Chevy And GM Engine Removal?

The details for replacing Engine.

Covers All U.S. And Canadian Models Of Chevrolet Avalanche, Chevrolet Express Van, and GM Savana car models.

In this chapter the details are there for following Engine model removal:----

• 4.3L Engine. 
• 4.8L, 5.3L & 6.0L Engines.

View all the engine removal part mentioned for your help.

The details are as follows :-----

Removal & Installation

4.3L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Hood

   Air cleaner

   Accessory drive belt

   Fan

   Water pump pulley

   Radiator and shroud

   Heater hoses at the engine

   Accelerator, cruise control and detent linkage if used

   Air conditioning compressor, if used, and lay aside

   Power steering pump, if used, and lay aside

   Wiring from the engine

   Fuel line

   Vacuum lines from the intake manifold

   Exhaust pipes from the manifold

   Strut rods at the engine mountings, if used

   Flywheel or torque converter cover

   Wiring along the oil pan rail

   Starter

   Wire for the fuel gauge

   Converter-to-flex plate bolts, if equipped with automatic transmission
5. Support the transmission 
   
   
   
   Fig. Transmission mounting bolts-4.3L engines
   
   
   
   Bell housing to engine bolts

   Rear engine mounting to frame bolts and the front through bolts and the engine

To install:

1. Lower the engine.
2. Install or connect the following:
   
   
   Engine mounting bolts. Torque the rear engine mounting to frame bolts or nuts to 45 ft. lbs. (54 Nm), the front through-bolts to 70 ft. lbs. (97 Nm) and the front nuts to 50 ft. lbs. (67 Nm).

   Bell housing to engine bolts and torque to 35 ft. lbs. (47 Nm)
3. Remove the transmission support.
   
   
   Converter-to-flex plate bolts and tighten to 35 ft. lbs. (47 Nm)

   Fuel gauge wiring

   Starter

   Flywheel or torque converter cover

   Strut rods at the engine mountings, if used

   Exhaust pipes at the manifold

   Vacuum lines to the intake manifold

   Fuel line

   Engine wiring harness

   Power steering pump, if used

   Air conditioning compressor, if used

   Accelerator, cruise control and detent linkage

   Heater hoses

   Radiator and shroud

   Accessory drive belts

   Hood

   Negative battery cable
4. Refill coolant and engine oil.

4.8L, 5.3L & 6.0L Engines

CAUTION

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove the engine cover.
3. Disconnect the negative battery cable.
4. Recover the HVAC refrigerant.
5. Drain the cooling system.
6. Remove the sheet metal to radiator support bolts and supports from the vehicle.
7. Remove the air cleaner assembly.
8. Remove the coolant reservoir.
9. Remove the right and left headlamp capsules.
10. Remove the front bumper.
11. Remove the radiator inlet hose from the water pump.
12. Remove the radiator outlet hose from the water pump.
13. Disconnect the transmission cooler lines from the radiator.
14. Disconnect the oil cooler line from the radiator, if equipped.
15. Disconnect and cap the HVAC lines from the condenser.
16. Disconnect the ground connection from the right hand inner fender and connector C4 at the underhood fuse block.
17. Disconnect the positive battery cable from the underhood fuse block and position aside.
18. Remove the core support retaining bolt .
19. With the aid of an assistant, remove the core support assembly with the radiator, condenser radiator hoses and fan shroud intact.
20. Remove the clutch fan.
21. Remove the accessory drive belt.
22. Remove the air bleed hose from the throttle body.
23. Remove the generator bracket from the engine. Leave the generator and power steering pump retained to the bracket. Use a suitable strap and position the bracket assembly aside.
24. Remove the radiator vent inlet hose from the throttle body.
25. Remove the ground straps from the frame and engine.
26. Remove the air conditioning compressor.
27. Disconnect the heater hoses from the water pump.
28. Remove the intake manifold.
29. Remove the ignition coils from the engine.
30. Remove the coolant air bleed pipe from the engine.
31. Raise and safely support the vehicle.
32. Remove the oil drain plug and drain the oil into a suitable container.
33. Remove the starter motor.
34. Disconnect the catalytic converter pipe from the exhaust manifolds.
35. Unplug the Crankshaft Position (CKP) sensor, engine oil level sensor, and the coolant heater, if equipped.
36. Remove the battery cable channel bolt.
37. Slide the channel pin out of the oil pan tab.
38. Gather all branches of the engine wiring harness and reposition off to the side.
39. Remove the lower 6 bell housing to engine studs and bolts. Leave the top 2 studs in place.
40. Remove the torque converter bolts.
41. Lower the vehicle.
42. Remove the left and right exhaust manifolds.
43. Install tool J42451-1 or similar lifting eye to the cylinder heads. Tighten the M10 engine lift bracket bolts to 37 ft. lbs. (50 Nm).
44. Remove the left and right engine mount-to-engine mount bracket bolts.
45. Remove the transmission oil level indicator tube nut.
46. Remove the transmission oil level indicator tube.
47. Remove the top 2 automatic transmission studs.
48. Position a floor jack under the transmission for support.
49. Install an engine hoist to the J 42451-1 lifting eyes.
50. Separate the engine from the automatic transmission, if equipped.
51. Install tool J 21366 to the transmission in order to hold the torque converter. 
    
    
    
    Fig. Transmission mounting bolts-4.8L, 5.3L and 6.0L engines
    
    
    
    
    Fig. Engine mounting bolts-4.8L, 5.3L and 6.0L engines
52. Remove the engine.

To install:

1. Installation is the reverse of removal. Note the following and observe the following torque specifications:
   
   
   Engine mount-to-engine mount bracket bolts to 48 ft. lbs. (65 Nm)

   If equipped with the 4L60-E, tighten the torque converter bolts to 37 ft. lbs. (63 Nm). If equipped with the 4L80-E, tighten the torque converter bolts to 44 ft. lbs. (60 Nm)

   If equipped with the 4L80-E automatic transmission, tighten the transmission converter cover bolts to 24 ft. lbs. (33 Nm)

   Tighten the automatic transmission bolts/studs to 37 ft. lbs. (50 Nm)

   Tighten the core support bolts to 18 ft. lbs. (25 Nm). Tighten the support nuts to 42 ft. lbs. (57 Nm)
2. Fill the engine to the proper level with oil and coolant.
3. Perform the CKP system variation learn procedure using a scan tool.
4. Check for and correct any leaks. Recharge the A/C system if equipped.

CAUTION

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

1. Remove or disconnect the following:
   
   
   Negative battery cable

   Coolant

   A/C refrigerant
2. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
   
   CAUTION

   In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.
   
   
   
   
   Upper and the lower radiator hoses from the engine

   Air cleaner duct from the engine

   A/C condenser mounting bolts

   Radiator support from the vehicle

   A/C compressor

   Coolant hose from the throttle body

   Heater hoses from the engine and the cowl

   Engine sight shield from the intake manifold

   Accelerator control cable mounting bracket from the intake manifold
   
   
   
   
   Accelerator control cable and the cruise control cable, if equipped, from the throttle shaft
3. Open the large electrical harness retainer. Remove one 10 mm nut in order to release the engine harness from the intake manifold.
4. Disconnect the electrical connectors from the following: 
   
   
   Eight injectors

   Idle Air Control (IAC) motor

   Throttle Position (TP) sensor

   Evaporative Emissions (EVAP) canister purge solenoid

   Manifold Absolute Pressure (MAP) sensor

   Camshaft Position (CMP) sensor 
   
   
   

   Fig. Ignition coil removal-2005-06 Avalanche 5.3L
   
   
   
   
   Ground splice at the rear of the right side of the block

   Ground splice and the ground strap at the rear of the left side of the block

   Coolant Temperature (CTS) sensor

   Oil pressure sensor/switch

   Electrical connector from intake and disconnect from harness

   Junction block bracket from alternator bracket
   
   

   

   

   Fig. Power steering pump removal-2005-06 Avalanche 5.3L
5. Set the electrical harness aside.
6. Remove or disconnect the following:
   
   
   EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid

   Battery negative cable from the engine block

   Drive belt

   Bolts holding the alternator mounting bracket to the cylinder head and block

   Bolt behind the power steering pump to engine block
   
   

   

   

   Fig. Power steering mount bracket removal-2005-06 Avalanche 5.3L
   
   
   
   
   Alternator mounting bracket. Position the bracket aside.

   Fuel pipes from the engine
7. Raise the vehicle.
   
   
   Steering linkage under body shield, if equipped

   Engine oil pan under body shield, if equipped

   Engine oil

   Starter motor
   
   

   

   

   Fig. Bell housing bolt removal-2005-06 Avalanche 5.3L
8. Disconnect the engine wiring harness from the following components:
   
   
   Crankshaft Position (CKP) sensor

   Engine oil level sensor

   Block heater, if equipped

   Oil pan wiring harness
9. Reposition wiring from the lower engine area.
   
   
   Exhaust pipes from the exhaust manifolds

   Transmission cooler pipe retainer from the right side of the engine block, if equipped

   Torque converter shield from the engine

   Torque converter bolts

   Nut and the transmission oil level indicator tube from the bell housing stud

   Lower bell housing studs from the engine
10. Lower the vehicle.
    
    
    Remaining bell housing bolts

    Engine electrical harness aside

    Ignition coil(s)
11. Install an engine crane.
12. Install a floor jack or stands to transmission for support.
13. Remove the engine mount bolts.
    
    NOTE

    Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.
14. Remove the engine from the vehicle.
    
    
    

    

    Fig. Engine mount disconnect-2005-06 Avalanche 5.3L

To install:

1. Install or connect the following:
   
   
   Engine to the vehicle

   Engine mount bolts

   Upper bell housing bolts
2. Remove transmission support apparatus.
3. Remove the lifting device.
4. Remove the lift brackets from both cylinder heads.
5. Install the ignition coil(s) and the spark plug wire(s).
6. Route the engine wiring harness to the lower right hand side of the engine.
7. Raise the vehicle.
8. Install or connect the following:
   
   
   Remaining bell housing bolts

   Torque converter bolts

   Torque converter shield

   Transmission oil level indicator tube and nut to bell housing stud

   A/C compressor

   Transmission cooler pipe retainer to right side of engine block

   Engine exhaust pipes to the exhaust manifolds
9. Reroute wiring to lower engine area and install bolt to oil pan.
10. Connect electrical connectors to the CKP sensor, the engine oil level sensor and the block heater, if equipped.
11. Install or connect the following:
    
    
    Starter motor

    Engine oil pan under body shield, if equipped

    Steering linkage under body shield
12. Lower the vehicle.
    
    
    Fuel pipes to the engine

    Alternator mounting bracket to the cylinder head using the nuts and the bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).

    Bolt at the rear of the power steering pump to the engine block and tighten to 37 ft. lbs. (50 Nm)

    Alternator

    Drive belt

    Battery negative cable to the engine block

    EVAP canister purge solenoid to the intake manifold
13. Route the engine harness over the top of the engine. Attach the connectors for following components:
    
    
    Eight injectors

    IAC motor

    TP sensor

    EVAP canister purge solenoid.

    MAP sensor

    CMP sensor

    Ground splice at the rear of the right side of engine block

    Ground splice and the ground strap at the rear of the left side of engine block

    CTS sensor
14. Install or connect the following:
    
    CAUTION

    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.
    
    
    
    
    Nut to the engine wiring harness bracket and tighten to 89 inch lbs. (10 Nm)
    
    
    
    
    NEW accelerator control cable

    Cruise control cable, if equipped, to the throttle shaft

    Bolts for the accelerator control cable mounting bracket and tighten to 89 inch lbs. (10 Nm)

    Engine sight shield to the intake manifold

    Heater hoses to the cowl and the engine

    Coolant hose to the throttle body

    Radiator support in the vehicle

    A/C condenser mounting bolts

    Air cleaner duct

    Lower radiator hoses to the engine
15. Lower the hood.
16. Fill the engine with oil.
17. Fill the engine with coolant.
18. Connect the negative battery cable.

CAUTION

Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

1. Remove or disconnect the following:
   
   
   Negative battery cable

   Coolant

   Engine oil

   A/C refrigerant
2. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
   
   
   Hood latch and radiator support

   Intake manifold

   Upper and the lower radiator hoses from the engine

   Heater hoses from the engine and the cowl

   Harness connectors from the oil pressure sensor and lifter oil manifold

   Ground strap from the left cylinder head

   Negative battery cable and harness ground from the right cylinder head
3. Raise and safely support the vehicle.
   
   
   Harness grounds and clips from the engine block

   Transmission oil cooler line clip bolt form the oil pan

   Starter

   Harness connectors for the knock sensors, CMP sensor, A/C pressure sensor, CKP sensor and oil level sensor

   Block heater connector, if equipped
4. Lower the vehicle.
   
   
   Power steering pump engine block bolt

   Alternator bracket assembly and set aside with the power steering pump

   Ignition coils to allow attachment of the engine lift brackets

   Transmission dipstick tube nut and tube
5. Install engine lift brackets J41798 or equivalent. Tighten the M8 bolts to 18 ft. lbs. (25 Nm) and the M10 bolts to 37 ft. lbs. (50 Nm).
   
   
   Engine mount bolts
6. Raise and safely support the vehicle.
   
   
   Engine shield or skid plate

   Exhaust pipes from the exhaust manifolds and catalytic converters

   Torque converter bolts

   Transmission mounting bolts
7. Lower the vehicle.
8. Install an engine crane.
9. Install a floor jack or stands to transmission for support.
10. Remove the engine from the vehicle.

To install:

1. Position the engine in the vehicle. Make sure the engine is properly aligned and mated with the transmission, then remove the crane.
2. Install the engine mount bolts; start with the middle bolt then the outer bolts. Tighten to 48 ft. lbs. (65 Nm).
3. Install the transmission bolts. Tighten to 37 ft. lbs. (50 Nm).
4. Align the torque converter bolt holes and install the bolts. Tighten to 47 ft. lbs. (63 Nm) except on 4L80E transmissions. On the 4L80E, tighten the bolts to 44 ft. lbs. (60 Nm).
5. The remaining installation is the reverse of removal.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html