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JOHN aka Eauto
JOHN aka Eauto, The Car Guy
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Experience:  ase tech
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How to remove old and install new 3.

Resolved Question:

how to remove old and install new 3.8 v6 in 2001 impala
Submitted: 4 years ago.
Category: Chevy
Expert:  JOHN aka Eauto replied 4 years ago.

Engine Replacement

Removal Procedure

Notice: Refer to Engine Emission Notice in Service Precautions.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

  1. Disconnect the negative battery cable.
  2. Remove the hood.
  3. Remove the fuel injector sight shield.
  4. Raise and support the vehicle. Refer to Vehicle Lifting.
  5. Drain the engine oil.
  6. Drain the cooling system.
  7. Remove the torque converter cover.
  8. Remove the starter motor.
  9. Remove the engine flywheel-to-torque converter bolts.
  10. Scribe the torque converter to the flywheel for installation.
  11. Remove the transaxle brace.
  12. Remove the engine mount lower nuts.

  1. Remove the right exhaust manifold pipe stud nuts from the catalytic converter.
  2. Remove the oil level sensor harness retainer bolt.
  3. Remove the oil level harness retainer from the engine.
  4. Disconnect and reposition the electrical connectors from the following:
    • The vehicle speed sensor (VSS)
    • The oil pressure sending unit
    • The oil level sensor
    • The knock sensors
    • The H02 sensor
  1. Remove the oil filter adapter housing.
  2. Remove the engine ground nut and engine ground from the transaxle stud.

  1. Remove the lower transaxle-to-engine bolt (6) and stud (1).
  2. Lower the vehicle while supporting the transaxle.
  3. Remove the air cleaner assembly. Important: Relieve the fuel pressure.

  1. Disconnect the fuel lines (1,2) from the fuel rail. Lay the fuel lines aside.
  2. Disconnect the fuel vapor line.
  3. Remove the throttle and cruise control cables and bracket from the throttle body.

  1. Loosen the water pump pulley bolts.
  2. Remove the drive belt.
  3. Remove the water pump pulley bolts and the water pump pulley.
  4. Remove the right and the left engine mount struts.
  5. Remove the engine mount strut brackets from the radiator support.
  6. Disconnect the positive battery cable.
  7. Remove the fan shroud.
  8. Remove the vacuum booster hose from the engine.
  9. Remove the A/C vacuum hose from the engine.

  1. Remove the power steering pump and the power steering bolts from the engine. Lay the power steering pump aside.
  2. Disconnect the upper engine electrical connectors from the following:
    • The fuel injectors
    • The throttle position (T/P) sensor
    • The idle air control (IAC) valve
    • The EVAP purge solenoid
    • The exhaust gas recirculation (EGR) valve
    • The manifold absolute pressure (MAP) sensor
  1. Remove upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal.
  2. Remove the radiator inlet hose from the engine.
  3. Remove the radiator outlet hose from the water pump.
  4. Remove the heater hoses from the drive belt tensioner.

  1. Remove the A/C compressor nuts and the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
  2. Install the engine lifting device.

  1. Remove the upper transaxle-to-engine bolts (2, 3, 4 and 5).
  2. With assistance remove the engine from the vehicle.
  3. Remove the flywheel.
  4. Install the engine to the engine stand.

  1. Remove the oil level indicator tube nut from the exhaust manifold.
  2. Remove the oil level indicator tube.
  3. Remove the engine mount bracket with the engine mount.
  4. Remove the drive belt tensioner.
  5. Remove the ignition control module and the ignition control module bracket.
  6. Remove the left and right side engine mount brackets.

  1. Remove the A/C compressor mounting bracket bolts and the A/C compressor bracket.

  1. Remove the fuel injector sight shield bracket nuts.
  2. Remove the fuel injector sight shield bracket
  3. Remove the EGR valve adapter from the right cylinder head.
  4. Remove the upper intake manifold.

  1. Remove the generator brace bracket bolts.
  2. Remove the generator brace bracket from the right cylinder head.
  3. Remove the engine lift brackets.
  4. Remove the crankshaft balancer.
  5. Remove the right exhaust manifold, the left exhaust manifold and the exhaust crossover.

Installation Procedure

Notice: Refer to Engine Emission Notice in Service Precautions.

  1. Install the right exhaust manifold, the left exhaust manifold and the exhaust crossover.
  2. Install the crankshaft balancer. Notice: Refer to Fastener Notice in Service Precautions.
  3. Install the engine lift brackets.
  4. Install the engine lift brackets bolts and nuts.
    • Tighten the engine lift bracket bolts and nuts to 30 Nm (22 ft. lbs.).
  1. Install the generator brace bracket to the right cylinder head.
  2. Install the generator brace bracket bolts.
    • Tighten the generator brace bracket bolts to 50 Nm (37 ft. lbs.).
  1. Install the upper intake manifold.
  2. Install the EGR valve adapter to the right cylinder head.
  3. Install the fuel injector sight shield bracket.

  1. Install the fuel injector sight shield bracket nuts.
    • Tighten the engine sight shield nuts to 30 Nm (22 ft. lbs.).

  1. Install the A/C compressor mounting bracket and the A/C compressor mounting bracket bolts.
    • Tighten the A/C compressor mounting bracket bolts to 50 Nm (37 ft. lbs.).
  1. Install the left and right side engine mount brackets.
  2. Install the ignition control module bracket and the ignition control module.
  3. Install the drive belt tensioner.
  4. Install the engine mount bracket with the engine mount to the engine.

  1. Ensure that the O-ring is in place and install the oil level indicator tube to the engine.
  2. Install the oil level indicator tube nut to the exhaust manifold stud.
    • Tighten the oil level indicator tube nut to 19 Nm (14 ft. lbs.).
  1. Remove the engine from the engine stand.
  2. Install the flywheel.
  3. With assistance install the engine to the vehicle.

  1. Install the upper transaxle-to-engine bolts (2, 3, 4 and 5).
    • Tighten the upper transaxle-to-engine bolts to 75 Nm (55 ft. lbs.).
  1. Remove the engine lifting device.

  1. Install the A/C compressor to the engine.
  2. Install the A/C compressor mounting nuts to the A/C compressor.
    • Tighten the A/C compressor nuts to 30 Nm (22 ft. lbs.).
  1. Install the heater hoses to the drive belt tensioner.
  2. Install the radiator outlet hose to the water pump.
  3. Install the radiator inlet hose to the engine.
  4. Reposition the engine wiring to the engine.
  5. Connect the upper engine electrical connectors to the following:
    • The manifold absolute pressure (MAP) sensor
    • The exhaust gas recirculation (EGR) valve
    • The EVAP purge solenoid
    • The idle air control (IAC) valve
    • The throttle position (T/P) sensor
    • The fuel injectors
  1. Install the upper engine wiring harness to the retaining clips.

  1. Install the power steering pump and the power steering bolts to the engine.
    • Tighten the power steering pump bolts to 34 Nm (25 ft. lbs.).
  1. Connect the A/C vacuum hose to the engine.
  2. Install the vacuum booster hose to the engine.
  3. Install the fan shroud.
  4. Connect the positive battery cable.
    • Tighten the positive battery cable terminal nut to 15 Nm (11 ft. lbs.).
  1. Install the engine mount brackets to the radiator support.
  2. Install the right and the left engine mount struts.
  3. Install the water pump pulley.

  1. Install the water pump pulley bolts.
    • Tighten the water pump pulley bolts to 13 Nm (116 inch lbs.).
  1. Install the drive belt.
  2. Install the throttle cable, the cruise control cable and bracket to the throttle body.
  3. Connect the fuel vapor line.

  1. Connect the fuel lines (1, 2) to the fuel rail.
  2. Install the air cleaner assembly.
  3. Raise the vehicle and remove the transaxle support.

  1. Install the lower transaxle-to-engine bolt (6) and stud (1)
    • Tighten the transaxle to engine bolt and stud to 75 Nm (55 ft. lbs.).
  1. Install the engine ground to the transaxle stud.
    • Tighten the engine ground nut to 35 Nm (26 ft. lbs.).
  1. Install the oil filter adapter housing.
  2. Reposition and connect the electrical connectors to the following:
  1. Install the oil level sensor harness retainer to the engine.

  1. Install the catalytic converter pipe to the right exhaust manifold.
  2. Install right exhaust manifold stud nuts.

  1. Install the engine mount lower nuts.
    • Tighten the engine mount lower nuts to 78 Nm (58 ft. lbs.).
  1. Install the transaxle brace.
  2. Install the engine flywheel-to-torque converter bolts.
  3. Install the starter motor.
  4. Install the torque converter cover.
  5. Lower the vehicle.
  6. Install the fuel injector sight shield.
  7. Install the hood.
  8. Connect the negative battery cable.
  9. Fill the crankcase with engine oil.
  10. Fill the cooling system.
  11. Inspect for leaks.
  12. Perform the CKP system variation learn procedure.

 

 

JOHN aka Eauto, The Car Guy
Category: Chevy
Satisfied Customers: 12942
Experience: ase tech
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