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Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 144 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  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. 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.
    CAUTION: 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.
  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).
      Fig 1: Removing J 41427
      G02077934Courtesy of GENERAL MOTORS CORP.
  8. Raise the vehicle.
  9. Install the remaining bolts from the transmission to the engine. Refer to INSTALLATION (4L60-E) for location of the proper bolts and tightening specifications.
  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).

    Fig 2: Installing Transmission Cooler Pipes Bracket Bolt
    G02077935Courtesy of GENERAL MOTORS CORP.
  12. Install the transmission cover.

    Tighten 

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

    Fig 3: Installing Transmission Cover
    G02077936Courtesy of GENERAL MOTORS CORP.
  13. Install the starter motor. Refer to STARTER MOTOR REPLACEMENT (4.3L) or STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L) .
  14. Install the engine oil cooler pipes to the engine. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT .
  15. Install the exhaust manifolds. Refer to the following procedures:
  16. Lower the vehicle.
  17. Install the AIR pipes to the engine. Refer to the following procedures:
  18. Install the upper intake manifold to the engine. Refer to Intake Manifold Replacement - Upper .
  19. Install the EGR valve inlet pipe. Refer to EGR PIPE .
  20. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
  21. 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).

    Fig 4: Installing Transmission Control Cable Bracket
    G02077937Courtesy of GENERAL MOTORS CORP.
  22. Install the distributor. Refer to DISTRIBUTOR .
  23. Install the power steering pump with the rear bracket to the engine. Refer to POWER STEERING PUMP REPLACEMENT (4.3L) or POWER STEERING PUMP REPLACEMENT (4.8L, 5.3L, AND 6.0L) .
  24. Install the power steering pump mounting bracket.
  25. Install the A/C compressor Discharge Hose from the vehicle. Refer to DISCHARGE HOSE REPLACEMENT .
  26. Install the A/C compressor Suction Hose from the vehicle. Refer to SUCTION HOSE REPLACEMENT .
  27. Install the radiator inlet and outlet hoses to the engine. Refer to the following procedures:
  28. Install the heater hoses to the engine. Refer to HEATER HOSE REPLACEMENT - INLET and HEATER HOSE REPLACEMENT - OUTLET .
  29. Install the generator mounting bracket.
  30. 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).

  31. 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).

    Fig 5: Installing Ground Wires Stud & Bolt
    G02077938Courtesy of GENERAL MOTORS CORP.
  32. Connect the crankshaft position (CKP) sensor (3).
  33. Install the engine wiring harness clip (1) from the stud on the generator mounting bracket.
  34. Install the engine wiring harness clip (2) at the front of the engine.
    Fig 6: Connecting CKP Sensor & Installing Engine Wiring Harness Clips
    G02077939Courtesy of GENERAL MOTORS CORP.
  35. Connect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
      Fig 7: Connecting Fuel Meter Body Assembly, EVAP Canister Purge Valve & MAP Sensor
      G02077940Courtesy of GENERAL MOTORS CORP.
  36. Connect the following electrical connectors:
    • The distributor (2)
    • The engine oil pressure sensor (3)
    • The knock (KS) sensor (1)
      Fig 8: Connecting Distributor, Engine Oil Pressure Sensor & KS Sensor
      G02077941Courtesy of GENERAL MOTORS CORP.
  37. Connect 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 A/C high pressure switch (4), if equipped
      Fig 9: Connecting TP Sensor, IAC Motor, ECT Gage Sensor & A/C High Pressure Switch
      G02077942Courtesy of GENERAL MOTORS CORP.
  38. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The EGR valve (2)
    • The engine coolant temperature (ECT) sensor (3)
  39. Install the nut holding the ground wire (4) to the water outlet stud.

    Tighten 

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

    Fig 10: Connecting A/C Compressor Clutch, EGR Valve, ECT Sensor & Ground Wire
    G02077943Courtesy of GENERAL MOTORS CORP.
  40. 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).

    Fig 11: Installing Battery Negative Cable & Ground Strap Bolt
    G02077944Courtesy of GENERAL MOTORS CORP.
    WARNING: 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.
    CAUTION: 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.
  41. Install a NEW accelerator control cable.
  42. 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 .
  43. Install the fan clutch to the water pump. Refer to FAN CLUTCH REPLACEMENT .
  44. Install the radiator support. Refer to Radiator Support Replacement in Body Front End .
  45. Install the oil filter and fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  46. Fill the cooling system with the proper quantity and type of coolant. Refer to DRAINING AND FILLING COOLING SYSTEM .
  47. Recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING .
  48. 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.
  49. Start the engine and listen for unusual noises.
  50. 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.

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