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Home >> Isuzu >> 2007 >> i-290 LS, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 78 (Engine Mechanical - 4.6L - 2 Of 4) >> On-Vehicle Repair Instructions (2 Of 2) >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2007 Cadillac DTS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Brake Booster Vacuum Hose
    GM1663944Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  3. Recover the air conditioning (A/C) refrigerant system. Refer to Refrigerant Recovery and Recharging .
  4. Reposition the brake booster vacuum hose clamp at the engine port.
  5. Disconnect the brake booster vacuum hose from the vacuum connection and position aside.
    6. Fig 2: Fuel Feed & EVAP Line
    GM1662130Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel feed and evaporative emission (EVAP) line quick-connect fittings (1, 2). Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
  7. Remove the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement .
  8. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
    9. Fig 3: View Of Junction Block Cover
    GM1664482Courtesy of GENERAL MOTORS CORP.
  9. Disengage the junction block cover lock tabs.
  10. Remove the junction block cover.
    11. Fig 4: Identifying Starter Solenoid Cable To Bussed Electrical Center (BEC)
    GM1663997Courtesy of GENERAL MOTORS CORP.
  11. Remove the nut (1) securing the starter cable to the bussed electrical center (BEC).
  12. Remove the starter cable clip (4) from the BEC.
  13. Remove the starter cable from the BEC terminal and secure to the top of the engine.
    14. Fig 5: View Of Engine Harness Electrical Connectors
    GM1664476Courtesy of GENERAL MOTORS CORP.
  14. Disengage the lever lock.
  15. Disconnect the engine harness electrical connector from the transaxle control module (TCM).
    16. Fig 6: Identifying Engine Harness Electrical Connectors
    GM1664478Courtesy of GENERAL MOTORS CORP.
  16. Disengage the lever lock.
  17. Disconnect the engine harness electrical connector from the body harness electrical connector.
  18. Secure the TCM and engine harness wiring branches to the engine.
    19. Fig 7: Identifying Air Cleaner Lower Housing
    GM1664479Courtesy of GENERAL MOTORS CORP.
  19. Disengage the lever locks.
  20. Disconnect the engine harness electrical connectors from the engine control module (ECM).
    21. Fig 8: Locating Junction Block
    GM1664483Courtesy of GENERAL MOTORS CORP.
  21. Remove the junction block bolts.
  22. Remove the junction block.
    23. Fig 9: View Of Engine Harness & Clips
    GM1662854Courtesy of GENERAL MOTORS CORP.
  23. Remove the engine harness (1) from the BEC.
    24. Fig 10: Identifying Engine Ground Cable
    GM1664485Courtesy of GENERAL MOTORS CORP.
  24. Remove the engine ground strap bolt (1) from the right side frame rail.
  25. Secure the ground strap to the engine.
    26. Fig 11: Identifying Transaxle Shift Cable
    GM1664517Courtesy of GENERAL MOTORS CORP.
  26. Remove the transaxle shift cable clip from the shift cable bracket.
    27. Fig 12: Identifying Transaxle Shift Cable Retainer
    GM1664519Courtesy of GENERAL MOTORS CORP.
  27. Remove the transaxle shift cable retainer (1).
    28. Fig 13: View Of Transaxle Shift Cable
    GM1664523Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the transaxle shift cable end (2) from the range selector lever (1).
  29. Remove the transaxle shift cable from the bracket and position the cable aside.
  30. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac-N-Fill) .
    31. Fig 14: View Of Radiator Inlet Hose & Clamp
    GM1664570Courtesy of GENERAL MOTORS CORP.
  31. Using the J 37097-A  reposition the radiator inlet hose clamp (1). See Special Tools .
  32. Remove the radiator inlet hose (2) from the water pump housing and position aside.
    33. Fig 15: View Of Radiator Outlet Hose At Thermostat Housing
    GM1664571Courtesy of GENERAL MOTORS CORP.
  33. Using the J 38185  reposition the radiator outlet hose clamp (1).
  34. Remove the radiator outlet hose (2) from the thermostat housing and position aside.
    35. Fig 16: Identifying Surge Tank Inlet Hose/Pipe
    GM1662131Courtesy of GENERAL MOTORS CORP.
  35. Reposition the radiator surge tank inlet hose clamp at the surge tank.
  36. Remove the surge tank inlet hose from the surge tank.
    37. Fig 17: Identifying Heater Inlet & Outlet Hoses
    GM1664574Courtesy of GENERAL MOTORS CORP.
  37. Reposition the heater inlet (1) and outlet (2) hose clamps at the heater pipes.
  38. Remove the heater inlet (2) and outlet (3) hoses from the heater pipes.
    39. Fig 18: View Of Master Cylinder & Brake Booster
    GM1708313Courtesy of GENERAL MOTORS CORP.
  39. Remove the master cylinder nuts and master cylinder from the brake booster.
  40. Reposition the master cylinder and secure the master cylinder to the engine.
    41. Fig 19: Identifying Upper Transaxle Oil Cooler Pipe Bolt & Bolt
    GM1665069Courtesy of GENERAL MOTORS CORP.
  41. Loosen the upper transaxle oil cooler pipe bolt (1) from the fan shroud.
  42. Slide the plastic caps off the transaxle oil cooler pipe quick connect fittings.
  43. Remove the right front engine mount strut bolt.
  44. Disconnect the transaxle oil cooler pipes from the radiator using the J 41623-B  .
    45. Fig 20: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
    NOTE: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
  45. Lock the steering column by installing the J 42640  into the underside of the steering column.
    46. Fig 21: Locating Strut Tower Bolts
    GM1665072Courtesy of GENERAL MOTORS CORP.
  46. Remove the left and right side strut tower bolts (1). (Left side shown, right side similar.)
  47. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  48. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement - Rear .
  49. Remove the front wheels. Refer to Tire and Wheel Removal and Installation .
    50. Fig 22: Identifying Engine Harness Grommets & Clips
    GM1665075Courtesy of GENERAL MOTORS CORP.
  50. Remove the engine harness grommet (2) from the frame rail bracket.
  51. Remove the engine harness clip (3) from the ride lever sensor bracket.
    52. Fig 23: Identifying Electronic Suspension Front Position Sensor Link
    GM1665080Courtesy of GENERAL MOTORS CORP.
  52. Disconnect the electronic suspension front position sensor link from the lower control arms ball stud, if equipped.
    53. Fig 24: Identifying Front Brake Pipe Bracket
    GM1665082Courtesy of GENERAL MOTORS CORP.
  53. Loosen the nut (2) securing the left front brake pipe bracket (4) to the body frame rail.
  54. Remove the front brake pipe bracket (4) from the body frame rail.
    55. Fig 25: Identifying Front Brake Pipe Bracket
    GM1665084Courtesy of GENERAL MOTORS CORP.
  55. Loosen the nut (1) securing the right front brake pipe bracket (4) to the body frame rail.
  56. Remove the front brake pipe bracket (4) from the body frame rail.
    57. Fig 26: Identifying Rear Brake Pipes/Lines
    GM1665085Courtesy of GENERAL MOTORS CORP.
  57. Disconnect the rear brake pipes from the front brake pipes.
  58. Plug the open brake lines in order to prevent fluid loss and/or system contamination.
    59. Fig 27: View Of A/C Discharge Hose & Condenser
    GM1708342Courtesy of GENERAL MOTORS CORP.
  59. Remove the A/C compressor discharge hose bolt at the condenser.
  60. Remove the A/C compressor discharge hose from the condenser and secure to the engine.
  61. Plug the A/C condenser discharge port.
    62. Fig 28: View Of A/C Suction Hose & Condenser
    GM1708344Courtesy of GENERAL MOTORS CORP.
  62. Remove the A/C compressor suction hose nut at the condenser.
  63. Remove the A/C compressor suction hose from the condenser and secure to the engine.
  64. Plug the A/C condenser suction port.
    65. Fig 29: Identifying Steering Gear & Related Attachments
    GM1665092Courtesy of GENERAL MOTORS CORP.
    CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.
  65. Remove the intermediate steering shaft cover.
  66. Remove the intermediate shaft pinch bolt.
  67. Remove the intermediate shaft from the steering gear.
    68. Fig 30: Identifying Oxygen Sensor Wiring Harness Heat Shield
    GM1665113Courtesy of GENERAL MOTORS CORP.
  68. Remove the oxygen sensor wiring harness heat shield. Refer to Oxygen Sensor Wiring Harness Heat Shield Replacement .
  69. Disconnect the engine harness electrical connector from the heated oxygen sensor (HO2S).
    70. Fig 31: Identifying Transaxle To Engine Brace Bolts
    GM1662583Courtesy of GENERAL MOTORS CORP.
  70. Remove the transaxle brace bolts.
  71. Remove the transaxle brace.
    72. Fig 32: View Of Torque Converter Cover
    GM1662586Courtesy of GENERAL MOTORS CORP.
  72. Remove the torque converter cover bolt.
  73. Remove the torque converter cover.
    74. Fig 33: Identifying Flywheel-To-Torque Converter Bolts
    GM1665177Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Mark the flywheel to torque converter relationship prior to removal of the bolts.
  74. Remove the flywheel to torque converter bolts. (Engine removed for clarity).
    75. Fig 34: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  75. Position the J 39580  under the frame.
  76. Lower the vehicle onto the J 39580  .
    77. Fig 35: Locating Jackstands Under Engine Frame
    GM333761Courtesy of GENERAL MOTORS CORP.
  77. If the J 39580  is not available. Support the powertrain with four suitable jackstands.
  78. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.
    79. CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
  79. Secure the front hoist pads to the vehicle.
  80. Remove the front fascia. Refer to Front Bumper Fascia Replacement .
    81. Fig 36: Identifying Rearward Engine Frame-To-Body Bolts
    GM1665303Courtesy of GENERAL MOTORS CORP.
  81. Remove the 6 bolts (1) attaching the frame to the body. (Left side shown, right side similar).
    82. IMPORTANT: Ensure clearance is maintained between the engine/transaxle assembly and the following:
    • The A/C compressor components
    • The brake pipes
    • The heater hoses
    • The radiator hoses
    • The wheel speed sensor leads
    • The wiring harnesses
  82. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
  83. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
    84. Fig 37: Identifying Heater Outlet Pipe
    GM1665330Courtesy of GENERAL MOTORS CORP.
  84. Remove the heater outlet pipe nut (2) from the transaxle stud.
  85. Reposition the heater outlet pipe clamp (1) at the water pump housing.
  86. Remove the heater outlet pipe.
    87. Fig 38: Identifying Secondary AIR Pump Inlet Tube/Hose
    GM1665331Courtesy of GENERAL MOTORS CORP.
  87. Remove the secondary air injection (AIR) inlet hose retainer from the transaxle stud.
  88. Disconnect the AIR inlet hose quick connect fitting from the AIR pump. Refer to Plastic Collar Quick Connect Fitting Service .
  89. Remove the AIR inlet hose.
    90. Fig 39: View Of AIR Outlet Hose
    GM1665332Courtesy of GENERAL MOTORS CORP.
  90. Reposition the AIR outlet hose clamp at the AIR outlet pipe.
  91. Separate the AIR outlet hose from the outlet pipe.
    92. Fig 40: View Of AIR Pipe Outlet Pipe
    GM1665399Courtesy of GENERAL MOTORS CORP.
  92. Remove the AIR pipe outlet pipe nut (3) from the transaxle stud.
  93. Remove the AIR pipe outlet pipe nut (2) from the check valve bracket stud.
  94. Disconnect the AIR outlet pipe quick connect fitting from the check valve. Refer to Plastic Collar Quick Connect Fitting Service .
  95. Remove the AIR outlet pipe from the studs.
    96. Fig 41: Locating ICM Ground Strap & Bolt
    GM1662923Courtesy of GENERAL MOTORS CORP.
  96. Remove the ignition control module (ICM) ground strap bolt (3) from the right cylinder head.
  97. Remove the ICM ground strap (2) from the cylinder head.
    98. Fig 42: Locating Engine Harness Electrical Connectors
    GM1662118Courtesy of GENERAL MOTORS CORP.
  98. Disconnect the following engine harness electrical connectors from the rear of the engine:
    • The EVAP solenoid (1)
    • The exhaust gas recirculation (EGR) valve (2)
    • The fuel injectors (3)
    • The ICM (4)
    99. Fig 43: Identifying Engine Harness Electrical Connectors
    GM1662120Courtesy of GENERAL MOTORS CORP.
  99. Disconnect the following engine harness electrical connectors from the front of the engine:
    • The fuel injectors (1)
    • The ICM (3)
    • The manifold absolute pressure (MAP) sensor (4)
    • the throttle actuator (5)
  100. Remove the engine harness clip (2) from the fuel rail stud.
    101. Fig 44: Identifying Engine Harness Electrical Connectors
    GM1665457Courtesy of GENERAL MOTORS CORP.
  101. Disconnect the following engine harness electrical connectors from the top of the engine:
    • The starter inline (1)
    • The AIR check valve (4)
    102. Fig 45: View Of Engine Harness Electrical Connectors
    GM1665460Courtesy of GENERAL MOTORS CORP.
  102. Disconnect the engine harness electrical connector (1) from the engine valley jumper harness electrical connector.
    103. Fig 46: Locating Engine Harness Electrical Connectors
    GM1663209Courtesy of GENERAL MOTORS CORP.
  103. Disconnect the engine harness electrical connector (3) from the power steering sensor.
  104. Remove the engine harness clip (2) from the steering gear shield.
  105. Remove the engine harness ground nut (4).
  106. Remove the engine harness ground (5).
  107. Disconnect the engine harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
    108. Fig 47: Disconnecting/Connecting Engine Harness Clip At Steering Gear Heat Shield
    GM1665450Courtesy of GENERAL MOTORS CORP.
  108. Disconnect the engine harness electrical connector (1) from the vehicle speed sensor (VSS).
  109. Remove the engine harness clips (2, 3) from the rear engine mount bracket and steering gear shield.
    110. Fig 48: View Of Engine Harness Electrical Connector
    GM1665105Courtesy of GENERAL MOTORS CORP.
  110. Disconnect the engine harness electrical connector from the A/C pressure sensor.
    111. Fig 49: View Of Engine Harness Electrical Connectors
    GM1663951Courtesy of GENERAL MOTORS CORP.
  111. Remove the engine harness clip (1) from the boss on the engine block.
  112. Disconnect the following engine harness electrical connectors:
    • The oil pressure sensor (2)
    • The oil level sensor (3)
    • The A/C compressor (4)
    • The generator (5)
    113. Fig 50: Locating Engine Harness Electrical Connectors
    GM1665453Courtesy of GENERAL MOTORS CORP.
  113. Disconnect the engine harness electrical connectors from the following:
    • The AIR pump (1)
    • The brake modulator (2)
    114. Fig 51: View Of Engine Harness Electrical Connector & Clips
    GM1665455Courtesy of GENERAL MOTORS CORP.
  114. Remove the engine harness clip (1) from the engine bracket.
  115. Remove the connector position assurance (CPA) retainer.
  116. Disconnect the engine harness electrical connector (3) from the HO2S.
    117. Fig 52: View Of Engine Harness Electrical Connectors
    GM1665451Courtesy of GENERAL MOTORS CORP.
  117. Disconnect the engine harness electrical connector from the transaxle.
  118. Remove the engine harness ground bolts (2, 4, and 6).
  119. Gather all the branches of the engine harness and remove the engine harness from the engine.
    120. Fig 53: Identifying Power Steering Outlet Hose
    GM1665464Courtesy of GENERAL MOTORS CORP.
  120. Reposition the power steering outlet hose clamp at the pump reservoir.
  121. Remove the power steering outlet hose from the reservoir.
  122. Remove the power steering outlet pipe bolt from the engine mount strut bracket.
    123. Fig 54: Identifying Power Steering Inlet Pipe
    GM1665461Courtesy of GENERAL MOTORS CORP.
  123. Remove the power steering inlet pipe fitting from the power steering pump.
  124. Remove the power steering inlet pipe nut (1) from the rear engine mount bracket stud.
  125. Remove the power steering inlet pipe bracket from the stud.
    126. Fig 55: View Of A/C Compressor Discharge Hose
    GM1665087Courtesy of GENERAL MOTORS CORP.
  126. Remove the A/C compressor discharge hose nut at the compressor.
  127. Unsecure the hose from the engine and remove the A/C compressor discharge hose.
  128. Plug the A/C compressor discharge port.
    129. Fig 56: View Of A/C Compressor Suction Hose
    GM1665090Courtesy of GENERAL MOTORS CORP.
  129. Remove the A/C compressor suction hose nut at the compressor.
  130. Unsecure the hose from the engine and remove the A/C compressor suction hose.
  131. Plug the A/C compressor suction port.
    132. Fig 57: Identifying Engine Lift Bracket
    GM1660883Courtesy of GENERAL MOTORS CORP.
  132. Remove the transaxle brace bolt.
  133. Remove the transaxle brace nuts.
  134. Remove the transaxle brace.
    135. Fig 58: Identifying Transaxle Brace Bolt/Stud
    GM1665473Courtesy of GENERAL MOTORS CORP.
  135. Remove the transaxle brace bolt/stud to the transaxle.
    136. Fig 59: Identifying Transaxle Brace Bolts & Bolts
    GM1665474Courtesy of GENERAL MOTORS CORP.
  136. Remove the transaxle brace bolts to the engine.
  137. Remove the transaxle brace.
    138. Fig 60: View Of Lower Engine Mount Bracket-To-Engine Stud Nuts
    GM1660847Courtesy of GENERAL MOTORS CORP.
  138. Loosen the front engine mount bracket nut with the transaxle brace behind it.
    139. Fig 61: View Of Transaxle Brace & Bolt
    GM1660864Courtesy of GENERAL MOTORS CORP.
  139. Remove the transaxle brace bolt.
  140. Remove the transaxle brace.
    141. Fig 62: View Of Right Engine Mount To Frame Nut
    GM1665467Courtesy of GENERAL MOTORS CORP.
  141. Install an engine lift chain to the engine lift brackets and attach an engine lifting device.
  142. Remove the rear engine mount to frame nut.
    143. Fig 63: Identifying Right Engine Mount Bracket
    GM1660851Courtesy of GENERAL MOTORS CORP.
  143. Remove the rear engine mount bracket bolts and stud.
  144. Remove the rear engine mount bracket.
    145. Fig 64: Identifying Engine Mount To Frame Nut
    GM1665465Courtesy of GENERAL MOTORS CORP.
  145. Remove the front engine mount to frame nut.
    146. Fig 65: Identifying Rear Transaxle Bolt
    GM1665472Courtesy of GENERAL MOTORS CORP.
  146. Remove the rear transaxle bolt.
    147. Fig 66: Identifying Upper Transaxle Bolts
    GM1665471Courtesy of GENERAL MOTORS CORP.
  147. Remove the upper transaxle bolts.
  148. Separate the engine from the transaxle.
  149. Raise the engine from the supported frame and transaxle assembly.
    150. Fig 67: Identifying Front Engine Mount Bracket Bolts/Nuts
    GM1660849Courtesy of GENERAL MOTORS CORP.
  150. Remove the front engine mount bracket bolts/nuts.
  151. Remove the front engine mount bracket.
  152. Install the engine assembly to a suitable engine stand.
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