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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 4.3L >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

  1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the engine cover. Refer to ENGINE COVER REPLACEMENT in Interior Trim.
  3. Remove the air cleaner assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  4. Remove the air cleaner outlet duct from the throttle body. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  5. Remove the following components:
    • The upper fan shroud
    • The fan
    • The clutch
    • The lower fan shroud
    • Both radiator hoses
    • The oil cooler lines
    • The transmission cooler lines
  6. Disconnect the air conditioning hose at the accumulator and the condenser, if equipped. Refer to COMPRESSOR/CONDENSER HOSE REPLACEMENT - AUXILIARY in Heating, Ventilation and Air Conditioning.
  7. Remove the bolts holding the condenser to the radiator.
  8. Remove the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
    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.
  9. Remove the accelerator control cable. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  10. Remove the cruise control cable, if equipped, from the throttle shaft. Refer to CRUISE CONTROL CABLE REPLACEMENT in Cruise Control.
  11. Remove the cruise control cable from the accelerator control cable bracket.
  12. Remove the power steering reservoir and drain the fluid. Refer to REMOTE POWER STEERING FLUID RESERVOIR REPLACEMENT in Power Steering Systems.
  13. Disconnect the pipes from the hydro boost unit. Refer to DISC BRAKES in Hydraulic Brakes.
  14. Disconnect the master cylinder from the hydro boost unit. Refer to DISC BRAKES in Hydraulic Brakes.
  15. Tie the master cylinder to the oil fill tube.
  16. Disconnect the steering shaft from the steering gear. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT in Steering Wheel and Column.
  17. Disconnect the heater hoses from the engine. Refer to HEATER HOSE REPLACEMENT - INLET in Heating, Ventilation and Air Conditioning.
  18. Disconnect the vacuum hose to the vacuum tank from the intake manifold.
    Fig 1: Disconnecting Vacuum Hose To Vacuum Tank From Intake Manifold
    G01643742Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the engine wiring harness from the VCM.
  20. Disconnect the fuse box and the wiring harness from the bulkhead connector.
  21. Disconnect the negative battery cable from the battery. Disconnect the battery cable assembly from the fender and the radiator support. Refer to BATTERY NEGATIVE CABLE REPLACEMENT in Battery.
  22. Secure the battery cable assembly to the engine.
  23. Disconnect all related electrical connectors that connect the wiring harness to the body under the hood including the following:
    • The ground wires
    • The A/C module
    • The differential pressure input switch
  24. Remove the wiring harness from the retainers and lay the harness on the engine.
  25. Remove the front section of the running boards, if equipped. Refer to ASSIST STEP EXTENSION REPLACEMENT - FRONT < in Frame and Underbody.
    Fig 2: Removing Front Section Of Running Boards
    G01643743Courtesy of GENERAL MOTORS CORP.
  26. Install the J 41602  to the pinch weld area on both sides of the vehicle.
  27. Position the front hoist arms under the J 41602.  Refer to LIFTING AND JACKING THE VEHICLE in General Information for correct position of the rear hoist arms.
  28. Make sure the rear of the vehicle is slightly higher than the front.
  29. Raise the vehicle.
  30. Remove the oil pan drain plug and drain the engine oil into a suitable container.
    Fig 3: Removing Oil Pan Drain Plug
    G01643744Courtesy of GENERAL MOTORS CORP.
  31. Remove the engine oil cooler pipes from the oil filter adapter. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT in Engine Cooling.
  32. Remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
  33. Remove the starter. Refer to STARTING SYSTEM in Battery.
  34. Remove the transmission cover.
    Fig 4: Removing Transmission Cover
    G01643745Courtesy of GENERAL MOTORS CORP.
  35. Remove the torque converter bolts through the starter opening.
    Fig 5: Removing Torque Converter Bolts Through Starter Opening
    G01643746Courtesy of GENERAL MOTORS CORP.
  36. Disconnect the shift cable from the transmission. Refer to AUTOMATIC TRANSMISSION RANGE SELECTOR CABLE REPLACEMENT in Automatic Transmission-4L60-E.
  37. Remove the heat shield.
  38. Disconnect the exhaust system at the main flange behind the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (RWD) or CATALYTIC CONVERTER REPLACEMENT (A4WD) in Engine Exhaust.
  39. Remove the muffler and tail pipe section from the hangers and remove from the vehicle.
  40. Remove the park brake bracket from the frame.
    Fig 6: Removing Park Brake Bracket From Frame
    G01643747Courtesy of GENERAL MOTORS CORP.
  41. Disconnect the rear brake pipe from the brake pressure modulator valve (BPMV). Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) REPLACEMENT in Anti-lock Brake System.
  42. Remove the front bumper. Refer to IMPACT BAR REPLACEMENT - FRONT BUMPER in Bumpers.
  43. Disconnect the power steering cooler from the front air deflector. Refer to POWER STEERING COOLER PIPE/HOSE REPLACEMENT in Power Steering Systems.
  44. Disconnect the inflatable restraint front end discriminating sensor electrical connector. Refer to SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM in Airbag.
  45. Disconnect the fender wheelhouse extensions from the chassis to the frame. Refer to WHEELHOUSE EXTENSION REPLACEMENT in Body Front End.
  46. Disconnect the rear air conditioning pipes at the rear crossmember, if equipped.

    Leave the air conditioning pipes attached to the powertrain assembly. Refer to ACCUMULATOR TUBE REPLACEMENT - AUXILIARY SIDE in Heating, Ventilation and Air Conditioning.

  47. Disconnect the fuel pipes at the fuel filter. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  48. Pull the fuel pipes through the crossmember (forward). Lay the fuel pipes on the transmission.
  49. Disconnect the fuel tank electrical connector.
  50. Disconnect the EVAP vent valve electrical connector.
  51. Remove the bolt and the ground wire at the chassis by the EVAP vent valve.
  52. Make sure all the connections are disconnected between the chassis and the frame.
  53. Remove the engine wiring harness clips from the frame and the cross sills.
  54. Position the J 39580  under the engine/frame assembly.
    Fig 7: Positioning J 39580 Under Engine/Frame Assembly
    G01643748Courtesy of GENERAL MOTORS CORP.
  55. Lower the vehicle.
  56. Adjust J 39580  in order to correctly support the frame assembly with the following components:
    • The engine
    • The transmission
    • The front suspension components
    • The front differential carrier assembly, if equipped
  57. Remove the body mount bolts (1,2,3). Refer to FRAME CUSHION OR INSULATOR REPLACEMENT in Frame and Underbody.
    Fig 8: Removing Body Mount Bolts (1,2,3)
    G01643749Courtesy of GENERAL MOTORS CORP.
  58. Place a jack stand under the transmission crossmember to prevent the engine/frame assembly from tipping off of the J 39580. 
  59. Raise the hoist in order to separate the body from the engine/frame assembly.
  60. Install support stands under the rear axle.
  61. Move the engine/frame assembly from under the vehicle.
  62. Remove the bolt holding the starter wiring harness and the transmission oil cooler pipe bracket to the oil pan.
    Fig 9: Removing Bolt Holding Starter Wiring Harness
    G01643750Courtesy of GENERAL MOTORS CORP.
  63. Remove the generator. Refer to CHARGING SYSTEM in Generators & Regulators.
  64. Remove the nut and the A/C pipe bracket, if equipped from the fuel pipe bracket stud.
  65. Remove the stud holding the fuel pipe bracket to the rear of the left cylinder head.
    Fig 10: Removing A/C Pipe Bracket Nut And Fuel Pipe Bracket Bolt
    G01643751Courtesy of GENERAL MOTORS CORP.
  66. Remove the fuel pipe stud nut on the side of the transmission.
  67. Move the fuel pipes back to clear the engine.
  68. Disconnect the fuel pipes at the rear of the engine. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  69. Remove the ground wire bolt and ground wire from the rear of the left cylinder head.
  70. Remove the bolt holding the engine wiring harness clip to the rear of the right cylinder head.
    Fig 11: Removing Ground Wire Bolt And Engine Wiring Harness Clip
    G01643752Courtesy of GENERAL MOTORS CORP.
  71. Disconnect the crankcase position (CKP) sensor electrical connector (4).
    Fig 12: Disconnecting Crankcase Position (CKP) Sensor Electrical Connector
    G01643753Courtesy of GENERAL MOTORS CORP.
  72. Remove the CKP sensor wiring harness clip (3) from the bracket.
  73. Remove the engine wiring harness clip (1) from the negative battery cable stud (2).
  74. Remove the negative battery cable stud (1) and the cable.
  75. Remove the bolt holding the engine wiring harness bracket to the generator mounting bracket.
    Fig 13: Removing Engine Wiring Harness Bracket To Generator Mounting Bracket Bolt Holding
    G01643754Courtesy of GENERAL MOTORS CORP.
  76. Remove the ground wire from the stud at the water outlet.
  77. Disconnect the following electrical connectors:
    • The manifold absolute pressure (MAP) sensor (4)
    • The EVAP canister purge solenoid valve (1)
    • The ignition coil (2)
    • The ignition coil module (ICM) (3)
    Fig 14: Inspecting Electrical Connectors
    G01643755Courtesy of GENERAL MOTORS CORP.
  78. Disconnect the following electrical connectors:
    • The A/C compressor clutch, if equipped (1)
    • The A/C high pressure cutoff switch, if equipped (5)
    • The throttle position (TP) sensor (2)
    • The idle air control (IAC) motor (3)
    • The fuel meter body assembly connector (4)
    Fig 15: Disconnecting Electrical Connectors
    G01643756Courtesy of GENERAL MOTORS CORP.
  79. Disconnect the following electrical connectors:
    • The knock sensor (KS) (1)
    • The distributor (2)
    • The engine oil pressure sensor (3)
    Fig 16: Removing Knock Sensor, Distributor Engine, Oil Pressure Sensor
    G01643757Courtesy of GENERAL MOTORS CORP.
  80. Remove the engine wiring harness from the brackets.
  81. Remove the bolts holding the transmission fluid fill tube from the oil indicator and the bell housing bolt.
  82. Move the transmission fluid tube to the side.
  83. Position the engine wiring harness out of the way.
  84. Remove the transfer case to engine block brace, if equipped.
  85. Remove the exhaust pipe from the exhaust manifolds. Refer to CATALYTIC CONVERTER REPLACEMENT (RWD) or CATALYTIC CONVERTER REPLACEMENT (A4WD) in Engine Exhaust.
  86. Disconnect the spark plug wires from the spark plugs. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  87. Remove the distributor cap with the spark plug wire harness. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION in Engine Performance.
  88. Remove the air conditioning pipe bracket nut from the intake manifold stud.
  89. Remove the air conditioning compressor and the power steering pump, leaving the pump and the compressor on the bracket.
  90. Install the J 41427  using the following procedure:
    1. 90.1. Remove the 2 right rear lower intake manifold bolts.
    2. 90.2. Install the J 41427  marked RIGHT REAR.
      NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
    3. 90.3. Install the retaining bolts.

      Tighten 

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

    4. 90.4. Remove the 2 left front lower intake manifold bolts.
      Fig 17: Removing 2 Right Rear And 2 Left Front Lower Intake Manifold Bolts
      G01643758Courtesy of GENERAL MOTORS CORP.
    5. 90.5. Install the J 41427  marked LEFT FRONT with the arrow pointing to the front of the engine.
    6. 90.6. Install the retaining bolts

      Tighten 

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

  91. Remove the engine mount through bolts.
    Fig 18: Removing Engine Mount Through Bolts
    G01643759Courtesy of GENERAL MOTORS CORP.
  92. Raise the engine slightly. Support the front of the transmission with suitable floor stand and a block of wood. Do not support the transmission under the oil pan.
  93. Remove the transmission to engine bolts.
    Fig 19: Removing Transmission To Engine Bolts
    G01643760Courtesy of GENERAL MOTORS CORP.
  94. Disconnect the engine from the transmission.
  95. Remove the engine from the frame.
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