Engine Removal - 4-cyl GMC Cab & Chassis R2500

Astro & Safari Models

1. Disconnect negative battery cable. Drain cooling system. Remove engine cover. Remove headlight bezel, grille and hood latch mechanism. Remove radiator lower close-out panel and radiator support brace. Remove lower tie bar and cross brace.
2. Remove radiator hoses, transmission cooler lines (if equipped), upper core support and filler panels. Remove radiator and fan shroud as an assembly. Separate 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, cruise control and detent cables (if equipped). Disconnect ground strap at cylinder head. Remove oil filler neck and thermostat outlet. Remove air cleaner and canister purge hose. Raise vehicle. Separate exhaust pipe at manifold. Disconnect wiring harness at transmission and frame.
4. Remove starter and flywheel inspection cover. Disconnect and plug fuel lines. Remove motor mount through bolts and bellhousing bolts. Lower vehicle. Attach engine hoist. Support transmission and carefully remove engine.

"S" Series

1. Disconnect negative battery cable. Remove hood and air cleaner. Disconnect power steering reservoir at fan shroud. Remove upper fan shroud and fan. Drain cooling system. Remove radiator hoses and transmission oil cooler lines at radiator. Remove radiator.
2. Remove A/C compressor and power steering pump. 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 from engine.
3. Disconnect O2 sensor wire. Label and disconnect all electrical connectors on engine. Raise vehicle. On 2WD, remove strut rods, flywheel cover, and drive belt splash shield (if equipped). On 4WD, remove crossmember after disconnecting brake lines. Separate transmission cooler lines from flywheel cover. Remove drive shaft at front axle. On all models, disconnect exhaust pipe at exhaust manifold. Remove starter and flex plate-to-converter bolts.
4. Remove two outer air dam bolts (left side). Remove lower fan shroud and left side body mounting bolts. Install jack stands. Raise and support left side of body. 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 wiring loom bracket at rear of cylinder head. Remove engine.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS