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Home >> Chevrolet >> 2005 >> Chevy Express H1500, Van Passenger >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Install the engine assembly to the vehicle.
  2. Loosely install the 2 upper transmission to engine bolts.
  3. Install the engine mounts to the engine mount frame brackets. Refer to the following procedures:
  4. Remove the engine lifting device.
    5. Fig 1: Engine Lift Brackets J 41427
    GM33636Courtesy of GENERAL MOTORS CORP.
  5. Remove the J 41427 from the engine.
  6. Apply thread lock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
  7. Install the lower intake manifold bolts.

    Tighten: 

    1. Tighten the bolts to 3 N.m (27 lb in).
    2. Tighten the bolts to 12 N.m (106 lb in).
    3. Tighten the bolts to 15 N.m (11 lb ft).

  8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  9. Install the remaining bolts from the transmission to the engine. Refer to Transmission Replacement in Automatic Transmission - 4L60-E/4L65-E for location of the proper bolts and tightening specifications.
    10. Fig 2: Identifying Starter Wiring Harness & Transmission Cooler Pipes Bracket Retaining Bolt
    GM535378Courtesy of GENERAL MOTORS CORP.
  10. Install the bolt holding the transmission cooler pipes bracket to the oil pan.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  11. Install the torque converter bolts to the flywheel.

    Tighten:  Tighten the bolts to 62 N.m (46 lb ft).

    12. Fig 3: View Of Transmission Cover
    GM334324Courtesy of GENERAL MOTORS CORP.
  12. Install the transmission cover.

    Tighten:  Tighten the transmission cover bolts to 12 N.m (106 lb in).

  13. Install the starter motor. Refer to Starter Motor Replacement (4.8L, 5.3L, and 6.0L) or Starter Motor Replacement (4.3L) in Engine Electrical.
  14. Install the engine oil cooler pipes to the engine. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
  15. Install the exhaust manifolds. Refer to the following procedures:
  16. Lower the vehicle.
  17. Install the upper intake manifold to the engine. Refer to Intake Manifold Replacement - Upper .
    18. Fig 4: Rear Of Cylinder Head Ground Wires
    GM375408Courtesy of GENERAL MOTORS CORP.
  18. Install the transmission control cable bracket to the rear of the left cylinder head.

    Tighten:  Tighten the transmission control cable bracket bolts to 40 N.m (30 lb ft).

  19. Install the distributor. Refer to Distributor Replacement in Engine Controls - 4.3L.
  20. Install the power steering pump with the rear bracket to the engine. Refer to Power Steering Pump Replacement (4.8L, 5.3L, and 6.0L) or Power Steering Pump Replacement (4.3L) in Power Steering System.
  21. Install the power steering pump mounting bracket.
  22. Install the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement (4.8L, 5.3L, 6.0L ) in Heating, Ventilation, and Air Conditioning.
  23. Install the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
  24. Install the radiator inlet and outlet hoses to the engine. Refer to the following procedures:
  25. Install the heater hoses to the engine. Refer to Heater Hose Replacement - Inlet and Heater Hose Replacement - Outlet in Heating, Ventilation, and Air Conditioning.
  26. Install the generator mounting bracket.
    27. Fig 5: Rear Of Cylinder Head Ground Wires
    GM375426Courtesy of GENERAL MOTORS CORP.
  27. Install the stud and bolt holding the ground wires to the rear of both cylinder heads.

    Tighten:  Tighten the bolt and the stud to 10 N.m (88 lb in).

  28. Install the nut holding the engine wiring harness at the transmission to engine stud.

    Tighten:  Tighten the nut to 10 N.m (88 lb in).

    29. Fig 6: Engine Wiring Harness Clips & Crankshaft Position (CKP) Sensor
    GM535477Courtesy of GENERAL MOTORS CORP.
  29. Connect the CKP sensor (3).
  30. Install the engine wiring harness clip (1) from the stud on the generator mounting bracket.
  31. Install the engine wiring harness clip (2) at the front of the engine.
    32. Fig 7: Fuel Meter Body Assembly Connector, EVAP Canister Purge Solenoid Valve & Manifold Absolute Pressure Sensor
    GM532770Courtesy of GENERAL MOTORS CORP.
  32. Connect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The MAP sensor (3)
    33. Fig 8: Locating Knock Sensor & Engine Oil Pressure Sensor
    GM491825Courtesy of GENERAL MOTORS CORP.
  33. Connect the following electrical connectors:
    • The distributor (2)
    • The engine oil pressure sensor (3)
    • The KS (1)
    34. Fig 9: Throttle Position Sensor, Idle Air Control Motor, Engine Coolant Temperature Gage Sensor, & A/C High Pressure Switch
    GM532760Courtesy of GENERAL MOTORS CORP.
  34. Connect the following electrical connectors:
    • The TP sensor (1)
    • The IAC motor (2)
    • The ECT gage sensor (3)
    • The A/C high pressure switch (4), if equipped
    35. Fig 10: A/C Compressor, Exhaust Gas Recirculation (EGR) Connector & Ground Wire
    GM532777Courtesy of GENERAL MOTORS CORP.
  35. Disconnect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The EGR valve (2)
    • The ECT sensor (3)
  36. Install the nut holding the ground wire (4) to the water outlet stud.

    Tighten:  Tighten the nut to 10 N.m (88 lb in).

    37. Fig 11: Battery Negative Cable & Ground Strap To Front Of Engine Bolt
    GM105211Courtesy of GENERAL MOTORS CORP.
  37. Install the bolt holding the battery negative cable and the ground strap to the front of the engine.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    38. 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.
  38. Install a NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls - 4.3L.
  39. Install the cruise control cable, if equipped, to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
  40. Install the fan clutch to the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
  41. Install the radiator support. Refer to Radiator Support Replacement in Body Front End.
  42. Install the oil filter and fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  43. Fill the cooling system with the proper quantity and type of coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  44. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  45. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
  46. Start the engine and listen for unusual noises.
  47. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.

    If necessary, install an oil pressure gage and measure the engine oil pressure.

  48. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
  49. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
  50. Inspect for oil and/or coolant leaks while the engine is operating.
  51. Verify that the distributor is properly positioned.
  52. Perform a final inspection for the proper engine oil and coolant levels.
  53. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
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