Engine Removal - Pickup & Van Chevrolet Chevy Van G10

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

Removal & Installation ("C" & "K" SERIES)

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Disconnect battery. Remove underhood light (if equipped) and hood. Remove air cleaner and accessory drive belt. Drain cooling system. Remove fan and water pump pulley.
3. Remove radiator shroud and radiator. Disconnect heater hoses at engine. Disconnect accelerator and cruise control cables and linkage. Remove A/C compressor and power steering pump (if equipped) and position out of way.
4. Disconnect engine wiring harness from engine. Disconnect vacuum and fuel lines. Raise vehicle. Drain engine oil. Disconnect exhaust pipes from manifolds. Disconnect strut rods (if equipped) at engine mounts. Remove flywheel or torque converter cover.
5. Disconnect wiring along oil pan rail and wiring for fuel gauge. Remove starter. Remove converter-to-flexplate bolts (if equipped). Lower vehicle. Support transmission and attach engine hoist to engine. Remove bellhousing-to-engine bolts. Remove engine mount-to-frame bolts. Remove engine from vehicle.
6. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

Removal & Installation ("G" & "P" Series)

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Remove glove box and engine cover. Disconnect battery and drain cooling system. Remove outside air duct and air cleaner. Remove power steering reservoir, hood release cable and upper fan shroud bolts. Disconnect overflow hoses. Disconnect transmission oil cooler lines at radiator.
3. Remove upper fan shroud, fan and pulley. Remove heater hoses, radiator hoses and radiator. Remove cruise control servo and brake booster vacuum hose at TBI unit. Disconnect accelerator and throttle valve cables. Disconnect fuel line and vacuum hoses at TBI unit.
4. Remove TBI unit and distributor cap. Disconnect air injection hoses at diverter valve. Remove diverter valve. Disconnect PCV valve. Label and disconnect remaining vacuum hoses. Label and disconnect engine electrical harness. Discharge A/C system.
5. Remove A/C compressor brace and compressor. Remove upper half of oil dipstick tube. Remove oil filler tube and transmission dipstick tube. Disconnect and plug fuel lines at fuel pump. Remove power steering pump.
6. Remove headlight bezels and grille. Remove upper radiator support, lower filler panel and hood latch support. Disconnect A/C lines at condenser. Remove condenser. Raise vehicle. Drain engine oil. Disconnect exhaust pipe at exhaust manifolds.
7. Disconnect strut rods at flywheel inspection cover. Remove flywheel inspection cover, starter and torque converter mounting bolts (if equipped). Remove motor mount through bolts and bellhousing bolts. Lower vehicle. Support transmission. Install lift equipment and remove engine.
8. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

5.0L & 5.7L V8 ENGINES

Note. "P" Series information not available from manufacturer.

Removal & Installation ("C", "K", "R" & "V" Series)

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Disconnect battery cables and drain cooling system. Remove hood, air cleaner, accessory drive belts, fan and water pump pulley. Disconnect all hoses, lines, linkage and wiring from engine.
3. On A/C equipped models, remove compressor and set aside. Disconnect transmission oil cooler lines (if equipped). Remove radiator with shroud. Remove power steering pump (if equipped). Disconnect fuel lines. Raise vehicle and drain crankcase.
4. On 4WD models with automatic transmission, remove strut rods at motor mounts. Disconnect exhaust pipes from exhaust manifold. Remove converter inspection cover and converter-to-flexplate attaching bolts.
5. Remove starter and wiring along right pan rail. Support transmission and remove bellhousing-to-engine bolts. Remove lower engine mount bracket frame bolts. Lower vehicle and attach lift equipment. Remove engine.
6. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

Removal & Installation ("G" Series)

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Disconnect battery cables and drain cooling system. Remove engine cover, air cleaner and air stove pipe. Remove coolant reservoir, grille, upper radiator support and lower grille valance. Disconnect automatic transmission cooler lines (if equipped) and radiator hoses.
3. On A/C equipped models, discharge system and remove condenser. Remove radiator brackets, radiator and shroud. Remove power steering pump and set aside (if equipped).
4. Disconnect wiring from firewall connection. Disconnect vacuum lines and wiring as necessary. Disconnect accelerator cable and remove TBI unit. Remove thermostat housing, oil filler tube and disconnect heater hoses. Remove cruise control servo, transducer, and bracket (if equipped).
5. Raise vehicle. Disconnect exhaust pipe at manifold. Remove drive shaft and plug extension housing. Disconnect shift linkage and speedometer cable. Disconnect fuel and vapor hoses from engine. Remove transmission mount bolts and engine mount bracket-to-frame bolts.
6. Drain crankcase. Raise engine slightly and remove engine mounts. Block engine up with wooden blocks. Lower vehicle and attach lift equipment. Remove engine and transmission as an assembly. NOTE: When raising or supporting engine, DO NOT use jack under oil pan, crankshaft pulley or any sheet metal. Oil pan can bend against oil pump pickup and damage unit.
7. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

6.2L DIESEL V8 ENGINES

Note. "P" Series Information not available from manufacturer.

1. Disconnect batteries. Raise vehicle. Remove inspection cover. Disconnect torque converter (if equipped) and exhaust pipe. Remove starter, bellhousing bolts and motor mount bolts. Remove wire harness, automatic transmission cooler lines and front battery cable clamp at oil pan.
2. Disconnect block heaters. Disconnect fuel return and oil cooler lines at engine. Remove lower fan shroud bolts. Lower vehicle. Remove hood and drain cooling system. Remove air cleaner with resonator and primary filter from cowl. Remove wire harness from clips at valve covers and disconnect glow plugs.
3. Disconnect ground cable at alternator bracket, alternator wires and clips. Disconnect TPS, EGR/EPR and fuel cut-off at injection pump. Disconnect EGR/EPR solenoids, glow plug controller, temperature sender and move harness aside. Disconnect left side ground strap.
4. Remove fan, upper radiator hoses at engine, and fan shroud. Remove power steering pump and belt. Remove power steering reservoir and position aside. Disconnect vacuum hose at cruise servo and accelerator cable at injection pump.
5. Disconnect heater hose and lower radiator hose at engine. Disconnect oil cooler lines, heater hose and overflow at radiator. Disconnect automatic transmission cooler lines. Remove detent cable, upper radiator cover and radiator. Support transmission and remove engine.
6. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

1. Disconnect batteries. Remove headlight bezels, grille, bumper and lower grille valance. Remove hood latch, coolant recovery bottle, upper fan shroud and tie bar. Remove engine cover. On A/C equipped models, discharge system, disconnect A/C condenser lines and remove condenser.
2. Drain cooling system and remove radiator hoses at radiator. Disconnect engine oil and automatic transmission cooler lines. Remove radiator and fan assembly. Remove intake manifold. See INTAKE MANIFOLD in 6.2L DIESEL ENGINE article. Scribe mark on front cover at injection pump flange and remove fuel injection pump.
3. Raise vehicle. Disconnect exhaust pipe at manifold. Remove inspection cover, flexplate-to-converter bolts (if equipped), and motor mount through bolts. Disconnect block heater and ground wire at element. Remove starter and bellhousing-to-engine bolts.
4. Lower vehicle. Remove cruise control transducer (if equipped). On A/C equipped models, disconnect lines at compressor. Remove brackets and compressor. Remove power steering pump and set aside (if equipped). Remove oil filler tube upper bracket and glow plug relay. Disconnect oil pressure sender.
5. Remove air cleaner resonator with bracket. Remove transmission filler tube and position out of way. Disconnect heater, radiator and by-pass hoses at crossover/thermostat assembly. Remove alternator upper bracket and coolant crossover. Disconnect fuel lines at fuel pump. Attach lift equipment and remove engine.
6. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

Removal & Installation ("C", "K", "P", "R" & "V" Series)

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. On Throttle Body Injected (TBI) engines, although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Remove hood and air cleaner. Disconnect battery and drain cooling system. Disconnect radiator and heater hoses. Remove radiator and fan shroud. Disconnect all hoses, fuel lines, linkage and wiring from engine.
3. Without disconnecting lines, remove power steering pump and A/C compressor (if equipped) and support out of the way. Raise vehicle. Drain crankcase and separate exhaust pipe from manifold. Remove starter and torque converter bracket at transmission rear mount.
4. Remove bellhousing cover and flexplate-to-converter attaching bolts. Remove motor mount through bolts and bellhousing-to-engine bolts. Lower vehicle. Using floor jack, raise transmission. Attach lift equipment and raise engine. Remove motor mount-to-engine brackets. Remove engine.
5. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

1. Place transmission gear selector in Park (Neutral on manual transmissions). Set parking brake and block drive wheels. Although fuel pressure drops to zero when ignition is turned off, loosen fuel filler cap to relieve tank pressure. To further minimize risk of fire and personal injury, cover surrounding areas with a shop rag while removing fuel lines. WARNING: To avoid possible personal injury and fire danger, fuel pressure must be relieved as outlined in step 1).
2. Disconnect battery ground cables and drain cooling system. Remove engine cover, air cleaner and air stove pipe. Remove coolant reservoir, grille, upper radiator support and lower grille valance. Disconnect automatic transmission cooler lines (if equipped) and radiator hoses.
3. On A/C equipped models, discharge system and remove condenser. Remove radiator brackets, radiator and shroud. Remove A/C compressor and power steering pump and position out of the way (if equipped).
4. Remove engine cover. Disconnect wiring from firewall connection. Disconnect vacuum lines and wiring as necessary. Remove cruise control servo, transducer, and bracket (if equipped). Disconnect accelerator cable and remove TBI unit. Remove thermostat housing, oil filler pipe and disconnect heater hoses.
5. Raise vehicle. Disconnect exhaust pipe at manifold. Remove drive shaft and plug extension housing. Disconnect shift linkage and speedometer cable. Disconnect fuel and vapor hoses from engine. Remove transmission mount bolts and front engine mount bracket-to-frame bolts.
6. Drain crankcase. Raise engine slightly and remove engine mounts. Block engine up with wooden blocks. Lower vehicle and attach lift equipment. Remove engine and transmission as an assembly. NOTE: When raising or supporting engine, DO NOT use jack under oil pan, crankshaft pulley or any sheet metal. Oil pan can bend against oil pump pickup and damage unit.
7. To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.

V6

TORQUE SPECIFICATIONS (V6)

V8

TORQUE SPECIFICATIONS (V8)