Engine Removal - v6 GMC Cab & Chassis R2500

2WD

1. Disconnect battery. Remove hood and air cleaner. Drain cooling system. Remove radiator hoses, transmission cooler lines and upper fan shroud. Remove radiator and fan and heater hoses. Label and disconnect all vacuum hoses at engine. Disconnect throttle and cruise control cables.
2. Disconnect ground wires and cables, main feed wires and any necessary wiring at firewall. Remove distributor cap. Raise vehicle. Disconnect exhaust pipe at converter and both manifolds. Remove strut rods, flywheel inspection cover and torque converter bolts.
3. Remove converter hanger at exhaust pipe and rear shield. Disconnect fuel lines and hoses. Remove two outer air dam bolts and lower fan shroud. Remove left body mount bolts and raise body to remove bellhousing bolts. Lower body and remove motor mount through bolts.
4. Disconnect A/C compressor and power steering pump from engine and set aside (if equipped). Attach lift equipment to engine. Support transmission and carefully remove engine from vehicle.

4WD Models With Automatic Transmission

1. Remove hood. Disconnect battery and underhood light. Raise vehicle. On Blazer models, remove body mounts. On chassis cab models, loosen and remove two front body mounts. On all models, remove front air dam end bolts.
2. Raise body above frame and remove top transmission-to-engine bolts. Lower body to frame. Remove remaining transmission-to-engine bolts. Unbolt and remove No. 2 crossmember. Disconnect exhaust pipe at manifolds. Disconnect converter hanger.
3. Remove front drive shaft at differential and bellhousing cover. Unclip automatic transmission cooler lines at engine. Remove motor mount bolts and flex plate-to-converter bolts. Remove front splash shield and lower fan shroud. Lower vehicle.
4. Drain cooling system. Remove upper fan shroud and radiator hoses. Disconnect automatic transmission cooler lines at radiator. Remove radiator, fan, and air cleaner. Remove A/C compressor and power steering pump from engine and set aside (if equipped).
5. Disconnect fuel lines and hoses. Disconnect vacuum and emission hoses from engine. Disconnect accelerator, throttle valve, and cruise control cables (as equipped). Disconnect engine wiring harness at firewall.
6. Disconnect heater hoses at engine. Disconnect any remaining wiring from engine. Attach hoist to engine and support transmission securely. Remove engine from vehicle.

4WD Models With Manual Transmission

1. Remove hood and air cleaner. Disconnect battery and underhood light. Drain cooling system and remove upper fan shroud. Remove radiator hoses, fan and clutch. Remove radiator.
2. Remove A/C compressor and power steering pump (if equipped). Disconnect fuel lines and hoses. Remove vacuum hoses and heater hoses at engine. Disconnect accelerator and cruise control cables. Disconnect engine wiring harness, main feed wire, and ground strap at firewall.
3. Remove lower fan shroud. Disconnect battery ground at engine. Remove distributor cap and diverter valve. Remove shifter boot and console cover. Remove transfer case shifter, transmission shifter, and transmission shift lever.
4. Raise vehicle. Remove front and rear skid plates. Remove front splash shield. Drain transfer case and transmission. Remove rear drive shaft. Disconnect speedometer cable and front drive shaft. Disconnect shift linkage and vacuum hoses at transfer case.
5. Disconnect parking brake cable. Remove rear mount and converter bracket. Support transfer case. Unbolt transfer case and remove from vehicle. Remove crossmember. Disconnect back-up light wiring and clip. Unbolt slave cylinder and hang to side. Remove transmission. Remove clutch release bearing and flywheel inspection cover.
6. Remove left side body mounting bolts. Lift left side of body and remove bellhousing. Disconnect exhaust at manifolds and converter. Disconnect clutch cross shaft at frame. Remove starter. Remove motor mount bolts. Lower vehicle. Attach lifting device and remove engine.

Astro & Safari

1. Disconnect negative battery cable. Drain cooling system. Raise vehicle. Disconnect exhaust pipe at exhaust manifolds. Disconnect starter and strut rods. Remove flywheel inspection cover, torque converter bolts and oil filter.
2. Disconnect harness at transmission and frame. Disconnect and plug fuel lines. Disconnect transmission and engine oil cooler lines at radiator. Remove lower fan shroud bolts. Remove motor mount through bolts and bellhousing bolts. Lower vehicle. Remove headlight bezels and grille.
3. Remove radiator lower close-out panel and support braces. Remove lower tie bar. Remove hood latch mechanism. Disconnect master cylinder and set aside. Remove radiator hoses, fan shroud, radiator and upper radiator core support..
4. Discharge A/C system. Remove radiator filler panels. Remove engine cover and rear brace of A/C compressor. Disconnect A/C hose at accumulator. Remove A/C compressor and bracket. Remove power steering pump.
5. Label and disconnect necessary vacuum hoses. Disconnect wiring harness at bulkhead. Remove right kick panel. Disconnect wiring harness at ESC module and push through bulkhead. Remove distributor cap and A/C accumulator. Disconnect fuel line at TBI unit.
6. Disconnect and remove diverter valve. Remove transmission dipstick tube. Disconnect heater hoses at heater core. Remove horn. Remove air injection check valves. Install engine lifting device. Support transmission. Remove engine.

Van Models

1. Remove glove box and engine cover. Disconnect battery and drain cooling system. Remove outside air duct and air cleaner. Remove power steering reservoir bracket, hood release cable and upper fan shroud bolts. Disconnect overflow hoses. Disconnect transmission oil cooler lines at radiator.
2. 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.
3. 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.
4. Remove A/C compressor brace and compressor. Remove upper half of dipstick tube. Remove oil filler and transmission dipstick tubes. Disconnect and plug fuel lines at fuel pump. Remove power steering pump and A/C idler pulley.
5. 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.
6. Disconnect strut rods at flywheel inspection cover. Remove flywheel inspection cover, starter and torque converter mounting bolts. Remove motor mount through bolts and bellhousing bolts. Lower vehicle. Support transmission. Install lift equipment and remove engine.