Warning 1. Carefully study the following guidelines to familiarize yourself with the necessary operations before starting work. In addition, you will have to remove the gearbox, steering gear and lower suspension arms, since they are all attached to the subframe, which must be removed as a whole. This operation can only be performed safely by supporting the engine/gearbox assembly, steering box and subframe, disconnecting this assembly from the vehicle, and raising the vehicle high enough to fully expose the entire assembly. Therefore, it is not recommended to carry out this work without a car lift. Using any other means of lifting the vehicle to gain access to the engine could result in serious damage or serious injury if the vehicle falls.
Warning 2: Gasoline is highly flammable, so take extra precautions before disconnecting any part of the power system.
Warning 3. The air conditioning system is under high pressure. The workshop must be depressurized before any hoses or fittings are disconnected from the system.
Note. On models equipped with the Delco Loc II audio system, the interlock system must be disengaged before performing any operation to disconnect the battery.
Withdrawal
1. Relieve the fuel pressure in the system (see chapter 4, section 2) and disconnect the battery.
2. Close fenders and hood. It is often convenient to remove the hood to increase the working space (see chapter 11, section 9). But since you're about to lower the engine (rather than pick it up), it makes no sense to remove the hood in this case.
3. Remove the air filter (see chapter 4, section 8).
4. To ensure correct assembly, label all vacuum lines, exhaust system hoses, electrical connectors, "massive" tires and fuel lines. Pieces of sticky tape with numbers or letters written on them will help you avoid confusion during assembly (see illustration). Also, draw a diagram of the lines, hoses, and wires associated with the engine. When detaching parts, pay particular attention to those that provide clearance between the subframe and the frame. If you forget to install them, you risk seriously damaging the parts.
5.4. Label each wire before disconnecting the connector
5. Raise the vehicle using a hydraulic lift.
6. Working under the vehicle, complete the disconnection of all hoses, lines and wires (see illustrations). Do not forget to disconnect the three power steering pipe clamps from the right side of the vehicle frame - they are located next to the crankshaft anti-vibrator pulley. No further disassembly of the power steering system is required - all other parts are attached to the subframe and can be removed with it.
5.6a. These two bolts (shown by arrows) the power steering cooler is attached to the cross member of the subframe; they also attach clamps for a large wiring harness. Forgetting to disconnect these clamps, when separating the car from the engine, you will damage expensive wires | 5.6b. Also do not forget to disconnect the automatic transmission cooling radiator (shown by arrow) |
7. Drain the coolant from the cooling system (see chapter 1, section 29); tag and disconnect all coolant hoses from the engine.
8. Disconnect all fuel lines from the engine to the chassis (see chapter 4, section 4). Plug or shut off any open fuel lines.
9. Disconnect the throttle cable and economy mode cable (see chapter 4, section 9), as well as a cable "kick down" (see chapter 7, section 3).
10. Disconnect the air conditioning hoses from the compressor, move them aside, disconnect the air conditioner from its support bracket and remove it from the engine compartment (see chapter 3, section 15).
11. Drain engine oil and remove filter (see chapter 1, section 12).
12. Disconnect the steering rods from the steering knuckles (see chapter 10, section 5).
13. Remove the starter (see chapter 5, section 17). Remove flywheel cover (see illustrations).
5.13a. To remove the flywheel cover, unscrew these two bolts from below,... | 5.13b....one bolt at the back (to the thermal barrier)... |
5.13c....and one bolt in front
14. Scratch or draw a mark on the flywheel and torque converter (see illustration), then rotate the crankshaft and remove the flywheel mounting bolts.
5.14. Draw marks on the flywheel and torque converter to ensure that these parts are mutually balanced after assembly
15. Disconnect the engine shock absorber (see chapter 2, part 2.1, section 4).
16. Disconnect the exhaust system from the engine (see chapter 4, section 14).
17. Install under both sides of the subframe to support the knot "engine-gearbox-steering gear" wooden bars with a section of 10x10 cm.
18. Draw marks on all four corners of the stretcher (see illustrations) and remove the four screws (two front and two back) attaching the subframe to the frame. Check all four supports; if they are dry and cracked, replace them.
5.18a. Draw labels (shown by arrows) between the corners of the subframe and the vehicle frame to ensure they are correctly positioned during assembly (front right corner shown)... | 5.18b....and marks on the right rear corner of the subframe |
5.18c. Front subframe bolt to vehicle | 5.18g. Rear subframe bolt to vehicle |
19. Raise the car just enough to make sure everything is disconnected (see illustration). Raise the car to open the knot "engine-gearbox-steering gear".
5.19. Before jacking the car high enough, make sure you disconnect everything
20. Supporting the engine on a special lift, disconnect the flywheel mountings from the torque converter.
21. Remove the bolts and nuts on the engine mount under the timing cover (see illustration).
5.21. To disconnect the engine from the subframe, unscrew these two nuts (shown by arrow) on the engine support under the timing cover
22. Finally check that nothing is connecting the engine to the subframe.
23. Raise the engine slightly to disengage it from the timing cover strut. Carefully disconnect the engine from the gearbox. Make sure the torque converter is in place (to fix the torque converter, install a pair of clamps on the housing). Raise the engine slowly, separating it from the subframe (see illustration). Carefully check that nothing is hanging on the raised engine.
5.23. Raise the engine, separating it from the subframe using a hoist
24. Remove the flywheel (see section 27) and install the engine on a special stand.
Installation
25. Before installing the engine, check the condition of the engine mounts and gearbox mounts (see chapter 7, section 8). If they are worn or damaged, replace the bearings.
26. Carefully lower the engine onto the subframe. Make sure that the bolt holes of the timing cover are aligned.
Attention! Do not use the gearbox-to-engine bolts to hold the gearbox against the engine. Be careful when aligning the torque converter with the flywheel by following the procedures in Chapter 7, Section 9. Make sure that the marks you made on the flywheel and torque converter match when you removed the engine.
27. Lower the car onto a knot "engine-gearbox-steering gear-subframe". Install the subframe bolts, but do not tighten them yet. Using a pry bar or a large screwdriver, align the subframe with the vehicle frame (see illustration), then tighten the subframe bolts to the torque specified in the specifications in this chapter.
5.27. To align the subframe with the vehicle frame, insert a pry bar or large screwdriver into the holes in the subframe and frame and move the subframe with it until the marks you made on all four corners of the subframe line up
28. Install the bolts securing the flywheel to the torque converter and tighten them to the torque specified in the specifications of this chapter.
29. The remaining parts are installed in the reverse order. Check several times that everything is connected properly.
30. Add coolant, oil, and hydraulic fluid to the power steering and transmission as needed.
31. Start the engine and check for leaks and all components working properly, then install the hood and test drive.