LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 4.3L >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

Important: 

If you install a new engine, make sure any remaining components, brackets, or accessories are transferred to the new engine.

  1. Install the engine into the frame.
  2. Connect the engine to the transmission. Refer to TRANSMISSION REPLACEMENT in Automatic Transmission-4L60-E.
  3. Remove the support from under the transmission.
  4. Lower the engine and the transmission onto the engine mounts.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  5. Install the engine mount through-bolts and nuts.
    Fig 1: Installing Engine Mount Through-Bolts And Nuts
    G01643761Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the engine mount through-bolt nuts to 68 N.m (50 lb ft).

  6. Remove the J 41427  from the engine.
    Fig 2: Removing J 41427 From Engine
    G01643762Courtesy of GENERAL MOTORS CORP.
  7. Apply thread lock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
  8. Install the intake manifold bolts.

    Tighten 

    1. 8.1. Tighten each of the bolts to 3 N.m (27 lb in).
    2. 8.2. Tighten each of the bolts to 12 N.m (106 lb in).
    3. 8.3. Tighten each of the bolts to 15 N.m (11 lb ft).
  9. Install the air conditioning compressor, if equipped, and the power steering pump mounting bracket.
  10. Install the distributor cap.
  11. Install the spark plug wires.
  12. Install the exhaust pipe to the exhaust manifolds. Refer to CATALYTIC CONVERTER REPLACEMENT (RWD) or CATALYTIC CONVERTER REPLACEMENT (A4WD) in Engine Exhaust.
  13. Connect the fuel pipes at the rear of the engine. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  14. Install the transfer case to engine block brace, if equipped.
  15. Install the fuel pipe bracket and stud to the rear of the left cylinder head.

    Tighten 

    Tighten the fuel pipe bracket stud to 33 N.m (24 lb ft).

  16. Install the A/C pipe bracket and nut, if equipped, to the fuel pipe bracket stud.
    Fig 3: Installing A/C Pipe Bracket Nut And Fuel Pipe Bracket Bolt
    G01643763Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the A/C pipe bracket nut to 35 N.m (26 lb ft).

  17. Position the engine wiring harness.
  18. Install the engine wiring harness clips in the brackets.
  19. Install the engine wiring harness clip bolt to the rear of the right cylinder head.
    Fig 4: Installing Ground Wire Bolt And Engine Wiring Harness Clip
    G01643764Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the engine wiring harness clip bolt to 36 N.m (27 lb ft).

  20. Install the ground wire and bolt at the rear of the left cylinder head.

    Tighten 

    Tighten the ground wire bolt to 35 N.m (26 lb ft).

  21. Install the engine wiring harness bracket and bolt to the generator mounting bracket.
    Fig 5: Installing Engine Wiring Harness Bracket And Bolt To Generator Mounting Bracket
    G01643765Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the engine wiring harness bolt to 35 N.m (26 lb ft).

  22. Install the negative battery cable and stud (2).

    Tighten 

    Tighten the negative battery cable stud to 40 N.m (30 lb ft).

  23. Install the CKP sensor wiring harness clip (3) in the bracket.
  24. Connect the CKP sensor electrical connector (4).
    Fig 6: Installing Crankcase Position (CKP) Sensor Electrical Connector
    G01643766Courtesy of GENERAL MOTORS CORP.
  25. Install the engine wiring harness clip (1) on the negative battery cable stud (2).
  26. Connect the following electrical connectors:
    • The knock sensor (KS) (1)
    • The distributor (2)
    • The engine oil pressure sensor (3)
    Fig 7: Installing Knock Sensor, Distributor And Engine Oil Pressure Sensor
    G01643767Courtesy of GENERAL MOTORS CORP.
  27. Connect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor (4)
    • The EVAP canister purge solenoid valve (1)
    • The ignition coil (2)
    • The ICM (3)
    Fig 8: Connecting Electrical Connectors
    G01643768Courtesy of GENERAL MOTORS CORP.
  28. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The A/C high pressure cutoff switch (5), if equipped
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
    • The fuel meter body assembly connector (4)
    Fig 9: Connecting Electrical Connectors
    G01643769Courtesy of GENERAL MOTORS CORP.
  29. Install the ground wire and the nut to the water outlet stud.

    Tighten 

    Tighten the ground wire nut to 19 N.m (14 lb ft).

  30. Install the generator. Refer to CHARGING SYSTEM in Generators & Regulators.
  31. Install the bolt for the starter wiring harness and the transmission oil cooler pipe bracket.
    Fig 10: Installing Bolt For Starter Wiring Harness
    G01643770Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the starter wiring harness bracket bolt to 10 N.m (89 lb in).

    Important: 

    Align the frame using the 2 alignment holes in the frame and the body. Use a pry bar or dowel pin in order to align the holes as the vehicle is being lowered onto the engine/frame assembly.

  32. Lower the vehicle onto the engine/frame assembly and the J 39580. 
    Fig 11: Positioning SST Under Engine/Frame Assembly
    G01643771Courtesy of GENERAL MOTORS CORP.

    Important: 

    The 6 frame-to-body bolts must be tightened in sequence in order to ensure correct alignment of the frame to the chassis.

  33. Install the bolts (1,2,3).
    Fig 12: Installing Bolts
    G01643772Courtesy of GENERAL MOTORS CORP.
  34. Tighten the body bolts using the following sequence:

    Tighten 

    1. 34.1. Tighten all of the body bolts in the sequence shown to 35 N.m (26 lb ft).
    2. 34.2. Tighten the right center body bolt to 155 N.m (114 lb ft).
    3. 34.3. Tighten the left center body bolt to 155 N.m (114 lb ft).
    4. 34.4. Tighten the right front body bolt to 90 N.m (66 lb ft).
    5. 34.5. Tighten the left rear body bolt to 90 N.m (66 lb ft).
    6. 34.6. Tighten the left front body bolt to 90 N.m (66 lb ft).
    7. 34.7. Tighten the right rear body bolt to 90 N.m (66 lb ft).
    Fig 13: Body Bolts Tightening Sequence
    G01643773Courtesy of GENERAL MOTORS CORP.
  35. Raise the vehicle.
  36. Install the transfer case vent tube, if equipped.
  37. Connect the wire connector to the wiring harness above the transmission.
  38. Connect the shift cable to the transmission. Refer to AUTOMATIC TRANSMISSION RANGE SELECTOR CABLE REPLACEMENT in Automatic Transmission - 4L60-E.
  39. Install the torque converter bolts.

    Tighten 

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

  40. Install the transmission cover.
    Fig 14: Installing Transmission Cover
    G01643774Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  41. Install the starter. Refer to STARTING SYSTEM in Starter in Engine.
  42. Install the oil cooler pipes to the oil filter adapter. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT in Engine Cooling.
  43. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
  44. Connect the power steering cooler. Refer to POWER STEERING COOLER PIPE/HOSE REPLACEMENT in Power Steering Systems.
  45. Connect the inflatable restraint front end discriminating sensor electrical connector. Refer to SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM in Airbag.
  46. Connect the fender wheelhouse extensions from chassis to the frame. Refer to WHEELHOUSE EXTENSION REPLACEMENT in Body Front End.
  47. Install the front bumper. Refer to IMPACT BAR REPLACEMENT - FRONT BUMPER in Bumpers.
  48. Install the muffler and the tail pipe section to the hangers and install it to the converter assembly. Refer to CATALYTIC CONVERTER REPLACEMENT (RWD) or CATALYTIC CONVERTER REPLACEMENT (A4WD) in Engine Exhaust.
  49. Connect the fuel pipes at the fuel filter. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  50. Position the engine wiring harness in the clips on the frame and the cross sills.
  51. Connect the fuel tank electrical connector.
  52. Connect the EVAP vent valve electrical connector.
  53. Install the bolt and the ground wire at the chassis by the EVAP vent valve.

    Tighten 

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

  54. Ensure that all of the electrical connections are connected between the chassis and the frame.
  55. Install the bolt and the park brake bracket to the frame.
    Fig 15: Installing Park Brake Bracket To Frame
    G01643775Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the park brake bracket bolt to 24 N.m (18 lb ft).

  56. Connect the rear air conditioning pipes at the rear crossmember by the fuel tank fill hoses, if equipped.
  57. Connect the rear brake pipe to the BPMV. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) REPLACEMENT in Anti-lock Brake System.
  58. Remove the bell housing to transmission bolt.
  59. Lower the vehicle.
  60. Remove both of the J 41602. 
  61. Install the front section of the running boards. Refer to ASSIST STEP EXTENSION REPLACEMENT - FRONT in Frame and Underbody.
    Fig 16: Installing Front Section Of Running Boards
    G01643776Courtesy of GENERAL MOTORS CORP.
  62. Install the battery cable assembly to the fender and the radiator support. Refer to BATTERY NEGATIVE CABLE REPLACEMENT in Battery.
  63. Install the battery positive cable but do not install the battery negative cable.
  64. Install the wiring harness in the retainers clips along the bulkhead.
  65. Connect the fuse box and the wiring harness to the bulkhead connector.
  66. Connect all related connectors including the following:
    • The ground wires
    • The A/C module
    • The cruise control module
    • The wiper motor
    • The differential pressure input switch
  67. Connect the steering shaft to the steering gear. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT in Steering Wheel and Column.
  68. Connect the heater hoses to the engine. Refer to HEATER HOSE REPLACEMENT - INLET in Heating, Ventilation and Air Conditioning.
  69. Connect the vacuum hose for the vacuum tank to the intake manifold.
    Fig 17: Connecting Vacuum Hose To Vacuum Tank From Intake Manifold
    G01643777Courtesy of GENERAL MOTORS CORP.
  70. Connect the pipes to the hydro boost. Refer to DISC BRAKES in Hydraulic Brakes.
  71. Install the power steering reservoir. Refer to REMOTE POWER STEERING FLUID RESERVOIR REPLACEMENT in Power Steering System.
  72. Install the master cylinder to the hydro boost. Refer to DISC BRAKES in Hydraulic Brakes.
    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.
  73. Install the NEW accelerator control cable. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  74. Connect the cruise control cable to the throttle shaft and the accelerator control cable bracket. Refer to CRUISE CONTROL CABLE REPLACEMENT in Cruise Control.
  75. Connect the air conditioning pipes at the accumulator and the condenser, if equipped. Refer to COMPRESSOR/CONDENSER HOSE REPLACEMENT - AUXILIARY in Heating, Ventilation and Air Conditioning.
  76. Install the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
  77. Fill the cooling system with the correct grade of engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  78. Install the air cleaner outlet duct to the throttle body. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  79. Install the air cleaner assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  80. Fill the crankcase with the correct grade of engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  81. Fill and bleed the brake system. Refer to DISC BRAKES or DISC BRAKES in Hydraulic Brakes.
  82. Fill the transmission with the correct grade and quantity of transmission fluid. Refer to AUTOMATIC TRANSMISSION FLUID/FILTER REPLACEMENT in Automatic Transmission-4L60-E.
  83. Fill the power steering system with the correct grade and quantity of power steering fluid. Refer to CHECKING AND ADDING POWER STEERING FLUID in Power Steering System.
  84. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  85. Recharge the air conditioning system and check for correct operation, if equipped. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
  86. Install the engine cover. Refer to ENGINE COVER REPLACEMENT in Interior Trim.
  87. Perform a crankshaft variation learn procedure. Refer to COMPUTER RELEARN PROCEDURES in Engine Performance.
  88. Operate the engine and check for correct operation.
scientia non olet · About LEMON Manuals