERAL MOTORS CORP.
  45. On all engines, unbolt the A/C compressor and reposition out of the way.
    46. Fig 12: Engine Wiring Harness Ground Lead Nut And Stud
    GM1813437Courtesy of GENERAL MOTORS CORP.
  46. Remove the engine wiring harness ground lead nut (1) from the transaxle stud.
  47. Remove the negative battery cable lead (2) from the transaxle stud. Reposition the negative battery cable out of the way.
    48. Fig 13: View Of Starter And Electrical Connectors
    GM1813964Courtesy of GENERAL MOTORS CORP.
  48. Remove the positive battery cable to starter motor nut (4).
  49. Remove the positive battery cable lead (1) from the starter motor.
  50. Remove the positive battery cable from in between the starter and the engine. Reposition the positive battery cable out of the way.
    51. Fig 14: Identifying Engine Wiring Harness Electrical Connector
    GM1812206Courtesy of GENERAL MOTORS CORP.
  51. On LAT engine, disconnect the engine wiring harness electrical connector (2) from the auxiliary heater water pump.
    52. Fig 15: Auxiliary Heater Water Pump Bolt And Pump
    GM1814527Courtesy of GENERAL MOTORS CORP.
  52. Remove the auxiliary heater water pump bolt and pump.
  53. On all engines, lower the vehicle.
    54. Fig 16: Transaxle Shift Cable And Range Select Lever
    GM1834362Courtesy of GENERAL MOTORS CORP.
  54. Remove the transaxle shift cable from the range select lever.
  55. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.
    56. Fig 17: View Of Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
    NOTE: The radiator/condenser/fan assembly will stay in the vehicle during engine removal.
  56. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
  57. Raise the vehicle.
  58. Remove the front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement .
    59. NOTE: A piece of hardwood should be used between the transaxle and the engine cradle. This wood will support the engine when the left side engine mounts bolts are removed.
  59. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the engine cradle.
    60. NOTE: A piece of hardwood should be used between the oil pan and the engine cradle. This wood will support the engine when the right side engine mounts are removed.
  60. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the engine frame.
    61. Fig 18: Transaxle Oil Cooler Line To Transaxle Nut
    GM1847469Courtesy of GENERAL MOTORS CORP.
  61. Drain the transaxle fluid.
  62. Remove the transaxle oil cooler line to transaxle nut (1).
  63. Remove the transaxle oil cooler lines from the transaxle.
  64. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
    65. Fig 19: View Of Intermediate Shaft To Steering Gear Pinch Bolt
    GM1829617Courtesy of GENERAL MOTORS CORP.
    NOTE: Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.
  65. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.
    66. Fig 20: Outer Tie Rod To Steering Knuckle Nut
    GM1829556Courtesy of GENERAL MOTORS CORP.
  66. Remove and discard both outer tie rod to steering knuckle nuts.
    67. NOTE: Hold the ball stud to prevent turning during removal of the nut.
  67. Using the SA91100C 
    68. Fig 21: Stabilizer Link To Stabilizer Shaft Nut
    GM1829576Courtesy of GENERAL MOTORS CORP.
  68. Remove the stabilizer link to stabilizer shaft nuts and disconnect the stabilizer links from the stabilizer shaft.
    69. Fig 22: Lower Control Arm Ball Stud, Nut And Cotter Pin
    GM1847531Courtesy of GENERAL MOTORS CORP.
  69. Remove and discard both of the lower control arm ball stud cotter pins.
  70. Loosen the ball stud nuts until the nuts are level with the top of the ball stud.
    71. Fig 23: View Of Steering Knuckle & Lower Control Arm
    GM932518Courtesy of GENERAL MOTORS CORP.
  71. Using the J 43828 
  72. Remove the ball stud nuts.
  73. Remove the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement .
  74. Lower the vehicle.
    75. Fig 24: Engine Mount To Bracket Bolts
    GM1810250Courtesy of GENERAL MOTORS CORP.
  75. Remove the engine mount to engine mount bracket bolts (2).
    76. Fig 25: Left Transmission Mount & Bolts
    GM928777Courtesy of GENERAL MOTORS CORP.
  76. Remove the transaxle mount to transaxle adapter bolts.
  77. Raise the vehicle.
    78. Fig 26: Powertrain Assembly On Engine Support Table
    GM952078Courtesy of GENERAL MOTORS CORP.
    NOTE: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.
  78. Position a engine support table under the powertrain assembly.
    79. NOTE: Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.
  79. With the table positioned, fully raise the table to contact with the powertrain assembly.
  80. Remove the frame to body bolts. Discard the bolts.
    81. NOTE: When lowering the engine/transaxle assembly, verify all brake lines, shifter cables and other components are free during removal.
  81. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle.
    82. Fig 27: Identifying Engine Electrical Connectors Left Side
    GM1810743Courtesy of GENERAL MOTORS CORP.
  82. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
  83. Disconnect the engine wiring harness electrical connector (8) from the fuel injector wiring harness electrical connector (7).
  84. Remove the engine wiring harness clip (3) from the oil level indicator tube bracket.
    85. Fig 28: Identifying Engine Wiring Harness Electrical Connectors
    GM1811485Courtesy of GENERAL MOTORS CORP.
  85. Disconnect the engine wiring harness electrical connectors (1) from the ignition coils.
  86. Disconnect the engine wiring harness electrical connectors (2, 3) from the camshaft actuators.
    87. Fig 29: View Of Starter And Engine Electrical Connectors
    GM1809558Courtesy of GENERAL MOTORS CORP.
  87. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
  88. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
  89. Disconnect the engine wiring harness electrical connector (3) from the knock sensor.
    90. Fig 30: Locating Intake Camshaft Position (Cmp) Sensor And Intake Camshaft Position (Cmp) Sensor Connectors
    GM1815154Courtesy of GENERAL MOTORS CORP.
  90. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) sensor.
  91. Disconnect the engine wiring harness electrical connector (2) from the EVAP emission canister purge solenoid valve.
    92. Fig 31: Locating Exhaust CMP Sensor Connector
    GM1815153Courtesy of GENERAL MOTORS CORP.
  92. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP sensor.
    93. Fig 32: Identifying Engine Wiring Harness Electrical Connector
    GM1812206Courtesy of GENERAL MOTORS CORP.
  93. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
  94. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector.
  95. Remove the engine wiring harness clip (5) from the stud.
    96. Fig 33: Engine Wiring Harness Ground Bolt
    GM1847502Courtesy of GENERAL MOTORS CORP.
  96. Remove the engine wiring harness ground bolt (1) and reposition the ground terminal from the engine.
  97. Gather all branches of the engine wiring harness and reposition the harness out of the way.
    98. Fig 34: Identifying Starter Motor Bolts & Starter
    GM1814106Courtesy of GENERAL MOTORS CORP.
  98. Remove the starter motor bolts and starter.
    99. Fig 35: Torque Converter To Flexplate Bolts
    GM1847524Courtesy of GENERAL MOTORS CORP.
  99. Remove the torque converter to flexplate bolts (1).
  100. Install a suitable lifting devise to the engine.
    101. Fig 36: Transaxle To Engine Bolts
    GM1847526Courtesy of GENERAL MOTORS CORP.
  101. Remove the transaxle bolts from the engine.
  102. Separate the engine from the transaxle.
  103. Install the engine to a suitable engine stand.
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