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Removal & Installation: Engine: Removal

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover A/C system. See RECOVERY/EVACUATION & RECHARGING article in GENERAL SERVICING in HVAC. Disconnect battery cables. Move hood to service position by moving hood hinge bolts to service positions.
  2. Remove retaining bolt in front of shield. Lift up on front of shield. Lift shield off the rear bracket. Drain engine coolant and engine block. See DRAINING & REFILLING COOLING SYSTEM .
    3. NOTE: After removing turbocharger air ducts and hoses, cover turbocharger openings and ducts with tape to prevent entry of objects.
  3. Remove air cleaner outlet duct from air cleaner and turbocharger. Disconnect engine wire harness connectors, mass airflow switch, air conditioning pressure cycling switch and surge tank switch. Remove engine wire harness clip from accumulator. Remove engine wire harness clips from wheelhouse inner panel. Remove engine wire harness clip from engine bracket.
  4. Remove air cleaner assembly and bracket. Remove surge tank. See SURGE TANK . Raise vehicle.
  5. Support vehicle and remove both front tires and wheels. Remove both front fender wheelhouse inner panels. Lower vehicle. Remove charged air cooler pipes and hoses from engine and charged air cooler.
  6. Loosen hose clamps and remove radiator inlet hose from radiator and engine. Remove upper fan shroud. Remove lower fan shroud. Loosen hose clamp and remove radiator outlet hose from radiator. Disconnect outlet heater hose from outlet radiator hose. Remove hose clips from frame.
  7. Loosen hose clamp and remove radiator outlet hose from engine. Remove bolt retaining the outlet heater hose pipe to the generator mounting bracket. Remove nut retaining to outlet heater hose pipe to fuel filter mounting bracket. Move heater hose and secure aside. Remove upper radiator support. Remove radiator. See RADIATOR . Remove charged air cooler. Remove A/C condenser. See appropriate AIR CONDITIONING article.
  8. Disconnect generator harness connector, A/C refrigerant switch, dual generator harness connector (if equipped), and A/C compressor clutch. Remove harness clip from A/C compressor bracket.
  9. Remove battery cable to generator. Remove battery cable to auxiliary generator (if equipped). Remove battery cable harness clip from bracket. Remove bolt retaining battery cable junction block from power steering pump. Move and secure battery cables out of the way.
  10. Disconnect both fuel injection control module harness connectors. Flip latch up and it will disconnect the connector. Remove engine wire harness from retainer. Disconnect fuel lines at engine. Remove nut and fuel line bracket from upper valve rocker arm cover stud. Secure fuel lines out of the way.
  11. Remove power supply cable from glow plug relay. Remove drive belt. Disconnect suction hose from accumulator. The compressor end can remain on the compressor. Remove A/C compressor mounting bolts. Move A/C compressor with hoses attached to right side of engine compartment. Move wiring harness to left side of vehicle and secure out of the way.
  12. Remove bolts retaining power steering pump front bracket to power steering pump and A/C compressor mounting bracket. Remove compressor and power steering pump mounting bracket. When battery cables are removed from engine, power steering pump can be removed further out of the way.
  13. Remove the Positive Crankcase Ventilation (PCV) oil separator from bracket. Remove bolts retaining the PCV separator bracket and fuel bleed valve. Remove right idler pulley (ribbed). Remove generator mounting bracket and secure to the side. The generator and drive belt tensioner does not require removal.
  14. Use the Quick Connect Connector Removal (J-43181) to disconnect the inlet heater hose from the heater core inlet. Remove bolt and ground wires at rear of left cylinder head. Raise vehicle. Remove oil pan skid plate. Remove engine protection shield from vehicle, if equipped.
  15. Remove bolt for battery negative cable and engine wiring harness ground wire from the left side of engine. Remove bolts holding battery cable channel retainer to lower crankcase. Disconnect cord for engine coolant heater. Remove starter. See appropriate STARTERS article in 2002 STARTING & CHARGING SYSTEMS.
  16. Remove nut holding battery cable bracket to right side of lower crankcase. Remove bolt holding auxiliary battery negative cable and engine wiring harness ground wires to right side of engine. Move and secure battery cables out of way.
  17. Raise vehicle. Drain engine oil. Remove exhaust pipe to exhaust outlet clamp. Move clamp onto exhaust pipe. On 4WD models, remove lower oil pan. See OIL PAN .
  18. On A/T models, mark flywheel and torque converter relationship for assembly purposes. Remove torque convertor bolts through starter opening. Remove transmission oil line clip nut.
  19. On A/T models, remove nuts retaining transmission fluid fill tube bracket. On all models, remove transmission to engine stud and bolts. Note location of studs and any brackets attached to studs. Lower vehicle to work through wheelhouse opening. Remove engine mount to frame bracket bolts (left side shown). Lower vehicle.
  20. Install Engine Lift Brackets (J-36857) to rear of left cylinder head with a suitable bolt. Install engine lift brackets to the front of right cylinder head with a suitable bolt. Install a suitable lifting device. The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.
  21. Raise vehicle off the engine mounts. Remove left and right engine mount frame brackets. Remove engine assembly from vehicle. In order to secure engine to an engine stand remove the following and follow the special procedures:
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