- PDF Free Download

Size: px

Start display at page:

Download ""

Sheila King
5 years ago
Views:

1 1 of 8 12/12/2012 6:08 PM 1999 Chevrolet Express - 2WD Express, Savana VIN G Service Manual Engine Engine Mechanical - 6.5L Repair Instructions Engine Replacement Removal Procedure Tools Required J Engine Lift Bracket 1. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Body and 2. Disconnect the battery negative cables from the batteries. For the front battery, refer to Battery Cable Replacement in Engine Electrical. For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical. 3. Remove the battery from the vehicle. Refer to Battery Replacement in Engine Electrical. 4. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls 6.5L General Motors. All rights reserved.

2 2 of 8 12/12/2012 6:08 PM 5. Remove the air intake duct from the throttle body. 6. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling. 7. Remove the surge tank from the vehicle. Refer to Surge Tank (Diesel) Replacement in Engine Cooling. 8. Remove the front bumper from the vehicle. Refer to Front Bumper Replacement in Body and 9. Remove the grill and park light assembly from the vehicle. Refer to Grille Replacement in Body and 10. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging in HVAC. 11. Remove the radiator support from the vehicle. Refer to Radiator Support Replacement in Body and 12. Remove the radiator from the vehicle. Refer to Radiator Replacement in Engine Cooling. 13. Remove the air conditioning condenser from the vehicle. Refer to Air Conditioning Condenser Replacement in HVAC. 14. Remove the drive belt from the vehicle. Refer to Drive Belt 15. Remove the radiator hoses from the engine. Refer to Radiator Hose Replacement in Engine Cooling. 16. Remove the engine wiring harness and the connectors. 17. Remove the ground wires from the engine block. Refer to Engine Ground Strap

3 3 of 8 12/12/2012 6:08 PM 18. Disconnect the electrical connector for the block heater. 19. Remove the engine oil fill tube. 20. Remove the engine oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement. 21. Remove the left accessory bracket from the engine block. Refer to Accessory Brackets 22. Remove the right accessory bracket from the engine block. Refer to Accessory Brackets 23. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold 24. Remove the lower intake manifold from the cylinder head. Refer to Intake Manifold 25. Remove the turbocharger from the engine block. Refer to Turbocharger 26. Remove the exhaust manifolds from the engine block. Refer to Exhaust Manifold Replacement. 27. Remove the engine front cover from the engine block. Refer to Engine Front Cover 28. Remove the fuel injection pump from the engine block. Refer to Fuel Injection Pump Replacement in Engine Controls-6.5L. 29. Remove the transmission shift cable connector. 30. Raise the vehicle and support with safety stands. 31. Remove the starter motor from the engine block. Refer to Starter 32. Remove the flywheel inspection cover. 33. Remove the torque converter to flywheel bolts. 34. Remove the engine cooler lines from the retaining brackets. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling. 35. Remove the bolts from the transmission to the engine block. 36. Remove the safety stands and lower the vehicle.

4 4 of 8 12/12/2012 6:08 PM 37. Install the J and a length of chain, using GM P/N or equivalent attaching bolt, to the rear of the right cylinder head and the front of the left cylinder head. 38. Support the transmission with a strap between the frame rails. 39. Install the suitable lifting device to the engine. 40. Remove the front engine mount through bolts (left side shown). 41. Remove the engine from the vehicle. Important: It may be necessary to remove the flywheel from the crankshaft before the engine assembly is install on the engine stand. 42. Remove the flywheel from the crankshaft. 43. Install the engine assembly on a suitable engine stand. 44. Remove the suitable lifting devise from the engine assembly.

5 5 of 8 12/12/2012 6:08 PM 45. Remove the lifting brackets from the cylinder heads. Installation Procedure Tools Required J Engine Lift Bracket 1. Install the J and a length of chain, using GM P/N or equivalent attaching bolt, to the rear of the right cylinder head and the front of the left cylinder head. 2. Remove the engine assembly from the engine stand. 3. Install the flywheel on the crankshaft. Refer to Engine Flywheel 4. Install the engine assembly in the vehicle.

6 6 of 8 12/12/2012 6:08 PM 5. Install the front engine mount through bolts. 6. Remove the lifting device to the engine. 7. Remove the support from the transmission. 8. Remove the chain and attaching bolts from the cylinder heads. 9. Install the bolts from the transmission to engine block. 10. Raise the vehicle and support with safety stands. 11. Install the bolts from the flywheel to the torque convertor. 12. Install the engine cooler lines to the retaining brackets. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling. 13. Install the flywheel inspection cover. 14. Install the starter motor to the engine block. Refer to Starter Replacement in Engine Electrical. 15. Remove the safety stands and lower the vehicle. 16. Connect the transmission shift cable connector. 17. Install the fuel injection pump to the engine block. Refer to Fuel Injection Pump Replacement in Engine Controls-6.5L. 18. Install the engine front cover to the engine block. Refer to Engine Front Cover 19. Install the exhaust manifold to the cylinder heads. Refer to Exhaust Manifold 20. Install the turbocharger from the engine block. Refer to Turbocharger 21. Install the lower intake manifold from the cylinder head. Refer to Intake Manifold 22. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold 23. Install the right accessory bracket to the cylinder head. Refer to Accessory Brackets 24. Install the left accessory bracket to the cylinder head. Refer to Accessory Brackets 25. Install the oil level indicator and tube to the engine block. Refer to Oil Level Indicator Tube 26. Install the radiator hoses from the engine. Refer to Radiator Hose Replacement in Engine Cooling. 27. Install the drive belt on the pulleys. Refer to Drive Belt 28. Install the radiator in the vehicle. Refer to Radiator Replacement in Engine Cooling. 29. Install the engine wiring harness and the connectors. 30. Reconnect the ground wires to the engine block. Refer to Engine Ground Strap

7 7 of 8 12/12/2012 6:08 PM 31. Reconnect the block heater if needed. 32. Install the A/C condenser the vehicle. Refer to Air Conditioning Condenser Replacement in HVAC. 33. Install the radiator support in the vehicle. Refer to Radiator Support Replacement in Body and 34. Install grille and parking light assembly on the vehicle. Refer to Grille Replacement in Body and 35. Install the front bumper on the vehicle. Refer to Front Bumper Replacement in Body and 36. Install the surge tank in the vehicle. Refer to Surge Tank (Diesel) Replacement in Engine Cooling. 37. Install the air intake duct to the turbocharger.

8 8 of 8 12/12/2012 6:08 PM 38. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls 6.5L. 39. Connect the battery negative cables to the batteries. For the front battery, refer to Battery Cable Replacement in Engine Electrical. For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical. 40. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling. 41. Fill the engine with the proper grade and type of engine oil. 42. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in HVAC. 43. Install a scan tool and make any adjustments that are necessary. 44. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Body and

Exhaust Gas Recirculation Valve, Replace J S file://c:\program Files\cosids\DATA\TMP\ rtf.html. Remove

$Exhaust Gas Recirculation Valve, Replace J S file://c:\program Files\cosids\DATA\TMP\ rtf.html. Remove$ 1 Page 1 of 20 Exhaust Gas Recirculation Valve, Replace J982500 Remove 1. Disconnect battery negative lead 2. Disconnect hose (1) from oil filler on air cleaner assembly, then move to one side Release