GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 Savana 🢒 Engine 🢒 Engine Mechanical - 5.0L and 5.7L 🢒 Engine Replacement

Removal Procedure

    Object Number: 71686 Size: SH
  1. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  2. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in engine electrical.
  3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  5. Remove the front bumper. Refer to Front Bumper Replacement in Frame and Bumpers.
  6. Remove the radiator grille assembly. Refer to Grille Replacement .
  7. Remove the radiator support. Refer to Radiator Support Replacement in Sheet Metal.
  8. Remove the A/C condenser. Refer to Condenser Replacement in HVAC.
  9. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
  10. Remove the ground straps. Refer to Engine Ground Strap Replacement in Engine Electrical.
  11. Remove the fan clutch from the water pump. Refer to Fan Clutch Replacement
  12. Remove the heater hoses from the engine .Refer to Heater Hoses Replacement in Engine Cooling.
  13. Remove the engine wiring harness.

    14. Object Number: 26764 Size: SH

    Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  14. Remove the accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Control Cable Replacement
  15. Remove the generator from the mounting bracket. Refer to Generator Replacement in Engine Electrical.
  16. Remove the generator mounting bracket. Refer to Accessory Mounting Brackets Replacement .
  17. Remove the A/C compressor from the mounting bracket. Refer to Air Conditioning Compressor Replacement in HVAC.
  18. Remove the power steering pump from the mounting bracket. Refer to Power Steering Pump Replacement in Power Steering Gear and Pump.
  19. Remove the pulley from the power steering pump. Refer to Power Steering Pump Pulley Replacement in Power Steering Gear and Pump.

    20. Object Number: 188295 Size: SH
  20. Remove the power steering pump mounting bracket using the following procedure:
    21. • Remove three bolts from the front of the bracket.
    • Remove one nut from the front of the bracket.
    • Slide the bracket off of the stud.
    • Remove the stud from the cylinder head.
  21. In order to allow access for the lifting device, remove the upper intake manifold. Refer to Intake Manifold Replacement .
  22. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-5.0/5.7L.
  23. Remove the transmission oil level indicator and tube. Refer to Filler Tube Replacement and Transmission Fluid Filler Tube and Seal Replacement in Transmissions and Transaxles.
  24. Remove the transmission shift cable connector. Refer to Shift Cable Replacement .
  25. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle .
  26. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  27. Remove the exhaust pipes from the exhaust manifolds. Refer to General Exhaust System Replacement

    28. Object Number: 160842 Size: SH
  28. Remove the engine oil cooler lines from the retaining brackets.
  29. Remove the engine oil cooler lines from the engine. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.

    30. Object Number: 32688 Size: SH
  30. Remove the flywheel cover.
  31. Remove the starter motor. Refer to Starter Motor Replacement .
  32. Remove the torque converter bolts from the flywheel. Refer to Engine Flywheel Replacement .
  33. Remove the transmission cooler lines from the engine. Refer to Oil Cooler Line Replacement in Engine Cooling.
  34. Remove the bolts holding the transmission to the engine. Refer to Transmission Replacement and Transmission Replacement in Transmissions and Transaxles.
  35. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle .
  36. Install a length of chain, using GM P/N  23503910 attaching bolt to the rear of the left cylinder head.
  37. Support the transmission with a strap between the frame rails.
  38. Attach a suitable lifting device to the chain.
  39. Remove the engine mounts from the frame. Refer to Engine Mount Replacement .
  40. Remove the engine assembly from the vehicle.

Installation Procedure

    Object Number: 66189 Size: SH
  1. Install the engine assembly to the vehicle.
  2. Install the engine mounts to the frame. Refer to Engine Mount Replacement .
  3. Install the engine mount through bolts. Refer to Engine Mount Replacement .
  4. Remove the lifting device from the chain.
  5. Support the transmission with a strap between the frame rails.
  6. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle .
  7. Install the bolts from the transmission to the engine. Refer to Transmission Replacement and Transmission Replacement in Transmission and Transaxle.
  8. Install the transmission cooler lines to the engine block. Refer to Oil Cooler Line Replacement .
  9. Install the torque converter bolts to the flywheel. Refer to Engine Flywheel Replacement .

    10. Object Number: 32688 Size: SH
  10. Install the flywheel cover.
  11. Install the starter motor. Refer to Starter Motor Replacement .
  12. Install the engine oil cooler lines to the engine. Refer to Engine Oil Cooler Hose/Pipe Replacement .
  13. Install the engine oil cooler lines to the retaining brackets. Refer to Engine Oil Cooler Hose/Pipe Replacement .
  14. Install the exhaust pipes to the exhaust manifolds. Refer to General Exhaust System Replacement .
  15. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle .
  16. Install the transmission shift cable connector. Refer to Shift Cable Replacement in Transmissions and Transaxle.
  17. Install the transmission oil level indicator and the tube. Refer to Filler Tube Replacement and Transmission Fluid Filler Tube and Seal Replacement in Transmissions and Transaxle.
  18. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement in Engine Controls-5.0/5.7L.
  19. Install the upper intake manifold to the engine. Refer to Intake Manifold Replacement .
  20. Install the A/C compressor to the mounting bracket. Refer to Air Conditioning Compressor Replacement in HVAC.
  21. Install the generator mounting bracket. Refer to Accessory Mounting Brackets Replacement .
  22. Install the generator to the mounting bracket. Refer to Generator Replacement .

    23. Object Number: 26764 Size: SH

    Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  23. Install the NEW accelerator control cable and the cruise control cable, if equipped. Refer to Accelerator Control Cable Replacement in Engine Controls.
  24. Install the engine wiring harness.
  25. Install the heater hoses to the engine block. Refer to Heater Hoses Replacement in HVAC.
  26. Install the fan clutch to the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
  27. Install the ground straps. Refer to Engine Ground Strap Replacement in Engine Electrical.
  28. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
  29. Install the A/C condenser. Refer to Condenser Replacement in HVAC.
  30. Install the radiator support. Refer to Radiator Support Replacement in Sheet Metal.
  31. Install the radiator grille assembly. Refer to Grille Replacement in Sheet Metal.
  32. Install the front bumper. Refer to Front Bumper Replacement in Frame and Bumpers.
  33. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  34. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  35. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  36. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement in Engine Electrical.
  37. Fill the engine with the proper quantity and grade of engine oil. Refer to Engine Oil and Oil Filter Replacement .
  38. Fill the cooling system with the proper quantity and type of coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  39. Before starting a new engine, or one that has been repaired. Refer to Engine Set-Up and Testing .