Engine Removal on Chevrolet Corvette?

The complete detailed procedure to replace Engine.

In this chapter the step by step instructions are provided with diagrams to remove and install Engine for Chevy Corvette car model.

The procedure is as follows:------

The following tools will be required in addition to the basic hand tools:

Transverse spring compressor and adapters

Ball joint separator

Engine support table

Driveshaft support strap

Fuel pressure gauge

Power Steering Pump Pulley Remover/Installer

1. Relieve the fuel system pressure.
2. Drain the cooling system.
3. Drain the engine oil.
4. Recover the A/C refrigerant.
5. Remove or disconnect the following: 
   
   NOTE

   Cap and plug all openings for the fuel system to prevent contaminants from entering the system.
   
   
   
   CAUTION

   Failure to use the minimum fastener length specified will prevent the proper retention of the propeller shaft during assembly.
   
   
   
   
   Intake Air Temperature (IAT) sensor electrical connector

   Mass Air Flow (MAF) sensor electrical connector

   Air intake duct and air cleaner

   Upper radiator support

   Radiator

   Electronic Brake Control Traction Module/Brake Pressure Modulator Valve (EBTCM/BPMV) and bracket

   Brake pipes

   Accessory drive belt

   Fuel line from the connector at the front of the dash
   
   
   
   
   Fuel rail covers

   Fuel line at the fuel rail

   Radiator hoses from the water pump

   Heater hoses from the water pump

   Fuel injector electrical connectors

   Ignition coil main harness connector

   Evaporative Emission (EVAP) solenoid electrical connector

   Electric throttle motor electrical connector

   Throttle Position Sensor (TPS) electrical connector

   Engine Coolant Temperature (ECT) sensor electrical connector

   A/C compressor electrical connector

   Alternator electrical connectors

   Alternator

   Brake booster vacuum hose

   Intermediate shaft to steering gear bolt 
   
    
   

   Fig. Remove the intermediate steering shaft bolt to the steering gear

   Intermediate shaft from the steering gear

   Secondary Air Injection (AIR) hose from the left exhaust manifold

   Both front wheels

   Heated Oxygen Sensor (HO ₂ S) connectors from the intermediate exhaust pipes

   Intermediate exhaust pipes

   Catalytic converter

   Close-out panel

   Starter motor electrical connectors

   Starter motor

   Crankshaft Position (CKP) sensor electrical connector

   Oil level sensor connector

   Right Heated Oxygen Sensor (HO ₂ S)

   A/C compressor hose assembly

   Engine oil temperature sensor electrical connector

   Left Heated Oxygen Sensor (HO ₂ S)

   Ground straps

   Front stabilizer shaft

   Connectors from the cooling fans

   Cooling fan assembly

   Unclip the transmission wire harness from the engine wire harness.

   Tie rod ends from the steering knuckles

   Antilock Brake System (ABS) electrical connectors from the crossmember, if equipped

   Electronic Variable Orifice (EVO) connector clips from the crossmember, if equipped

   Real Time Damping (RTD) connector clips from the crossmember, if equipped

   Shock absorber lower mounting bolts

   Front transverse leaf spring 
   
   

   

   

   Fig. Use a compressor such as J-33432-A to compress the front transverse spring

   Automatic transmission cooler pipes at the flywheel housing junction

   Automatic transmission cooler pipe clamps from the engine oil pan

   Automatic transmission cooler pipe from the radiator
   
   
   
   
   

   

   Fig. On automatic transmission vehicles, remove the plugs from the driveline support assembly and install 2 M10 x 1.5 bolts into the plug holes
6. For vehicles with an automatic transmission, perform the following steps:
   1. Remove the two plug bolts in the driveline support assembly.
   2. Install an M10 x 55 bolt, or longer, in each plug location. Torque the bearing support bolts to 26 ft. lbs. (35 Nm).
   3. Remove the bell housing inspection cover, then turn the flywheel hub collar to access the bolt and loosen it.
      
      
      

      

      Fig. Loosen the bolt on the flywheel hub collar after turning it for access
   4. Remove the engine flywheel housing access plug.
   5. Rotate the automatic transmission collar so that the bolt is facing down.
   6. Loosen the bolt and unclip the wire harness from the engine and reposition it to the driveline.
   7. Install a driveline support tool to the close out panel flange.
      
      CAUTION

      Never use a driveline support tool to support the weight of the engine assembly.
      
      
      
      
      

      

      Fig. Install a Driveline Support tool J-42203 to the under cover flange
7. If equipped with a manual transmission, perform the following steps:
   1. Unclip the clutch actuator hose from the master cylinder hose.
   2. Using a hydraulic clutch line separator tool, depress the white release ring on the actuator hose and pull lightly on the master cylinder hose.
   3. Remove the flywheel housing bolts from the driveline support.
8. Support the engine and crossmember assembly.
9. Remove or disconnect the following:
   
   
   Front crossmember nuts BY HAND and lower the engine assembly slightly

   Secondary Air Injection (AIR) tube bracket bolt and reposition the bracket to gain access to the ground strap

   Ground strap from the rear of the left cylinder head

   Engine oil pressure sensor electrical connector

   Camshaft Position (CMP) sensor electrical connector

   Manifold Absolute Pressure (MAP) sensor electrical connector

   Knock Sensor (KS) electrical connector

   Front driveline support assembly bolts

   Engine from the driveline, by placing a flat blade tool between edge of the driveline and the flywheel housing
   
   

   

   

   Fig. Separate the flywheel housing from the driveline support
10. Pull the engine away from the propeller shaft.
11. Raise the vehicle off of the engine and crossmember.
12. Remove the power steering pump (with reservoir) from the engine and reposition them to the crossmember
13. Remove the A/C, alternator and power steering pump brackets
14. Remove the AIR pipe and gasket
15. Remove the spark plugs
16. Remove the engine mount-to-crossmember nuts.
17. Remove the engine from the crossmember.

To install:

1. Install the engine on the crossmember and torque the nuts to 48 ft. lbs. (65 Nm).
2. Lower the vehicle onto the engine/crossmember assembly.
3. Install or connect the following:
   
   
   Spark plugs

   AIR pipe and gasket

   A/C, alternator and power steering pump brackets

   Power steering pump and reservoir on the engine and torque the bolts to 18 ft. lbs. (25 Nm)

   Ground strap to the rear of the left cylinder head and torque the bolt to 24 ft. lbs. (32 Nm)

   Engine oil pressure sensor electrical connector

   CMP sensor electrical connector

   MAP sensor electrical connector

   KS electrical connector

   Front driveline support bolts and torque them to 37 ft. lbs. (50 Nm)

   Air tube and bracket and torque the bolt to 15 ft. lbs. (20 Nm)

   New crossmember nuts and torque them to 81 ft. lbs. (110 Nm)

   Flywheel housing bolts and torque them to 37 ft. lbs. (50 Nm)

   Clutch actuator hose to the flywheel housing (if equipped)

   Master cylinder hose to the clutch actuator hose (if equipped)

   Wire harness to the rear of the engine
4. Remove the driveline support tool.
5. Remove the M10 x 55mm bolts from the driveline support assembly.
6. Install the following:
   
   
   Two plugs in the driveline support assembly after removing the M10 x 55 bolts and torque them to 37 ft. lbs. (50 Nm)

   Automatic transmission oil cooler pipes at the flywheel housing junction and torque them to 20 ft. lbs. (27 Nm), if equipped

   Automatic transmission cooler pipes to the front and rear of the oil pan

   Front transverse spring and torque the bolts to 46 ft. lbs. (62 Nm)

   Shock absorber lower mounting nuts and torque them to 21 ft. lbs. (28 Nm)

   Front stabilizer shaft and torque the bolts to 53 ft. lbs. (72 Nm)

   ABS electrical connector

   EVO electrical connector

   RTD electrical connector

   Tie rods to the steering knuckle and torque the nuts to 33 ft. lbs. (45 Nm).

   Radiator

   Cooling fan assembly to the radiator and attach the electrical connectors to the fans

   Ground wires to the left side of the engine

   Left HO ₂ S connector

   Engine oil temperature sensor connector

   A/C compressor hoses to the compressor

   A/C compressor line retaining bolt and torque it to 26 ft. lbs. (35 Nm)

   Right HO ₂ S connector

   CKP sensor electrical connector

   Oil level sensor electrical connector

   Wire harness ground wires to the right side of the engine

   Starter motor and torque the bolts to 37 ft. lbs. (50 Nm)

   Driveline close out panel and torque the bolts to 106 inch lbs. (12 Nm)

   Catalytic converters and torque the mounting nuts to 15 ft. lbs. (20 Nm)

   Intermediate exhaust pipe and hangers and torque the bolts to 37 ft. lbs. (50 Nm) and the nuts to 15 ft. lbs. (20 Nm)

   Front wheels

   Automatic transmission cooler pipes to the radiator (if equipped) and torque the fittings to 26 ft. lbs. (35 Nm)

   AIR hose to the left exhaust manifold

   Intermediate steering shaft to the steering gear and torque the bolt to 35 ft. lbs. (48 Nm)

   Brake booster vacuum hose

   Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)

   Alternator and torque the bolts to 37 ft. lbs. (50 Nm)

   Alternator connectors and torque the nuts to 10 ft. lbs. (13 Nm)

   Fuel injector electrical connectors

   Ignition coil main electrical connectors

   EVAP solenoid electrical connectors

   Throttle motor electrical connector

   ECT sensor electrical connector

   TPS electrical connector

   A/C compressor electrical connector

   Heater hoses to the water pump

   Radiator hoses to the water pump

   Fuel line to the fuel rail

   Fuel rail covers

   Drive belt

   EBTCM/BPMV bracket and torque the bolts to 20 ft. lbs. (27 Nm)

   EBTCM/BPMV to the bracket and torque the nuts to 89 inch lbs. (10 Nm)

   Upper radiator hose

   Upper radiator support

   Air cleaner and air intake duct

   IAT sensor electrical connector

   MAF sensor electrical connector

   Negative battery cable

   Engine flywheel housing inspection plug
7. Fill the engine with new oil.
8. Fill the cooling system.
9. Evacuate and recharge the A/C system.
10. On vehicles with an automatic transmission, start the engine and allow it to idle for 10 minutes. Torque the hub collar bolt to 92 ft. lbs. (125 Nm) and install the flywheel inspection plug.
11. A wheel alignment is recommended when the engine and crossmember have been removed from the vehicle.
12. Check the vehicle for leaks and repair if necessary.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html