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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 >> Removal Procedure

Removal Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  1. Open the hood.
  2. Place fender covers over both fenders.
  3. Raise the hood to the service position, perform the following:
    1. Remove the hood hinge bolts (1).
    2. Raise the hood until vertical.
    3. Install the hood hinge bolts until snug in the service position (2).
  4. Remove the air conditioning (AC) compressor. Refer to COMPRESSOR .
  5. Remove the radiator supports. Refer to RADIATOR SUPPORT REPLACEMENT in Body Front End.
    6. Fig 2: View Of Inlet Hose & Water Pump
    GM659418Courtesy of GENERAL MOTORS CORP.
  6. Reposition the radiator inlet hose clamp at the water pump.
  7. Remove the radiator inlet hose from the water pump.
    8. Fig 3: Radiator Outlet Hose & Clamp
    GM308983Courtesy of GENERAL MOTORS CORP.
  8. Reposition the radiator outlet hose clamp at the water pump.
  9. Remove the radiator outlet hose from the water pump.
  10. Remove the heater hoses. Refer to HEATER PIPE .
    11. Fig 4: View Of Top Engine Cover
    GM665886Courtesy of GENERAL MOTORS CORP.
  11. If equipped with the 4.8L, 5.3L, or 6.0L regular production option (RPO) LQ4, loosen the intake manifold sight shield bolt.
  12. Remove the sight shield from the retainer.
    13. Fig 5: Intake Manifold Sight Shield & Bolts (6.0L (LQ9))
    GM665888Courtesy of GENERAL MOTORS CORP.
  13. If equipped with the 6.0L with RPO LQ9, loosen the intake manifold sight shield bolt.
  14. Remove the sight shield from the retainer.
    15. Fig 6: Left Fuel Rail Cover & Bolts
    GM665895Courtesy of GENERAL MOTORS CORP.
  15. If equipped with the 6.0L with RPO LQ9, loosen the left fuel rail cover bolts.
  16. Remove the left fuel rail cover.
    17. Fig 7: Right Fuel Rail Cover & Bolts
    GM665889Courtesy of GENERAL MOTORS CORP.
  17. If equipped with the 6.0L with RPO LQ9, loosen the right fuel rail cover bolts.
  18. Remove the right fuel rail cover.
    19. Fig 8: Cruise Control Cable At Throttle Body Lever
    GM600833Courtesy of GENERAL MOTORS CORP.
  19. Unsnap the cruise control cable from the throttle body lever, if equipped.
  20. Remove the cruise control cable from the bracket, if equipped.
    21. Fig 9: Cruise Control Cable Clip At Sight Shield Retainer
    GM684149Courtesy of GENERAL MOTORS CORP.
  21. Remove the cruise control cable clip from the sight shield retainer, if equipped.
    22. Fig 10: View Of Accelerator/Throttle Cable
    GM389031Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the accelerator control cable from the throttle body lever, if required.
  23. Remove the accelerator control cable from the bracket, if required.
    24. Fig 11: Accelerator Control Cable At Sight Shield Retainer
    GM684150Courtesy of GENERAL MOTORS CORP.
  24. Remove the accelerator control cable from the sight shield retainer, if required.
  25. Remove the upper intake manifold sight shield retainer bolts and retainer, if necessary.
    26. Fig 12: Identifying Purge Solenoid Electrical Connector, Wiring Harness Nut & Generator Electrical Connector
    GM663672Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the following electrical connectors:
    • Evaporative emissions (EVAP) canister purge solenoid (1)
    • Generator (3)
  27. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.
    28. Fig 13: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  28. Reposition the vent inlet hose clamp at the throttle body.
  29. Remove the radiator vent inlet hose from the throttle body.
    30. Fig 14: View Of Generator Cable & Nut
    GM395686Courtesy of GENERAL MOTORS CORP.
  30. Remove the generator cable from the generator, perform the following:
    1. Slide the boot down revealing the terminal stud.
    2. Remove the generator cable nut from the terminal stud.
    3. Remove the generator cable.
    31. Fig 15: Left Ignition Coil Electrical Connectors & Harness Clips
    GM679597Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    32. Fig 16: Right Ignition Coil Electrical Connectors & Harness Clips
    GM679598Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the following electrical connectors:
    • Main coil harness (1)
    • Fuel injectors (3)
    • Exhaust gas recirculation (EGR) valve (4)
    33. Fig 17: TP Sensor & IAC Valve Electrical Connectors
    GM389028Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
    34. Fig 18: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.
    35. Fig 19: Coolant Temperature Sensor & Electronic Variable Orifice Switch
    GM684221Courtesy of GENERAL MOTORS CORP.
  35. Remove the harness ground bolt.
  36. Reposition the harness ground and negative battery cable from the block.
  37. Disconnect the following electrical connectors:
    • Coolant temperature sensor (1)
    • Electronic variable orifice switch (2)
    38. Fig 20: View Of Oil Pressure Sensor & CMP Sensor Connectors
    GM684224Courtesy of GENERAL MOTORS CORP.
  38. Remove the harness ground bolt at the right rear of the engine block.
  39. Reposition the harness ground, and auxiliary negative battery cable, if equipped from the block.
  40. Remove the harness ground bolt at the left rear of the engine block
  41. Reposition the harness ground, and engine ground strap from the block.
  42. Disconnect the following electrical connectors:
    • Oil pressure sensor (1)
    • Camshaft position (CMP) sensor (2)
  43. Unclip all of the engine harness clips from the engine.
    44. Fig 21: Battery Cable Junction Block
    GM662505Courtesy of GENERAL MOTORS CORP.
  44. Remove the battery cable junction block from the junction block bracket.
    45. Fig 22: View Of EVAP Purge Solenoid Vent Tube
    GM372717Courtesy of GENERAL MOTORS CORP.
  45. Remove the EVAP purge solenoid vent tube, perform the following:
    • Remove the EVAP tube end (2) from the solenoid (1).
    • Remove the EVAP tube end (3) from the vapor pipe.
  46. Disconnect the fuel pipes. Refer to REMOVAL & INSTALLATION (METAL COLLAR) or REMOVAL & INSTALLATION (PLASTIC COLLAR).
  47. Raise the vehicle.
    48. Fig 23: Identifying Electrical Connector (Right Side Of Engine)
    GM662991Courtesy of GENERAL MOTORS CORP.
  48. Disconnect the following electrical connectors:
    • The crankshaft position (CKP) sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
    49. Fig 24: View Of Positive Battery Cable, Channel & Bolt
    GM662508Courtesy of GENERAL MOTORS CORP.
  49. Remove the battery cable channel bolt.
  50. Slide the channel pin out of the oil pan tab.
  51. Gather all branches of the engine wiring harness and reposition off to the side.
  52. Lower the vehicle.
    53. Fig 25: View Of Generator Bracket & Bolts
    GM310813Courtesy of GENERAL MOTORS CORP.
  53. Remove the rear power steering pump-to-engine block bolt.
  54. Remove the generator bracket mounting bolts.
  55. Position the bracket aside.
    56. Fig 26: Vacuum Brake Booster Hose At Intake Manifold Rear
    GM382483Courtesy of GENERAL MOTORS CORP.
  56. Remove the vacuum brake booster hose.
  57. Remove the ignition coil, as required for the proper fit of the J 41798  before lifting the engine. Refer to IGNITION COILS .
    58. Fig 27: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  58. Install the J 41798  to the cylinder heads.

    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).

    59. Fig 28: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  59. Remove the left and right engine mount-to-engine mount bracket bolts.
  60. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
    61. Fig 29: View Of Engine Protection Shield
    GM349061Courtesy of GENERAL MOTORS CORP.
  61. Remove the engine shield bolts and shield.
    62. Fig 30: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  62. Remove the oil pan skid plate bolts and plate, if equipped.
  63. Drain the engine oil.
  64. Remove the starter motor. Refer to STARTER .
  65. Remove 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.
    66. Fig 31: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  66. Remove the positive battery cable clip bolt and clip.
    67. Fig 32: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  67. Remove the flywheel to torque converter bolts, if equipped.
    68. Fig 33: View Of Oil Level Indicator Tube Nut
    GM396797Courtesy of GENERAL MOTORS CORP.
  68. Remove the transmission oil level indicator tube nut, if equipped.
    69. Fig 34: View Of Oil Level Indicator Tube & Seal
    GM396798Courtesy of GENERAL MOTORS CORP.
  69. Remove the transmission oil level indicator tube, if equipped.
    70. Fig 35: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  70. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.
    71. Fig 36: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  71. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.
    72. Fig 37: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  72. Remove the automatic transmission bolt/studs, if equipped.
  73. Separate the engine from the automatic transmission, if equipped.

    Install the J 21366  to the transmission in order to hold the torque converter.

  74. Lower the vehicle.
  75. Install an engine hoist to the J 41798  .
  76. 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.
  77. Remove the engine.
  78. Install the engine to an engine stand.
  79. Remove the engine hoist.
    80. Fig 38: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  80. Remove the J 41798  from the engine.
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