GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 Savana 🢒 Engine 🢒 Engine Mechanical - 7.4L 🢒 Engine Replacement

Removal Procedure
  1. Open the hood.
  2. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
  3. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in engine electrical.
  4. Remove the battery from the vehicle. Refer to Battery Replacement .
  5. Remove the air intake duct from the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls-7.4L.
  6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-7.4L.
  7. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    8. Object Number: 71686 Size: SH
  8. Remove the coolant reservoir. Refer to Cooling System Draining and Filling in Engine Cooling.
  9. Remove the front bumper from the vehicle.
  10. Remove the grill and park light assembly from the vehicle. Refer to Grille Replacement .
  11. Evacuate the air conditioning system.
  12. Remove the radiator support from the vehicle. Refer to Radiator Support Replacement in Engine Cooling.
  13. Remove the radiator from the vehicle. Refer to Radiator Replacement in Engine Cooling.
  14. Remove the air conditioning condenser from the vehicle. Refer to Condenser Replacement in HVAC.
  15. Remove the drive belt from the vehicle. Refer to Drive Belt Replacement .
  16. Remove the fan clutch from the water pump. Refer to Fan Clutch Replacement in Engine Cooling.

    17. Object Number: 71659 Size: SH
  17. Remove the radiator hoses from the engine. Refer to Heater Hoses Replacement in Engine Cooling.
  18. Remove the engine wiring harness and the connectors.

    19. Object Number: 184051 Size: SH
  19. Remove the engine oil fill tube.

    20. Object Number: 234451 Size: SH
  20. Remove the engine oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
  21. Remove the air conditioning compressor from the mounting bracket. Refer to Air Conditioning Compressor Replacement in HVAC.
  22. Remove the power steering pump from the mounting bracket. Refer to Power Steering Pump Replacement in Steering.
  23. Remove the A/C mounting bracket from the engine block. Refer to Accessory Brackets Replacement in HVAC.
  24. Remove the generator from the mounting bracket. Refer to Generator Replacement in Engine Electrical.

    25. Object Number: 105620 Size: SH
  25. Remove the generator mounting bracket from the engine block. Refer to Accessory Brackets Replacement .

    26. 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.

  26. Remove the throttle body from the upper intake manifold. Refer to Throttle Body Removal in Engine Controls-7.4L.
  27. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement .
  28. Remove the lower intake manifold from the cylinder head. Refer to Intake Manifold Replacement .

    29. Object Number: 104974 Size: SH
  29. Remove the transmission oil level and indicator tube. Refer to Filler Tube Replacement .
  30. Remove the transmission shift cable connector.
  31. Disconnect the fuel supply lines at the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-7.4L.
  32. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  33. Remove the starter motor from the engine block. Refer to Starter Motor Replacement in Engine Electrical.

    34. Object Number: 32688 Size: SH
  34. Remove the flywheel inspection cover.
  35. Remove the exhaust pipes at the exhaust manifolds. Refer to General Exhaust System Replacement in Engine Controls.

    36. Object Number: 160854 Size: SH
  36. Remove the engine cooler lines from the retaining brackets. Refer to Engine Oil Cooler Hose/Pipe Replacement .

    37. Object Number: 9096 Size: SH
  37. Remove the torque converter to flywheel bolts.

    38. Object Number: 177057 Size: SH
  38. Remove the transmission to engine bolts.
  39. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  40. Install a length of chain, using GM P/N 23503910  or equivalent attaching bolt, to the rear of the right cylinder head and the front of the left cylinder head.
  41. Support the transmission with a strap between the frame rails.
  42. Install the suitable lifting device to the engine.

    43. Object Number: 66191 Size: SH
  43. Remove the front engine mount through bolts.
  44. Remove the engine from the vehicle.

Installation Procedure
  1. Install the engine from the vehicle.

    2. Object Number: 66191 Size: SH
  2. Install the front engine mount through bolts.
  3. Remove the lifting device to the engine.
  4. Remove the support from the transmission.
  5. Remove the chain and attaching bolts from the cylinder heads.
  6. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Install the bolts from the transmission to engine. Refer to Transmission Oil Cooler Replacement or Transmission Replacement in Transmissions and Transaxles.

    8. Object Number: 9096 Size: SH
  8. Install the bolts from the flywheel to the torque convertor.
  9. Install the engine cooler lines to the retaining brackets. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
  10. Install the exhaust pipes to the exhaust manifolds. Refer to General Exhaust System Replacement in Engine Exhaust.

    11. Object Number: 32688 Size: SH
  11. Install the flywheel inspection cover.
  12. Install the starter motor to the engine block. Refer to Starter Motor Replacement in Engine Electrical.
  13. Remove the safety stands and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  14. Connect the fuel supply lines at the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-7.4L.
  15. Connect the transmission shift cable connector.

    16. Object Number: 64532 Size: SH
  16. Install the lower intake manifold to the cylinder head. Refer to Intake Manifold Replacement .
  17. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement

    18. 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.

  18. Install the throttle body to the upper intake manifold. Refer to Throttle Body Replacement in Engine Controls-7.4L.
  19. Install the generator mounting bracket to the engine block. Refer to Accessory Brackets Replacement .
  20. Install the generator to the mounting bracket. Refer to Generator Replacement in Engine Electrical.

    21. Object Number: 104974 Size: SH
  21. Install the transmission oil level and indicator tube. Refer to Filler Tube Replacement in Transmissions and Transaxles.
  22. Install the A/C mounting bracket to the engine block. Refer to Accessory Brackets Replacement in HVAC.
  23. Install the power steering pump to the mounting bracket. Refer to Power Steering Pump Replacement in Steering.
  24. Install the air conditioning compressor to the mounting bracket. Refer to Air Conditioning Compressor Replacement in HVAC.

    25. Object Number: 234451 Size: SH
  25. Install the engine oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .

    26. Object Number: 184051 Size: SH
  26. Install the engine oil fill tube to the engine block.
  27. Install the engine wiring harness and the connectors.

    28. Object Number: 71659 Size: SH
  28. Install the radiator hoses to the engine. Refer to Radiator Hose Replacement in Engine Cooling.
  29. Install the fan clutch to the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
  30. Install the drive belt to the vehicle. Refer to Drive Belt Replacement .
  31. Install the air conditioning condenser to the vehicle. Refer to Condenser Replacement in HVAC.
  32. Install the radiator to the vehicle. Refer to Radiator Replacement in Engine Cooling.
  33. Install the radiator support to the vehicle. Refer to Radiator Support Replacement in Engine Cooling.
  34. Install the grill and park light assembly to the vehicle. Refer to Grille Replacement .
  35. Install the front bumper to the vehicle.

    36. Object Number: 71686 Size: SH
  36. Install the coolant reservoir in the vehicle. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  37. Install the air intake duct to the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  38. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 7.4L.
  39. Install the battery in the vehicle. Refer to Battery Replacement in Engine Electrical.
  40. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  41. Recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging in HVAC.
  42. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Interior Trim.
  43. Install the Oil Filter and Engine Oil. Refer to Engine Oil and Oil Filter Replacement .
  44. Before starting a new engine, or one that has been repaired. Refer to Engine Set-Up and Testing .