Lumina APV
PROCEDURE FOR LUMINA APV'S1. Disconnect battery cables. Be certain to note all radio settings, etc. prior to disconnecting.
2. Remove air cleaner assembly.
3. Drain cooling system.
4. Discharge/recover A/C system refrigerant. Refer to service manual for discharging A/C system (section 1B).
5. Disconnect ECM harness at ECM and push harness through to engine compartment.
6. Remove necessary ECM harness fasteners to chassis and lay harness on engine assembly.
7. Remove throttle and throttle valve cable at TBI unit.
8. Disconnect fuel lines at TBI unit.
9. Remove transaxle shift linkage and bracket at transaxle.
10. Remove radiator and heater hoses at engine side.
11. Remove left-hand engine compartment crossbrace with washer reservoir assembly.
12. Remove engine wiring harness from block connector at left hood hinges and lay on engine assembly.
13. Remove engine torque strut to engine.
14. Raise vehicle.
15. Drain oil and remove filter.
16. Remove transaxle cooler lines at radiator.
17. Remove front right-hand and left-hand wheel locks, if equipped.
18. Remove front right-hand and left-hand tire and wheel assemblies.
19. Remove right-hand and left-hand tie rod ends to steering knuckle.
20. Remove right-hand and left-hand ball joints from steering knuckles. Refer to service manual for details of removal procedure (section 4D).
21. Remove right-hand and left-hand axle shaft from transaxle. Refer to service manual for details of removal procedure (section 4D).
22. Position axle/hub assembly up and wire to strut.
23. Remove intermediate steering shaft pinch bolt and shaft from steering gear.
24. Remove A/C compressor suction/discharge fitting at rear of compressor and cover to prevent damage/contamination.
25. Remove starter wiring at starter assembly and remove engine ground.
26. Remove starter assembly and A/C compressor brace from engine.
27. Remove transaxle convertor shields.
28. Remove flywheel to convertor attaching bolts.
29. Remove exhaust pipe to exhaust manifold bolts and springs.
30. Remove right-hand inner fender shield and power steering hose retaining clamps at right-hand frame rail.
31. Remove engine ground strap to lower tie bar. Refer to service manual (section 6D5, Figure 9).
32. Remove engine mount to frame retaining bolts and washers.
33. Lower vehicle and support engine/transaxle for removal from vehicle onto stand J 36295.
34. Remove engine/transaxle frame to body retaining bolts and raise vehicle.
35. Remove serpentine belt guide cover and belt.
36. Remove alternator wiring, generator and bracket.
37. Remove power steering pump and lines from engine. Wire pump assembly and lines to frame.
Notice:
Do not disconnect lines from pump.
38. Remove A/C compressor support brace and compressor assembly.
39. Remove front and rear coolant by-pass pipes from engine.
40. Remove water pump from front cover.
41. Remove spark plug wiring at spark plugs and remove spark plug wire routing retainers.
42. Remove TBI wiring. hoses. and TBI unit from intake manifold.
43. Remove engine wiring harness from engine.
44. Remove distributor retainer and distributor assembly from engine.
45. Remove both rocker arm covers.
46. Remove intake manifold assembly.
47. Remove serpentine belt tensioner from engine front cover.
48. Remove torque strut and A/C compressor mounting bracket.
49. Remove torsional damper bolt from crankshaft.
50. Remove torsional damper from crankshaft using J 24420-B.
51. Remove exhaust crossover pipe from both engine exhaust manifolds.
52. Remove engine exhaust manifolds.
53. Remove ignition coil and bracket.
54. Remove electronic vacuum regulator valve (EVRV) and bracket.
55. Remove oil filter adaptor and sensor assembly.
56. Remove engine spark control (ESC) knock sensor.
57. Remove engine coolant sensor from cylinder head.
58. Remove engine to transaxle bracket bolts and bracket.
59. Remove engine block heater, if equipped.
60. Remove engine to transaxle retaining bolts.
61. Separate engine from transaxle.
62. Remove engine mount bracket bolts at engine block.
63. Remove flywheel from engine.
64. Clean all gasket surfaces on new engine.
65. Install flywheel to new engine, apply GM Thread Lock to all flywheel bolts and tighten bolts to 70 Nm (52 lb. ft.)
66. Install engine to front mount bracket. Tighten three front bolts to 80 Nm (59 lb. ft.) and one side bolt to 110 Nm (80 lb. ft.).
67. Install engine to transaxle retaining bolts. Tighten bolts to 75 Nm (55 lb. ft.).
68. Install engine to transaxle bracket. Refer to service manual for details of installation procedure (section 6A).
69. Install new engine oil level indicator (dipstick) tube to new engine (tube packaged loose with Goodwrench engine).
70. Install new engine oil level indicator (dipstick) into indicator tube (indicator packaged loose with Goodwrench engine)
71. Install engine block heater, if equipped.
72. Install engine coolant sensor.
73. Install ESC knock sensor. Tighten sensor to 19 Nm (14 lb. ft.).
Notice:
Be sure threads are clean.
74. Install oil filter adaptor, including [1][2]oil pressure sensor and new adaptor gasket. Tighten connector through adaptor to 39 Nm (29 lb. ft.).
75. Install EVRV and bracket to cylinder head.
76. Install ignition coil and bracket to cylinder head.
77. Install both engine exhaust manifolds and new exhaust manifold gaskets. Refer to service manual for details of installation procedure (section 6A4).
78. Install exhaust crossover pipe. Tighten nuts to 25 Nm (18 lb. ft.).
79. Install torque strut/air conditioning compressor mounting bracket on engine.
80. Install torsional damper to crankshaft. Refer to installation procedure (section 6A4).
78. Install exhaust crossover pipe. Tighten nuts to 25 Nm (18 lb. ft.).
79. Install torque strut/air conditioning compressor mounting bracket on engine.
80. Install torsional damper to crankshaft. Refer to service manual for details of installation procedure (section 6A4)
81. Install serpentine belt tensioner assembly to front cover. Refer to service manual for details of installation procedure (section 6A4).
82. Install intake manifold assembly and new intake manifold gasket. Refer to service manual for details of installation procedure (section 6A4).
83. Install both rocker arm covers. Use rocker cover gaskets which came with Goodwrench engine. Refer to service manual for details of installation procedure (section 6A4).
84. Install distributor assembly and new seal o-ring. Refer to service manual for deteals of installation procedure (section 6D4).
Notice:
Do not tighten retaining bolt at this time.
85. Install TBI unit and new gasket. Refer to service manual for details of installation procedure (section 6E2).
86. Install engine wiring harness and vacuum harness.
87. Install spark plugs and attach spark plug wires.
88. Install water pump and new gasket. Tighten bolts to 10 Nm (89 lb. in.).
89. Install front and rear coolant by-pass pipes.
90. Install A/C compressor assembly and support brace. Refer to service manual for details of installation procedure (section 1B)
91. Install power steering pump and lines. Refer to service manual for details of installation procedure (section 3B1).
92. Install alternator assembly, braze and wiring.
93. Install serpentine drive belt and cover.
94. Install engine/transaxle on frame into vehicle by raising stand J 36295 up to vehicle. Tighten bolts to 140 Nm (103 lb. ft.).
95. Install power steering line retaining clamps and right-hand inner fender shield.
96. Install exhaust pipe to exhaust manifold bolts and springs. and new exhaust manifold pipe seal. Refer to service manual for details of installation procedure (section 6F)
97. Install flywheel to convertor attaching bolts. Tighten bolts to 60 Nm (44 lb. ft.).
98. Install convertor cover.
99. Install starter assembly including all wiring and A/C compressor brace.
100. Install A/C compressor suction/discharge fitting to compressor.
101. Install intermediate steering shaft to gear and pinch bolt.
102. Install right-hand and left-hand axle assemblies to transaxle.
103. Install right-band and left-hand steering knuckle-to-ball joint pinch bolt. Refer to service manual for details of installation procedure (section 4D).
104. Install right-hand and left-hand tie rod ends to steering knuckle. Refer to service manual for details of installation procedure (section 4D).
105. Install right-hand and left-hand tire and wheel assemblies (with wheel locks if equipped).
106. Install ground strap at lower tie bar from engine harness.
107. Install transaxle cooler lines at radiator.
108. Lower vehicle.
109. Install engine torque strut to engine.
110. Install engine wiring harness to block connector at left hood hinge.
111. Install left-hand engine compartment crossbrace with washer reservoir.
112. Install radiator and heater hoses to engine.
113. Install transaxle shift bracket and linkage to transaxle.
114. Install throttle and throttle valve cables to TBI unit.
115. Install fuel lines at TBI unit.
116. Install necessary ECM harness fasteners to chassis.
117. Install engine harness through cowl and connect at ECM.
114. Install throttle and throttle valve cables to TBI unit.
115. Install fuel lines at TBI unit.
116. Install necessary ECM harness fasteners to chassis.
117. Install engine harness through cowl and connect at ECM.
118. Refill coolant system with new coolant. Add two (2) engine cooling system sealer pellets to radiator. Coolant must be mixed with an equal amount of water and coolant (50/50) to provide proper protection.
119. Fill engine to appropriate level with new engine oil.
120. Install air cleaner assembly.
121. Reconnect battery cables.
122. Check engine timing and tighten distributor retainer.
123. Check and adjust front suspension toe to specifications.
124. Recharge A/C system. Refer to service manual for recharging procedure (section 1B)
125 Start engine and verify no fluid leaks.
126. Reset radio, clock, etc.