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Removal Procedure

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    WARNING:

    Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

    The High Voltage Disabling procedure will perform the following tasks:

    • Identify how to disable high voltage.
    • Identify how to test for the presence of high voltage.
    • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

    Failure to follow the procedures exactly as written may result in serious injury or death.

  1. Disable the high voltage system. Refer to High Voltage Disabling
    2. Fig 1: Ground Strap And Nut
    GM1823089Courtesy of GENERAL MOTORS CORP.
  2. Remove the ground strap nut at the hood stud.
  3. Remove the ground strap from the stud.
    4. Fig 2: Hood Strut Rod, Grille End Caps And Hood Hinge Bolts
    GM1711842Courtesy of GENERAL MOTORS CORP.
  4. Assemble 2 sets of the following: an M6 bolt, 2 each 19.05 mm (0.75 in) flat washers and an M6 nut.
  5. Release the retainer securing the hood strut rod to the hood strut bracket stud.
  6. Remove the hood strut rod (1) from the stud.
  7. Remove the air inlet grille end caps (2), lift the end cap up in order to disengage the retainers.
  8. Have an assistant support the hood.
  9. Remove the hood hinge bolts (3) and set aside.
    10. Fig 3: Service Piston Notch
    GM1711844Courtesy of GENERAL MOTORS CORP.
    NOTE:

    There is a positive stop which limits the hood from being opened too far.

  10. Raise the hood until the service position notch (1) in the upper hinge is reached.
  11. Install the 2 sets of the M6 bolts to both the left and right side service notches and tighten finger tight.
    12. CAUTION:

    Refer to Fastener Caution .

  12. Lower the hood until the bolts rest against the lower hinge, tighten the bolts to secure the hood.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

  13. The hood is now set in the service position.
  14. Remove the hood latch. Refer to Hood Primary and Secondary Latch Replacement .
  15. Remove the front end upper tie bar. Refer to Front End Upper Tie Bar Replacement .
  16. Remove the intake manifold. Refer to Intake Manifold Replacement .
  17. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) .
  18. Disconnect the A/C lines from the A/C compressor. Refer to Discharge Hose Replacement (HP2) , and Suction Hose Replacement (W/O C69-HP2) , Suction Hose Replacement (W/C69-HP2) .
  19. Disconnect the A/C pressure sensor electrical connector.
  20. Disconnect the cables from the generator control module.
    21. Fig 4: Radiator Vent Inlet Hose
    GM1699347Courtesy of GENERAL MOTORS CORP.
  21. Remove the radiator vent inlet hose (2) from the radiator inlet hose clip (3).
  22. Reposition the radiator vent inlet hose clamp (1) at the air bleed pipe.
  23. Remove the radiator vent inlet hose (2) from the air bleed pipe and reposition.
    24. Fig 5: Radiator Vent Inlet Hose Clamp At Water Pump
    GM1696566Courtesy of GENERAL MOTORS CORP.
  24. Reposition the radiator inlet hose clamp (3) at the water pump.
  25. Remove the radiator inlet hose from the water pump.
    26. Fig 6: Radiator Outlet Hose Clamp At Water Pump
    GM1969001Courtesy of GENERAL MOTORS CORP.
  26. Reposition the radiator outlet hose clamp (1) at the water pump.
  27. Remove the radiator outlet hose from the water pump.
  28. Remove the heater hoses. Refer to Heater Inlet Hose Replacement (Pump to Engine-HP2) , Heater Inlet Hose Replacement (Pump to Heater Core-HP2) .
    29. Fig 7: Drive Motor Generator Power Inverter Module Cover, Bolt And Electrical Connector
    GM1966180Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the engine wiring harness electrical connector (3) from the drive motor generator power inverter module cover.
  30. Loosen the drive motor generator power inverter module cover bolt (1).
  31. Remove the drive motor generator power inverter module cover (2).
    32. Fig 8: Engine Bracket, Nut And Bolts
    GM1965810Courtesy of GENERAL MOTORS CORP.
  32. Remove the engine bracket bolts (2).
  33. Remove the engine bracket (3)
    34. Fig 9: 3-Phase Cable Clip Nut And Engine Bracket
    GM1965809Courtesy of GENERAL MOTORS CORP.
  34. Remove the generator control module 3 phase cable clip nut (1).
  35. Remove the generator control module 3 phase cable clip from the engine bracket (2).
  36. Reposition the generator control module 3 phase cables out of the way.
  37. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side .
    38. Fig 10: Engine Harness Electrical Connectors And Inlet Hose Clamp
    GM1697098Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the engine harness electrical connector (1) from the oil pressure sensor.
  39. Disconnect the engine harness electrical connector (2) from the lifter oil manifold.
    40. Fig 11: Engine Ground Strap And Bolt
    GM1699550Courtesy of GENERAL MOTORS CORP.
  40. Remove the engine ground strap bolt from the rear of the left cylinder head and cowl and reposition.
  41. Remove the engine ground wire from the right cylinder head.
    42. Fig 12: Engine Harness Components
    GM1699536Courtesy of GENERAL MOTORS CORP.
  42. Remove the engine harness clip (1) from the ground stud.
  43. Remove the engine harness ground stud (2) from the engine block.
  44. Remove the engine harness grounds (3) from the engine block.
  45. Disconnect the engine harness electrical connector (4) from the knock sensor.
    46. Fig 13: CMP Sensor And Connector
    GM1968149Courtesy of GENERAL MOTORS CORP.
  46. Disconnect the engine harness electrical connector (1) from the camshaft position (CMP) sensor wire harness.
    47. Fig 14: A/C Refrigerant Pressure Sensor Harness And Connector
    GM1969134Courtesy of GENERAL MOTORS CORP.
  47. Disconnect the auxiliary heater water pump electrical connector (1).
  48. Disconnect the engine harness electrical connector (2) from the A/C refrigerant pressure sensor.
    49. Fig 15: CKP Sensor Harness And Connector
    GM1969176Courtesy of GENERAL MOTORS CORP.
  49. Disconnect the engine harness electrical connector (1) from the crankshaft position (CKP) sensor.
  50. Disconnect the engine harness electrical connector (2) from the knock sensor.
  51. Disconnect the engine harness electrical connector (3) from the oil level sensor.
    52. Fig 16: Coolant Heater Cord
    GM1699547Courtesy of GENERAL MOTORS CORP.
  52. Disconnect the coolant heater cord from the coolant heater, if equipped.
  53. Lower the vehicle.
  54. Remove the ignition coil, as required for proper fit of the J 41798 . Before lifting the engine, refer to Ignition Coil Replacement .
  55. Remove the 3 phase cable bracket from the right cylinder head.
    56. Fig 17: Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS CORP.
  56. Install the J 41798 to left and right cylinder heads.

    Tighten 

    • Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
    • Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).
    57. Fig 18: Engine Mount Bracket Bolts
    GM1701018Courtesy of GENERAL MOTORS CORP.
  57. Remove the left and right engine mount to frame bolts (1).
  58. Raise the vehicle.
    59. Fig 19: Oil Pan Skid Plate And Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  59. Remove the oil pan skid plate bolts and plate, if equipped.
    60. Fig 20: Oil Pan Drain Plug
    GM1658109Courtesy of GENERAL MOTORS CORP.
  60. Place a suitable drain pan under the oil pan drain plug.
  61. Remove the oil pan drain plug (430).
  62. Allow the oil to drain completely.
  63. Reinstall and tighten the oil pan drain plug.

    Tighten 

    Tighten the drain plug to 25 N.m (18 lb ft).

  64. Remove the catalytic converter. Refer to Catalytic Converter Replacement (with Exhaust Clamp) .
    65. Fig 21: Right Flex Plate Inspection Cover Bolt
    GM1970180Courtesy of GENERAL MOTORS CORP.
  65. Remove the right flex plate inspection cover bolt (2).
  66. Remove the right flex plate inspection cover (1).
    67. Fig 22: Flywheel And Torque Converter Bolts
    GM1701022Courtesy of GENERAL MOTORS CORP.
    NOTE:

    Rotate engine clockwise only.

  67. With the aid of an assistant, hold the crank pulley, then remove the flywheel to torque dampener bolts.
    68. Fig 23: Fluid Filler Tube Bracket
    GM1975010Courtesy of GENERAL MOTORS CORP.
  68. Remove the fluid filler tube retaining nut (2) and reposition fill tube aside as necessary.
    69. Fig 24: Transmission Bolts/Studs
    GM1969442Courtesy of GENERAL MOTORS CORP.
  69. Remove the transmission bolts/studs (1).
  70. Lower the vehicle.
  71. Remove the fuel/evaporative emission (EVAP) pipe bracket nut from the transmission stud.
  72. Remove the fuel/EVAP pipe bracket from the stud. Reposition the bracket out of the way.
    73. Fig 25: Engine Lift Bracket
    GM309151Courtesy of GENERAL MOTORS CORP.
  73. Position and install an engine hoist to the J 41798 .
  74. Install a floor jack under the transmission for support.
  75. Remove the engine from the vehicle.
  76. Install the J 21366 .
  77. Position and install the engine onto an engine stand.
  78. Remove the engine hoist. from the J 41798 .
  79. Remove the J 41798 .
  80. Transfer parts as necessary.
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