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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 421 (Engine Mechanical - 4.8L, 5.3L, & 6.0L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

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    Fig 1: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. Install the J 41798  to the engine.

    Tighten: 

    • Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
    • Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).

  2. Install an engine hoist to the J 41798 
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
    6. Fig 2: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  6. Install the left and right engine mount-to-engine mount bracket bolts.

    Tighten:  Tighten the engine mount-to-engine mount bracket bolts to 65 N.m (48 lb ft).

  7. Install the upper transmission bolts until snug.
  8. Remove the floor jack from under the transmission.
  9. Remove the engine hoist.
    10. Fig 3: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  10. Remove the J 41798  from the engine.
    11. Fig 4: View Of Ignition Coils & Spark Plug Wires
    GM339300Courtesy of GENERAL MOTORS CORP.
  11. Install the ignition coils and the spark plug wires. Refer to IGNITION COILS .
  12. Raise the vehicle.
    13. Fig 5: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  13. Remove the J 21366  from the transmission.
  14. Install the automatic transmission bolt/studs, if equipped.
    15. Fig 6: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  15. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.
    16. Fig 7: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  16. If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side.

    Tighten:  Tighten the automatic transmission bolts/studs to 50 N.m (37 lb ft).

    17. Fig 8: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  17. Install the automatic transmission oil level indicator tube, if equipped.
    18. Fig 9: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  18. Install the automatic transmission oil level indicator tube nut, if equipped.

    Tighten:  Tighten the automatic transmission oil level indicator tube nut to 18 N.m (13 lb ft).

    19. Fig 10: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  19. Install the flywheel to torque converter bolts, if equipped.

    Tighten: 

    • If equipped with a 4L60E transmission, tighten the bolts to 63 N.m (47 lb ft).
    • If equipped with a 4L80E transmission, tighten the bolts to 60 N.m (44 lb ft).

    20. Fig 11: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  20. Install the positive battery cable clip and bolt.

    Tighten:  Tighten the positive battery cable clip bolt to 9 N.m (80 lb in).

  21. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (4.8L AND 5.3 ENGINES) or CATALYTIC CONVERTER REPLACEMENT (6.0L AND 8.1L ENGINES) in Engine Exhaust.
  22. Install the starter motor. Refer to STARTER .
    23. Fig 12: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  23. Install the oil pan skid plate and bolts, if equipped.

    Tighten:  Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).

    24. Fig 13: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  24. Install the engine shield and bolts.

    Tighten:  Tighten the engine shield bolts to 20 N.m (15 lb ft).

  25. Lower the vehicle.
    26. Fig 14: Vacuum Brake Booster Hose At Intake Manifold Rear
    GM382483Courtesy of GENERAL MOTORS CORP.
  26. Install the vacuum brake booster hose.
    27. Fig 15: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  27. Position the generator bracket to the front of the engine.
  28. Install the generator bracket bolts until snug.
  29. Install the rear power steering pump-to-engine block bolt until snug.

    Tighten: 

    • Tighten the rear power steering pump bolt to 50 N.m (37 lb ft).
    • Tighten the generator bracket bolts to 50 N.m (37 lb ft).

  30. Route the engine wiring harness to the lower engine area.
  31. Raise the vehicle.
    32. Fig 16: View Of Positive Battery Cable, Channel & Bolt
    GM662508Courtesy of GENERAL MOTORS CORP.
  32. Slide the channel pin into the oil pan tab.
  33. Install the battery cable channel bolt.

    Tighten:  Tighten the battery cable channel bolt to 12 N.m (106 lb in).

    34. Fig 17: Identifying Electrical Connector (Right Side Of Engine)
    GM662991Courtesy of GENERAL MOTORS CORP.
  34. Connect the following electrical connectors:
    • The CKP sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
  35. Lower the vehicle.
  36. Connect the fuel pipes.
    37. Fig 18: View Of EVAP Purge Solenoid Vent Tube
    GM372717Courtesy of GENERAL MOTORS CORP.
  37. Install the EVAP purge solenoid vent tube to the solenoid (1).
  38. Install the EVAP tube end (3) to the vapor pipe.
    39. Fig 19: Battery Cable Junction Block
    GM662505Courtesy of GENERAL MOTORS CORP.
  39. Install the battery cable junction block to the junction block bracket.
  40. Clip all of the engine wiring harness clips to their correct location.
    41. Fig 20: View Of Oil Pressure Sensor & CMP Sensor Connectors
    GM684224Courtesy of GENERAL MOTORS CORP.
  41. Connect the following electrical connectors:
    • Oil pressure sensor (1)
    • CMP sensor (2)
  42. Position the harness ground and the engine ground strap to the block.
  43. Install the harness ground bolt at the left rear of the engine block.
  44. Position the harness ground, and auxiliary negative battery cable, if equipped to the block.
  45. Install the harness ground bolt at the right rear of the engine block.

    Tighten:  Tighten the harness ground bolts at the rear of the block to 16 N.m (12 lb ft).

    46. Fig 21: Coolant Temperature Sensor & Electronic Variable Orifice Switch
    GM684221Courtesy of GENERAL MOTORS CORP.
  46. Connect the following electrical connectors:
    • Coolant temperature sensor (1)
    • Electronic variable orifice switch (2)
  47. Position the harness ground and negative battery cable to the block.
  48. Install the harness ground bolt.

    Tighten:  Tighten the harness ground bolt to 25 N.m (18 lb ft).

    49. Fig 22: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  49. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    50. Fig 23: TP Sensor & IAC Valve Electrical Connectors
    GM389028Courtesy of GENERAL MOTORS CORP.
  50. Connect the TP sensor and IAC valve electrical connectors.
    51. Fig 24: Right Ignition Coil Electrical Connectors & Harness Clips
    GM679598Courtesy of GENERAL MOTORS CORP.
  51. Connect the following electrical connectors:
    • Main coil harness (1)
    • Fuel injectors (3)
    • EGR valve (4)
    52. Fig 25: Left Ignition Coil Electrical Connectors & Harness Clips
    GM679597Courtesy of GENERAL MOTORS CORP.
  52. Connect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    53. Fig 26: View Of Generator Cable & Nut
    GM395686Courtesy of GENERAL MOTORS CORP.
  53. Install the generator cable to the generator, perform the following:
    • Install the generator cable.
    • Install the generator cable nut to the terminal stud.

      Tighten:  Tighten the generator output terminal nut to 9 N.m (80 lb in).

    • Slide the boot over the terminal stud.
    54. Fig 27: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  54. Install the radiator vent inlet hose to the throttle body.
  55. Position the vent inlet hose clamp at the throttle body.
    56. Fig 28: Identifying Purge Solenoid Electrical Connector, Wiring Harness Nut & Generator Electrical Connector
    GM663672Courtesy of GENERAL MOTORS CORP.
  56. Install the engine wiring harness bracket and nut (2).

    Tighten:  Tighten the engine wiring harness bracket nut to 5 N.m (44 lb in).

  57. Connect the following electrical connectors:
    • EVAP canister purge solenoid (1)
    • Generator (3)
  58. Install the engine sight shield retainer and bolts.

    Tighten:  Tighten the engine sight shield retainer bolts to 5 N.m (44 lb in).

    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.
  59. Install a NEW accelerator control cable, if required.
    60. Fig 29: Cruise Control Cable Clip At Sight Shield Retainer
    GM684149Courtesy of GENERAL MOTORS CORP.
  60. Install the cruise control cable clip to the sight shield retainer, if equipped.
    61. Fig 30: Cruise Control Cable At Throttle Body Lever
    GM600833Courtesy of GENERAL MOTORS CORP.
  61. Install the cruise control cable to the bracket, if equipped.
  62. Snap the cruise control cable to the throttle body lever, if equipped.
    63. Fig 31: Right Fuel Rail Cover & Bolts
    GM665889Courtesy of GENERAL MOTORS CORP.
  63. If equipped with the 6.0L with RPO LQ9, install the right fuel rail cover.
  64. Tighten the fuel rail cover bolts.

    Tighten:  Tighten the bolts to 9 N.m (80 lb in).

    65. Fig 32: Left Fuel Rail Cover & Bolts
    GM665895Courtesy of GENERAL MOTORS CORP.
  65. If equipped with the 6.0L with RPO LQ9, install the left fuel rail cover.
  66. Tighten the fuel rail cover bolts.

    Tighten:  Tighten the bolts to 9 N.m (80 lb in).

    67. Fig 33: Intake Manifold Sight Shield & Bolts (6.0L (LQ9))
    GM665888Courtesy of GENERAL MOTORS CORP.
  67. If equipped with the 6.0L with RPO LQ9, install the engine sight shield to the retainer.
  68. Tighten the engine sight shield bolt.

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

    69. Fig 34: View Of Top Engine Cover
    GM665886Courtesy of GENERAL MOTORS CORP.
  69. If equipped with the 4.8L, 5.3L, or 6.0L with RPO LQ4, install the engine sight shield to the retainer.
  70. Tighten the engine sight shield bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in)

  71. Install the heater hoses. Refer to HEATER PIPE .
    72. Fig 35: Radiator Outlet Hose & Clamp
    GM308983Courtesy of GENERAL MOTORS CORP.
  72. Install the radiator outlet hose to the water pump.
  73. Position the radiator outlet hose clamp at the water pump.
    74. Fig 36: View Of Inlet Hose & Water Pump
    GM659418Courtesy of GENERAL MOTORS CORP.
  74. Install the radiator inlet hose to the water pump.
  75. Position the radiator inlet hose clamp at the water pump.
  76. Install the radiator supports. Refer to RADIATOR SUPPORT REPLACEMENT in Body Front End.
  77. Install the A/C compressor. Refer to COMPRESSOR .
    78. Fig 37: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  78. Remove the hood hinge bolts from the service position (2).
  79. Lower the hood to the normal position.
  80. Install the hood hinge bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  81. Remove the fender covers.
  82. Fill the crankcase with the proper quantity and grade of engine oil.
  83. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR .
    IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
    1. Disable the ignition system.
    2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    3. Enable the ignition system.
    4. Start the engine and listen for unusual noises.
    5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    6. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
    7. Listen for sticking lifter and other unusual noises.
    8. Inspect for fuel, oil and/or coolant leaks while the engine is running.
    9. Perform a final inspection for the proper engine oil and coolant levels.
  84. Close the hood.
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