Engine Replacement. Chevrolet Corsica 1996

For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 28467-360 Engine Support Fixture

Notice: If the engine is replaced, be sure to measure the dowel in the engine block which aligns the transmission to the engine. In 1995 the dowel measured 19 mm and in 1996 the dowel measures 15 mm. If assembly of the transmission to the engine is attempted with the wrong size dowel, transmission case damage will occur.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
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. Drain and recover the coolant. Refer to Draining and Filling Cooling System .
4. Remove the air cleaner outlet duct.
5. Remove the upper radiator hose at the coolant outlet.
6. Disconnect the brake booster vacuum hose.
7. Disconnect the IAC electrical connection.
8. Disconnect the generator electrical connection.
9. Disconnect the throttle position (TPS) sensor electrical sensor.
10. Disconnect the MAP electrical connection.
11. Disconnect the EVAP emission solenoid electrical connection.
12. Disconnect the injector harness electrical connection.
13. Disconnect the EGR electrical connection.
14. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connection.
15. Disconnect the TCC electrical connection.
16. Disconnect the Oxygen (02S) sensor electrical connection.
17. Disconnect the Park/Neutral position switch.
18. Disconnect the engine grounds electrical connection.
19. Remove the drive belt. Refer to Drive Belt Replacement .
20. Remove the transmission shift control cable from the range select lever and bracket. Refer to Section 7A.
21. Remove the coolant surge tank .
22. Remove the coolant surge tank hose.
23. Disconnect the vacuum line near the master cylinder.
24. Install the J 28467-360 .
25. Disconnect the lower radiator hose from the coolant pump.
26. Raise the vehicle. Refer to SECTION 0A.
27. Remove the front tire and wheel assemblies. Refer to SECTION 3E.
28. Remove both of the splash shields. Refer to SECTION 10-4.
29. Remove the exhaust pipe at the exhaust manifold and catalytic converter. Refer to Section 6F.
30. Remove the engine mount strut.
31. Remove the wheel speed sensor wire harness from the control arms.
32. Separate the ball joints from the steering knuckles. Refer to SECTION 3C.
33. Separate the tie rod ends from the struts. Refer to Section 3C.
34. Remove the brake lines from the suspension support. Refer to SECTION 5.
35. Remove the A/C compressor and support with the lines attached.
36. Disconnect the electronic ignition module electrical connection.
37. Disconnect the vehicle speed sensor electrical connections.
38. Disconnect the cooling fan electrical connection.
39. Disconnect the starter electrical connection.
40. Disconnect the A/C compressor electrical connector.
41. Disconnect the oil pressure sensor electrical connector.
42. Disconnect the oil level sensor electrical connector.
43. Disconnect the ground wires.
44. Disconnect the power steering lines from the rack and pinion assembly.
45. Remove the flexible coupling joint at the rack and pinion assembly.
46. Remove the following cables from the accelerator control bracket:

• | The accelerator control

• | The cruise control

• | The TV

47. Remove the suspension support assembly. Refer to SECTION 3C
48. Disconnect the heater hoses at the front of the dash.
49. Remove both of the drive axles from the transmission and position them aside. Refer to SECTION 4D.
50. Disconnect the fuel lines.
51. Disconnect the transmission cooler lines from the transmission. Refer to Section 7A.
52. Remove the transmission mount. Refer to Section 7A.
53. Remove the engine mount assembly. Refer to Engine Mount Replacement .
54. Support the vehicle. Raise the vehicle. Refer to Section 0A.
55. Lower the vehicle until it rests lightly against the support.
56. Remove the J 28467-360 from the engine.
57. Raise the vehicle. Leave the engine and the transmission assembly on the table.
58. Remove the engine from the transmission.

### Installation Procedure

#### Tools Required

J 28467-360 Engine Support Fixture

1. Install the engine to the transmission.
2. Install the transmission bolts.

Tighten
Tighten the bolts to 75 N·m (55 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Lower the vehicle onto the engine and transmission assembly.
4. Install the J 28467-360 .
5. Install the engine mount assembly.
6. Install the transmission mount. Refer to Section 7A.
7. Connect the transmission cooler lines to the transmission. Refer to Section 7A.
8. Connect the fuel lines. Refer to Section 6C.
9. Install both of the drive axles. Refer to SECTION 4D.
10. Connect the heater hoses.
11. Install the suspension support assembly. Refer to Section 3C.
12. Install the following cables to the accelerator control bracket:

• | The accelerator control

• | The cruise control

• | The TV

13. Install the flexible coupling joint to the rack and pinion assembly. Refer to SECTION 3B.
14. Connect the power steering lines. Refer to SECTION 3B.
15. Install the electronic ignition module electrical connection.
16. Connect the brake lines to the suspension support.
17. Connect the vehicle speed sensor electrical connections.
18. Connect the cooling fan electrical connection.
19. Connect the starter electrical connection.
20. Connect the A/C compressor electrical connection.
21. Connect the oil pressure sensor electrical connection.
22. Connect the oil level sensor electrical connection.
23. Connect the grounds electrical connection
24. Install the A/C compressor. Refer to SECTION 1B.
25. Install the brake lines to the suspension support.
26. Install the tie rod ends to the struts. Refer to SECTION 3B.
27. Install the ball joints to the steering knuckles. Refer to SECTION 3C.
28. Install the wheel speed sensor wire harness to the control arms.
29. Install the engine mount strut.
30. Install the exhaust pipe to the exhaust manifold and catalytic converter. Refer to Section 6F.
31. Install both of the splash shields. Refer to SECTION 10-4.
32. Install the front tire and wheel assemblies. Refer to SECTION 3E.
33. Lower the vehicle.
34. Connect the lower radiator hose to the coolant pump.
35. Remove the J 28467-360 .
36. Connect the vacuum line near the master cylinder.
37. Install the coolant surge tank.
38. Install the coolant surge tank hose.
39. Connect the transmission shift control cable.
40. Install the drive belt. Refer to Drive Belt Replacement .
41. Install the IAC electrical connection.
42. Connect the generator electrical connection.
43. Connect the Throttle Position (TPS) sensor electrical connection.
44. Connect the MAP electrical connection.
45. Connect the EVAP emission solenoid electrical connector.
46. Connect the injector harness.
47. Connect the EGR electrical connector.
48. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
49. Connect the TCC electrical connector.
50. Reconnect the Oxygen (02S) sensor
51. Reconnect the Park/Neutral position switch
52. Reconnect the engine ground wires.
53. Connect the brake booster vacuum hose.
54. Install the upper radiator hose at the coolant outlet.
55. Install the air cleaner outlet duct.
56. Fill the coolant system. Refer to Draining and Filling Cooling System .
57. Refill the engine with oil.
58. Reconnect the negative battery cable.