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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1354 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Open the hood.
  2. Place fender covers over both fenders.
  3. Raise the hood to the service position, perform the following:
    Fig 1: Removing Hood Hinge Bolts
    G02106816Courtesy of GENERAL MOTORS CORP.
    1. 3.1. Remove the hood hinge bolts (1).
    2. 3.2. Raise the hood until vertical.
    3. 3.3. Install the hood hinge bolts until snug in the service position (2).
  4. Remove the air conditioning (A/C) compressor. Refer to COMPRESSOR REPLACEMENT (LR4, LM7, AND LQ4) .
  5. Remove the radiator support. Refer to RADIATOR SUPPORT REPLACEMENT .
  6. Remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)  or Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88) .
  7. Open the hose clamp and remove the radiator inlet hose from the water pump.
    Fig 2: Removing Radiator Inlet Hose
    G02106817Courtesy of GENERAL MOTORS CORP.
  8. Open the hose clamp and remove the radiator outlet hose from the water pump.
  9. Remove the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET (LR4, LM7, LQ4) and HEATER HOSE REPLACEMENT - INLET (LR4, LM7, LQ4) .
    Fig 3: Removing Radiator Outlet Hose
    G02106818Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the following electrical connectors:
    • Evaporative emissions (EVAP) canister purge solenoid (1)
    • Generator (3)
  11. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.
    Fig 4: EVAP Canister Purge Solenoid, Harness Bracket Nut & Generator
    G02106819Courtesy of GENERAL MOTORS CORP.
  12. Reposition the vent inlet hose clamp at the throttle body.
  13. Remove the radiator vent inlet hose from the throttle body.
    Fig 5: Removing Radiator Vent Inlet Hose
    G02106820Courtesy of GENERAL MOTORS CORP.
  14. Remove the generator cable from the generator, perform the following:
    1. 14.1. Slide the boot down revealing the terminal stud.
    2. 14.2. Remove the generator cable nut from the terminal stud.
    3. 14.3. Remove the generator cable.
    Fig 6: Removing Generator Cable & Nut
    G02106821Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the main coil harness (2) and fuel injector electrical connectors on the left side.
    Fig 7: Disconnect Main Coil Harness
    G02106822Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the following electrical connectors:
    • Main coil harness (1)
    • Fuel injectors (2)
    • Electronic throttle control (ETC) (3)
    Fig 8: Main Coil Harness, Fuel Injectors & ETC Electrical Connectors
    G02106823Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.
    Fig 9: Disconnect Manifold Absolute Pressure (MAP) Sensor & Knock Sensor Electrical Connectors
    G02106824Courtesy of GENERAL MOTORS CORP.
  18. Remove the harness ground bolt.
  19. Reposition the harness ground and negative battery cable from the block.
  20. Disconnect the following electrical connectors:
    • Engine coolant temperature (ECT) sensor (1)
    • Electronic variable orifice switch (2)
    Fig 10: Harness Ground Bolt, ECT Sensor & Electronic Variable Orifice Switch
    G02106825Courtesy of GENERAL MOTORS CORP.
  21. Remove the harness ground bolt at the right rear of the engine block.
  22. Reposition the harness ground, and auxiliary negative battery cable, if equipped, from the block.
  23. Remove the harness ground bolt at the left rear of the engine block.
  24. Reposition the harness ground, and engine ground strap from the block.
  25. Disconnect the following electrical connectors:
    • Oil pressure sensor (1)
    • Camshaft position (CMP) sensor (2)
  26. Unclip all of the engine harness clips from the engine.
    Fig 11: Harness Ground Bolt, Oil Pressure Sensor & CMP Sensor
    G02106826Courtesy of GENERAL MOTORS CORP.
  27. Remove the battery cable junction block from the junction block bracket.
    Fig 12: Battery Cable Junction Bracket
    G02106827Courtesy of GENERAL MOTORS CORP.
  28. Remove the EVAP purge solenoid vent tube; perform the following:
    • Remove the EVAP tube end from the solenoid (1).
    • Remove the EVAP tube end from the vapor pipe (2).
  29. Disconnect the fuel pipes. Refer to REMOVAL & INSTALLATION (METAL COLLAR) .
  30. Raise the vehicle.
    Fig 13: Solenoid & Vapor Pipe
    G02106828Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the following electrical connectors:
    • Crankshaft position (CKP) sensor (1)
    • Engine oil sensor (6)
    • Coolant heater, if equipped.
    Fig 14: Disconnect Crankshaft Position (CKP) Sensor & Engine Oil Sensor
    G02106829Courtesy of GENERAL MOTORS CORP.
  32. Remove the battery cable channel bolt.
  33. Slide the channel pin out of the oil pan tab.
  34. Gather all branches of the engine wiring harness and reposition off to the side.
  35. Lower the vehicle.
    Fig 15: Removing Battery Cable Channel Bolt
    G02106830Courtesy of GENERAL MOTORS CORP.
  36. Remove the rear power steering to engine block bolt.
  37. Remove the generator bracket bolts.
  38. Position the bracket aside.
    Fig 16: Removing Generator Bracket Bolts
    G02106831Courtesy of GENERAL MOTORS CORP.
  39. Remove the vacuum brake booster hose.
  40. Remove the ignition coil(s) (as required) for the proper fit of the J 41798  before lifting the engine. Refer to REMOVAL (4.8L, 5.3L, 6.0L & 8.1L) .
    Fig 17: Removing Vacuum Brake Booster Hose
    G02106832Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  41. Install the J 41798  to the cylinder heads.

    Tighten 

    • Tighten the M8 bolts to 25 N.m (18 lb ft).
    • Tighten the M10 bolts to 50 N.m (37 lb ft).
    Fig 18: Installing J 41798
    G02106833Courtesy of GENERAL MOTORS CORP.
  42. Remove the left and right engine mount to engine mount bracket bolts.
  43. Raise the vehicle.
    Fig 19: Removing Left & Right Engine Mount To Engine Mount Bracket Bolts
    G02106834Courtesy of GENERAL MOTORS CORP.
  44. Remove the engine sight shield bolts and shield.
    Fig 20: Removing Engine Sight Shield & Bolts
    G02106835Courtesy of GENERAL MOTORS CORP.
  45. Remove the oil pan skid plate bolts and plate, if equipped.
  46. Drain the engine oil.
  47. Remove the starter motor. Refer to STARTER MOTOR .
  48. Remove the catalytic converter. CATALYTIC CONVERTER REPLACEMENT (4.3L, 4.8L, AND 5.3L ENGINES)
    Fig 21: Removing Oil Pan Skid Plate & Bolts
    G02106836Courtesy of GENERAL MOTORS CORP.
  49. Remove the positive battery cable clip bolt and clip.
    Fig 22: Removing Positive Battery Cable Clip & Bolt
    G02106837Courtesy of GENERAL MOTORS CORP.
  50. Remove the torque converter bolts, if equipped.
    Fig 23: Removing Torque Converter Bolts
    G02106838Courtesy of GENERAL MOTORS CORP.
  51. Remove the transmission oil level indicator tube nut, if equipped.
    Fig 24: Removing Transmission Oil Level Indicator Tube Nut
    G02106839Courtesy of GENERAL MOTORS CORP.
  52. Remove the transmission oil level indicator tube, if equipped.
    Fig 25: Removing Transmission Oil Level Indicator Tube
    G02106840Courtesy of GENERAL MOTORS CORP.
  53. If equipped with a 4L60E transmission, remove the transmission bolt and stud on the right side.
    Fig 26: Removing Transmission Bolt & Stud On Right Side
    G02106841Courtesy of GENERAL MOTORS CORP.
  54. If equipped with a 4L80E transmission, remove the transmission converter cover bolts.
    Fig 27: Removing Transmission Converter Cover Bolts
    G02106842Courtesy of GENERAL MOTORS CORP.
  55. Remove the automatic transmission bolt/studs, if equipped.
  56. Separate the engine from the automatic transmission, if equipped. Install the J 21366  to the transmission in order to hold the torque converter.
    Fig 28: Removing Automatic Transmission Bolt/Studs
    G02106843Courtesy of GENERAL MOTORS CORP.
  57. Using J 42371  remove the clutch line from the concentric slave cylinder.
    Fig 29: Removing Clutch Line
    G02106844Courtesy of GENERAL MOTORS CORP.
  58. Remove the manual transmission stud on the right side of the transmission, if equipped.
    Fig 30: Removing M/T Stud On Right Side Of Transmission
    G02106845Courtesy of GENERAL MOTORS CORP.
  59. Remove the manual transmission bolt/studs, if equipped.
  60. Separate the manual transmission from the engine, if equipped.
    Fig 31: Removing Manual Transmission Bolt/Studs
    G02106846Courtesy of GENERAL MOTORS CORP.
  61. Mark the flywheel and a clutch pressure plate lug for installation alignment.
  62. Remove the clutch pressure plate bolts, if equipped.
  63. Remove the clutch pressure plate and disc, if equipped.
  64. Lower the vehicle.
  65. Install an engine hoist to the J 41798  .
  66. Install a floor jack under the transmission for support.
    NOTE: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.
  67. Remove the engine.
  68. Install the engine to an engine stand.
  69. Remove the engine hoist.
    Fig 32: Removing Clutch Pressure Plate & Bolts
    G02106847Courtesy of GENERAL MOTORS CORP.
  70. Remove the J 41798  from the engine.
    Fig 33: Removing J 41798
    G02106848Courtesy of GENERAL MOTORS CORP.
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