GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Beretta 🢒 Engine 🢒 Engine Mechanical - 3.1L and 3.4L 🢒 Engine Replacement

Removal Procedure

Tools Required

J 28467-360 Engine Support Fixture

  1. Depressurize the fuel system. Refer to Fuel System Pressure Relief in Engine Fuel.
  2. Disconnect the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
  3. Remove the top half of the air cleaner assembly. Remove the throttle body duct.
  4. Drain the coolant. Recover the coolant. Refer to Draining, Flushing and Filling the Cooling System in Cooling and Radiator.
  5. Remove the upper radiator hose from the engine. Pull the upper radiator hose back.
  6. Remove the lower radiator hose from the engine. Pull the lower radiator hose back.

    7. Object Number: 63668 Size: SH
  7. Remove the coolant inlet line from the surge tank.
  8. Remove the following vacuum hoses:
    9. • Vacuum modulator
    • EVAP canister purge
    • Power brake booster line
  9. Remove the heater outlet hose from the water pump.
  10. Remove the drive belt. Refer to Drive Belt Replacement .
  11. Remove the accelerator cable and the cruise control cable, if equipped, from the throttle linkage.
  12. Remove the following upper wiring items from the engine:
    13. • Electronic ignition
    • Heated Oxygen sensor (HO2S)
    • Injector harness
    • IAC
    • Throttle Position (TP) sensor
    • Engine Coolant Temperature (ECT) sensor
    • Park/Neutral position switch
    • Transmission shift solenoid and TCC solenoid
    • EGR
    • Ground at the transmission
  13. Remove the generator. Refer to Generator in Charging System.
  14. Remove the power steering lines at the pump. Refer to Power Steering Gear and Pump.
  15. Remove the fuel lines. Refer to Fuel Feed and Return Pipes and Hoses in Engine Fuel.
  16. Remove the cooling fan assembly. Refer to Electric Coolant Fan in Cooling and Radiator.
  17. Remove the shift cable linkage from the mounting bracket. Remove the shift cable from the mounting bracket. Put the transmission in low gear for accessibility if necessary.
  18. Remove the transmission vent tube from the transmission.
  19. Remove the vacuum hose at the vacuum reservoir.
  20. Install the J 28467-360 .

    21. Object Number: 63663 Size: SH
  21. Loosen the top two A/C compressor bolts.

    22. Do not remove the bolts.

  22. Raise the vehicle. Support the vehicle. Refer to General Information.
  23. Remove the front tire and wheel assemblies. Refer to Wheel Removal in Tires and Wheels.
  24. Remove the splash shields. Refer to Splash Shield Replacement in Bumpers.
  25. Remove the engine mount strut from the suspension support. Refer to Engine Mount Strut Bracket Replacement .
  26. Remove both front ABS wheel speed sensors connectors and the harness from the suspension supports.
  27. Remove both of the ball joints. Refer to Ball Joints in Front Suspension.
  28. Remove the suspension support assembly. Refer to Suspension Support in Front Suspension.
  29. Remove the drive axles from the transmission. Support the drive axles. Refer to Drive Axle in Drive Axle.
  30. Remove the oil filter.
  31. Remove the oil filter adapter. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  32. Remove the transmission converter cover. Refer to Flywheel to Converter Bolts in Automatic Transmission.
  33. Remove the starter. Refer to Starter in Cranking Systems.
  34. Remove the following lower wiring items from the engine:
    35. • Knock sensor
    • Front crankshaft position sensor
    • Side crankshaft position sensor
    • Oil level sensor
    • VSS
    • Grounds from the transmission
  35. Remove both of the heater hoses.

    36. Object Number: 63664 Size: SH
  36. Remove the A/C compressor lower bolts. Support the compressor aside.
  37. Remove the vacuum reserve tank.
  38. Remove the exhaust pipe from the manifold. Position the exhaust pipe aside. If necessary, push the engine forward while you position the exhaust system aside.
  39. Remove the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
  40. Remove the transmission cooler lines at the radiator. Refer to Transmission Oil Cooler Pipes and Fitting in Automatic Transmission.
  41. Remove the transmission fluid indicator and tube. Refer to Filler Tube and Seal in Automatic Transmission.
  42. Lower the vehicle and the engine/ transmission onto a suitable table.
  43. Remove the transmission mount to body bolts. Refer to Transmission Mounts in Automatic Transmission.
  44. Remove the intermediate bracket from the right engine mount support bracket.
  45. Raise the vehicle. Support the vehicle. Leave the powertrain on the table. Refer to General Information.
  46. Separate the engine from the transmission assembly.

Installation Procedure
  1. Connect the engine and the transmission.
  2. Position the engine under the vehicle.
  3. Lower the vehicle onto the table.
  4. Loosely install the drive belt.
  5. Install the engine mount support bracket to the intermediate bracket.
  6. Install the transmission mount to body bolts. Refer to Transmission Mounts in Automatic Transmission.
  7. Raise the vehicle. Support the vehicle. Refer to General Information.
  8. Install the transmission fluid indicator and tube. Refer to Filler Tube and Seal in Automatic Transmission.
  9. Install the transmission cooler lines at the radiator. Refer to Transmission Oil Cooler Pipes and Fittings in Automatic Transmission.
  10. Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
  11. Install the exhaust pipe to the exhaust manifold. If necessary, push the engine forward while you position the exhaust system.
  12. Install the vacuum reserve tank.

    13. Object Number: 63663 Size: SH
  13. Loosely assemble the A/C compressor bracket and the upper compressor bolts. Retain the bolts and the bracket to the compressor for ease of assembly.

    14. Object Number: 63664 Size: SH
  14. Install the lower A/C compressor bolts.

    15. Object Number: 545 Size: SH
  15. Connect both heater hoses to the cowl.
  16. Connect the following lower wiring items to the engine:
    17. • Knock sensor
    • Front crankshaft position sensor
    • Side crankshaft position sensor
    • Oil level sensor
    • VSS
    • Grounds from the transmission
  17. Install the starter. Refer to Starter in Cranking Systems.
  18. Install the transmission converter cover. Refer to Flywheel to Converter Bolts in Automatic Transmission.
  19. Install the oil filter adapter. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  20. Install the oil filter.
  21. Install the drive axles to the transmission. Refer to Drive Axle in Drive Axle.
  22. Install the suspension support assembly. Refer to Suspension Support in Front Suspension.
  23. Install both of the ball joints. Refer to Ball Joints in Front Suspension.
  24. Connect both of the front ABS wheel speed sensor connectors.
  25. Install the engine mount strut to the suspension support. Refer to Engine Mount Strut Bracket Replacement .
  26. Install the splash shields. Refer to Splash Shield Replacement in Bumpers.
  27. Install the front tire and wheel assemblies. Refer to Wheel Removal in Tires and Wheels.
  28. Lower the vehicle.

    29. Object Number: 63663 Size: SH
  29. Install the upper A/C compressor bolts.
  30. Remove the engine support fixture.
  31. Install the vacuum hose at the vacuum reservoir.
  32. Install the transmission vent tube to the transmission.
  33. Connect the shift cable linkage to the mounting bracket. Connect the shift cable to the mounting bracket.
  34. Install the cooling fan assembly. Refer to Electric Coolant Fan in Cooling and Radiator.
  35. Install the fuel lines. Refer to Fuel Feed and Return Pipes and Hoses in Engine Fuel.
  36. Install the power steering lines at the pump. Refer to Power Steering Gear and Pump.
  37. Install the generator. Refer to Generator in Charging System.
  38. Connect the following upper wiring items to the engine:
    39. • Electronic Ignition
    • Heated Oxygen sensor (HO2S)
    • Injector harness
    • IAC
    • Throttle Position (TP) sensor
    • Engine Coolant Temperature (ECT) sensor
    • Park/Neutral position switch
    • Transmission shift solenoid and TCC solenoid
    • EGR
    • Ground at the transmission
  39. Connect the accelerator cable and cruise control cable, if equipped, to the throttle linkage.
  40. Install the drive belt. Refer to Drive Belt Replacement .
  41. Install the heater outlet hose to the water pump.
  42. Connect the following vacuum hoses:
    43. • Vacuum modulator
    • EVAP canister purge
    • Power brake booster line

    Object Number: 63668 Size: SH
  43. Install the coolant inlet line to the surge tank.
  44. Install the lower radiator hose to the engine.
  45. Install the upper radiator hose to the engine.
  46. Install the top half of the air cleaner assembly. Install the throttle body duct.
  47. Connect the negative battery cable.
  48. Bleed the power steering system.