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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure 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 - 4.3L.
  5. Remove the front bumper. Refer to Bumper Replacement - Front in Bumpers.
  6. Remove the grille. Refer to Grille Replacement (Uplevel) or Grille Replacement (Base) in Exterior Trim.
  7. Remove the radiator support. Refer to Radiator Support Replacement in Body Front End.
  8. Remove the A/C condenser. Refer to Condenser Replacement in Heating, Ventilation, and Air Conditioning.
  9. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
    10. 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.
  10. Remove the accelerator control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls - 4.3L.
  11. Remove the cruise control cable, if equipped, from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
    12. Fig 1: Rear Of Cylinder Head Ground Wires
    GM375426Courtesy of GENERAL MOTORS CORP.
  12. Remove the stud and bolt holding the ground wires to the rear of both cylinder heads.
  13. Remove the nut holding the wiring harness at the transmission to engine stud.
    14. Fig 2: Throttle Position Sensor, Idle Air Control Motor, Engine Coolant Temperature Gage Sensor, & A/C High Pressure Switch
    GM532760Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the following electrical connectors:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gage sensor (3)
    • The air conditioning (A/C) high pressure switch (4), if equipped
    15. Fig 3: Fuel Meter Body Assembly Connector, EVAP Canister Purge Solenoid Valve & Manifold Absolute Pressure Sensor
    GM532770Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The evaporative emission (EVAP) canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
    16. Fig 4: Locating Knock Sensor & Engine Oil Pressure Sensor
    GM491825Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the following electrical connectors:
    • The distributor (2)
    • The engine oil pressure sensor (3)
    • The knock (KS) sensor (1)
    17. Fig 5: A/C Compressor, Exhaust Gas Recirculation (EGR) Connector & Ground Wire
    GM532777Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The exhaust gas recirculation (EGR) valve (2)
    • The ECT sensor (3)
  18. Remove the ground wire (4) from the stud at the water outlet.
    19. Fig 6: Engine Wiring Harness Clips & Crankshaft Position (CKP) Sensor
    GM535477Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the crankshaft position (CKP) sensor (3).
  20. Remove the engine wiring harness clip (1) from the stud on the generator mounting bracket.
  21. Remove the engine wiring harness clip (2) at the front of the engine.
  22. Move the engine wiring harness aside.
    23. Fig 7: Battery Negative Cable & Ground Strap To Front Of Engine Bolt
    GM105211Courtesy of GENERAL MOTORS CORP.
  23. Remove the bolt holding the battery negative cable and the ground strap to the front of the engine.
  24. Remove the generator mounting bracket.
  25. Remove the heater hoses from the engine. Refer to Heater Hose Replacement - Inlet and Heater Hose Replacement - Outlet in Heating, Ventilation, and Air Conditioning.
  26. Remove the radiator inlet and outlet hoses. Refer to the following procedures:
  27. Remove 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.
  28. Remove the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
  29. Remove the power steering pump mounting bracket.
    30. Fig 8: Power Steering Pump & Mounting Bolts
    GM288829Courtesy of GENERAL MOTORS CORP.
  30. Remove the power steering pump rear mounting bracket from the engine. Set the pump aside.
  31. Remove the distributor. Refer to Distributor Replacement in Engine Controls - 4.3L.
  32. In order to allow access for the lifting device, remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
    33. Fig 9: Rear Of Cylinder Head Ground Wires
    GM375408Courtesy of GENERAL MOTORS CORP.
  33. Remove the transmission control cable bracket from the rear of the left cylinder head.
  34. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  35. Remove both exhaust manifolds. Refer to the following procedures:
  36. Remove the oil pan drain plug and drain the engine oil into a suitable container.
  37. Remove the engine oil filter.
  38. Remove the engine oil cooler pipes from the engine. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
  39. Remove the starter motor. Refer to Starter Motor Replacement (4.8L, 5.3L, and 6.0L) or Starter Motor Replacement (4.3L) in Engine Electrical.
    40. Fig 10: View Of Transmission Cover
    GM334324Courtesy of GENERAL MOTORS CORP.
  40. Remove the transmission cover.
    41. Fig 11: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  41. Remove the torque converter bolts from the flywheel through the transmission cover opening.
    42. Fig 12: Identifying Starter Wiring Harness & Transmission Cooler Pipes Bracket Retaining Bolt
    GM535378Courtesy of GENERAL MOTORS CORP.
  42. Remove the transmission cooler pipes from the engine.
    43. Fig 13: Transmission To Engine Bolts
    GM32774Courtesy of GENERAL MOTORS CORP.
  43. Remove the bolts holding the transmission to the engine except the top 2 bolts.
  44. Lower the vehicle.
  45. Support the transmission with a strap between the frame rails or use a suitable transmission jack.
    46. Fig 14: Engine Lift Brackets J 41427
    GM33636Courtesy of GENERAL MOTORS CORP.
  46. Install the J 41427 using the following procedure:
    1. Remove the 2 right rear lower intake manifold bolts.
    2. Install the J 41427 marked RIGHT REAR.
      3. NOTE: Refer to Fastener Notice in Cautions and Notices.
    3. Install the retaining bolts.

      Tighten:  Tighten the retaining bolts to 15 N.m (11 lb ft).

    4. Remove the 2 left front lower intake manifold bolts.
    5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
    6. Install the retaining bolts.

      Tighten:  Tighten the retaining bolts to 15 N.m (11 lb ft).

  47. Attach a suitable engine lifting device to the J 41427 .
  48. Remove the engine mounts from the engine mount frame brackets. Refer to the following procedures:
  49. Remove the 2 remaining engine to transmission bolts.
  50. Remove the engine assembly from the vehicle.
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