Engine Removal - 4-cyl Chevrolet Cab & Chassis C20

1.9L

1. Open hood, mark position of hood hinges and remove hood. Disconnect negative battery cable and raise vehicle. Remove rear transmission mount nuts. Support transmission and remove crossmember at frame. Remove top transmission bolts and reinstall crossmember. Remove transmission support.
2. Remove engine-to-transmission bolts. Remove torque converter cover. Disconnect exhaust at manifold. Disconnect starter leads and remove motor mount bolts. Disconnect fuel lines and automatic transmission cooler lines. Lower vehicle and drain coolant.
3. Disconnect necessary wires and hoses from alternator, carburetor and other accessories. If equipped, remove power steering pump and A/C compressor and lay aside.
4. Loosen alternator and disconnect front heater hose. Remove upper fan shroud, radiator and heater hoses, fan assembly and transmission oil cooler lines. Remove radiator assembly.
5. Disconnect accelerator cable, spring and detent cable from carburetor. Using floor jack, support transmission. Install lifting device and remove engine from vehicle.

Astro & Safari Models

1. Disconnect negative battery cable. Drain cooling system. Remove engine cover. Remove headlight bezel and grille. Remove radiator lower close-out panel. Remove radiator support brace. Remove lower tie bar and cross brace. Remove hood latch mechanism.
2. Remove upper core support. Remove upper and lower radiator hoses. Remove radiator filler panels. Remove radiator and fan shroud as an assembly. Disconnect engine wiring harness at bulkhead connector. Disconnect wiring harness at ECM and pull through bulkhead.
3. Disconnect heater hoses at heater core. Remove accelerator cable. Disconnect ground cable at cylinder head. Disconnect canister purge hose. Remove air cleaner. Raise vehicle. Disconnect exhaust pipe at manifold. Disconnect wiring harness at transmission and frame.
4. Disconnect and remove starter. Remove flywheel inspection cover. Disconnect and plug fuel lines. Remove motor mount through bolts. Remove bellhousing bolts. Lower vehicle. Remove oil filler neck. Remove thermostat outlet. Install engine lifting device. Support transmission. Remove engine.

2WD Models

1. Disconnect negative battery cable. Remove hood. Disconnect power steering reservoir at fan shroud. Remove upper fan shroud and fan. Drain cooling system. Remove upper and lower radiator hoses. Remove radiator overflow hose. Disconnect transmission oil cooler lines at radiator.
2. Remove radiator. Remove A/C compressor and power steering pump and set aside. Remove air cleaner. Disconnect fuel line bracket at filter. Disconnect and plug fuel lines. Label and disconnect all vacuum hoses. Disconnect accelerator, cruise control and throttle valve cables. Remove heater hoses.
3. Disconnect O2 sensor wire. Label and disconnect all electrical connectors on engine. Raise vehicle. Remove strut rods. Disconnect exhaust pipe at exhaust manifold. Remove flywheel cover. Remove drive belt splash shield, if equipped. Remove starter. Remove flex plate-to-converter bolts.
4. Remove 2 outer air dam bolts (left side). Remove lower fan shroud. Remove left side body mounting bolts. Install jack stands. Raise left side of body and support with block of wood. Remove upper transmission mounting bolts. Lower body.
5. Remove remaining transmission mounting bolts. Remove motor mount through bolts. Lower vehicle. Support transmission. Lift engine and remove ground wire and wire loom bracket at rear of cylinder head. Remove engine.

4WD Models

1. Disconnect negative battery cable. Remove hood. Disconnect power steering reservoir at fan shroud. Remove upper fan shroud and fan. Drain cooling system. Remove upper and lower radiator hoses. Remove radiator overflow hose. Disconnect transmission oil cooler lines at radiator.
2. Remove radiator. Remove A/C compressor and power steering pump and set aside. Remove air cleaner. Disconnect fuel line bracket at filter. Disconnect and plug fuel lines. Label and disconnect all vacuum hoses. Disconnect accelerator, cruise control and throttle valve cables. Remove heater hoses.
3. Disconnect O2 sensor wire. Label and disconnect all electrical connectors on engine. Raise vehicle. Remove clips holding brake line to crossmember. Remove crossmember. Disconnect transmission cooler lines at flywheel cover. Disconnect drive shaft at front axle.
4. Disconnect exhaust pipe at exhaust manifold. Remove flywheel cover. Remove drive belt splash shield, if equipped. Remove starter. Remove flex plate-to-converter bolts.
5. Remove 2 outer air dam bolts (left side). Remove lower fan shroud. Remove left side body mounting bolts. Install jack stands. Raise left side of body and support with block of wood. Remove upper transmission mounting bolts. Lower body.
6. Remove remaining transmission mounting bolts. Remove motor mount through bolts. Lower vehicle. Support transmission. Lift engine and remove ground wire and wire loom bracket at rear of cylinder head. Remove engine.

2.2L DIESEL

1. Disconnect battery. Disconnect exhaust pipe at manifold. Remove radiator hoses and drain cooling system. Remove power steering reservoir and upper fan shroud. Remove radiator and fan. Remove lower fan shroud.
2. Disconnect heater hoses at engine. Disconnect PCV at valve cover and remove air cleaner. Discharge A/C system and disconnect hoses from A/C compressor. Remove power steering pump from bracket and place aside with hoses connected. Disconnect accelerator cable.
3. Disconnect all wiring, vacuum hoses, and fuel lines at engine. Remove rear air cleaner bracket. Remove starter. Remove hood. Remove shifter boot and shifter. Raise vehicle. Remove right motor mount through bolt. Disconnect lower clutch cable. Disconnect clutch bellcrank at frame.
4. Disconnect back-up light wiring and speedometer cable at transmission. Remove drive shaft. Remove transmission mount nut and support transmission. Remove crossmember and transmission-to-bellhousing bolts. Remove transmission. Remove bellhousing.
5. Lower vehicle. Disconnect upper clutch cable and remove bellcrank. Attach lifting equipment to engine. Remove left motor mount through bolt. Disconnect battery ground at block. Raise engine and remove from vehicle.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS