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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 834 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

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  1. Open the hood.
  2. Place fender covers over both fenders.
  3. Raise the hood to the service position, then perform the following:
    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).
    Fig 1: Removing Hood Hinge & Bolts
    G02116534Courtesy of GENERAL MOTORS CORP.
  4. Remove the air conditioning (AC) compressor. Refer to COMPRESSOR REPLACEMENT (LR4, LM7, AND LQ4) in HVAC Systems - Manual.
  5. Remove the radiator supports. Refer to RADIATOR SUPPORT REPLACEMENT in Body Front End.
  6. Reposition the radiator inlet hose clamp at the water pump.
  7. Remove the radiator inlet hose from the water pump.
    Fig 2: Removing Radiator Inlet Hose From Water Pump
    G02116535Courtesy 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 HOSE REPLACEMENT - INLET (UTILITY LR4, LM7, LQ4) or HEATER HOSE REPLACEMENT - INLET (AVALANCHE/XIT LR4, LM7, LQ4) or HEATER HOSE REPLACEMENT - OUTLET (UTILITY LR4, LM7, LQ4) or HEATER HOSE REPLACEMENT - OUTLET (AVALANCHE/XIT LR4, LM7, LQ4) in HEATING, VENTILATION AND AIR CONDITIONING .
    Fig 3: Removing Radiator Outlet Hose From Water Pump
    G02116536Courtesy 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.
    Fig 4: Removing Sight Shield From Retainer - 4.8L, 5.3L, or 6.0L
    G02116537Courtesy of GENERAL MOTORS CORP.
  13. If equipped with the 6.0L with RPO LQ9, perform the following:
    1. 13.1. Loosen the intake manifold sight shield bolt.
    2. 13.2. Loosen the left fuel rail cover bolts.
    3. 13.3. Remove the left fuel rail cover.
    4. 13.4. Loosen the right fuel rail cover bolts.
    5. 13.5. Remove the right fuel rail cover.
    6. 13.6. Remove the sight shield from the retainer.
    Fig 5: Removing Sight Shield From Retainer - 6.0L with RPO LQ9
    G02116538Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the following electrical connectors:
    • Evaporative emissions (EVAP) canister purge solenoid (1)
    • Generator (3)
    • Electronic throttle control (ETC)
  15. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.
    Fig 6: Disconnecting Electrical Connectors
    G02116539Courtesy of GENERAL MOTORS CORP.
  16. Reposition the vent inlet hose clamp at the throttle body.
  17. Remove the radiator vent inlet hose from the throttle body.
    Fig 7: Removing Radiator Vent Inlet Hose From Throttle Body
    G02116540Courtesy of GENERAL MOTORS CORP.
  18. Remove the generator cable from the generator, perform the following:
    1. 18.1. Slide the boot down revealing the terminal stud.
    2. 18.2. Remove the generator cable nut from the terminal stud.
    3. 18.3. Remove the generator cable.
    Fig 8: Removing Generator Cable From Generator
    G02116541Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    Fig 9: Disconnecting Main Coil Harness & Fuel Injector Electrical Connectors On Left Side
    G02116542Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the following electrical connectors:
    • The main coil harness (1)
    • The fuel injectors (3)
    Fig 10: Disconnecting Main Coil Harness & Fuel Injectors
    G02116543Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.
    Fig 11: Disconnecting MAP Sensor & Knock Sensor electrical connectors
    G02116544Courtesy of GENERAL MOTORS CORP.
  22. Remove the harness ground bolt.
  23. Reposition the harness ground and negative battery cable from the block.
  24. Disconnect the following electrical connectors:
    • The coolant temperature sensor (1)
    • The electronic variable orifice switch (2)
    Fig 12: Disconnecting Coolant Temperature Sensor & Electronic Variable Orifice Switch
    G02116545Courtesy of GENERAL MOTORS CORP.
  25. Remove the harness ground bolt at the right rear of the engine block.
  26. Reposition the harness ground, and auxiliary negative battery cable, if equipped from the block.
  27. Remove the harness ground bolt at the left rear of the engine block
  28. Reposition the harness ground, and engine ground strap from the block.
  29. Disconnect the following electrical connectors:
    • The oil pressure sensor (1)
    • The camshaft position (CMP) sensor (2)
  30. Unclip all of the engine harness clips from the engine.
    Fig 13: Disconnecting CMP Sensor & Oil Pressure Sensor
    G02116546Courtesy of GENERAL MOTORS CORP.
  31. Remove the battery cable junction block from the junction block bracket.
    Fig 14: Removing Battery Cable Junction Block From Junction Block Bracket
    G02116547Courtesy of GENERAL MOTORS CORP.
  32. 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.
  33. Disconnect the fuel pipes. Refer to FUEL LINE DISCONNECT FITTINGS in Engine Controls - 4.8L, 5.3L, and 6.0L.
  34. Raise the vehicle.
    Fig 15: Removing EVAP Tube End From Solenoid & Vapor Pipe
    G02116548Courtesy of GENERAL MOTORS CORP.
  35. Disconnect the following electrical connectors:
    • The crankshaft position (CKP) sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
    Fig 16: Disconnecting CKP Sensor, Coolant Heater & Engine Oil Level Sensor
    G02116549Courtesy of GENERAL MOTORS CORP.
  36. Remove the battery cable channel bolt.
  37. Slide the channel pin out of the oil pan tab.
  38. Gather all branches of the engine wiring harness and reposition off to the side.
  39. Lower the vehicle.
    Fig 17: Removing Battery Cable Channel Bolt
    G02116550Courtesy of GENERAL MOTORS CORP.
  40. Remove the rear power steering pump-to-engine block bolt.
  41. Remove the generator bracket mounting bolts.
  42. Position the bracket aside.
    Fig 18: Removing Generator Bracket Mounting Bolts
    G02116551Courtesy of GENERAL MOTORS CORP.
  43. Remove the vacuum brake booster hose.
  44. Remove the ignition coil, as required for the proper fit of the J 41798  before lifting the engine. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
    Fig 19: Removing Vacuum Brake Booster Hose
    G02116552Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  45. 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).
    Fig 20: Installing J 41798 To Cylinder Heads
    G02116553Courtesy of GENERAL MOTORS CORP.
  46. Remove the left and right engine mount-to-engine mount bracket bolts.
  47. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
    Fig 21: Removing Left & Right Engine Mount-To-Engine Mount Bracket Bolts
    G02116554Courtesy of GENERAL MOTORS CORP.
  48. Remove the engine shield bolts and shield.
    Fig 22: Removing Engine Shield Bolts & Shield
    G02116555Courtesy of GENERAL MOTORS CORP.
  49. Remove the oil pan skid plate bolts and plate, if equipped.
  50. Drain the engine oil.
  51. Remove the starter motor. Refer to STARTER MOTOR in Engine Electrical.
  52. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (4.8L AND 5.3L ENGINES) or CATALYTIC CONVERTER REPLACEMENT (6.0L AND 8.1L ENGINES) in Engine Exhaust.
    Fig 23: Removing Oil Pan Skid Plate Bolts & Plate
    G02116556Courtesy of GENERAL MOTORS CORP.
  53. Remove the positive battery cable clip bolt and clip.
    Fig 24: Removing Positive Battery Cable Clip Bolt & Clip
    G02116557Courtesy of GENERAL MOTORS CORP.
  54. Remove the flywheel to torque converter bolts.
    Fig 25: Removing Flywheel To Torque Converter Bolts
    G02116558Courtesy of GENERAL MOTORS CORP.
  55. Remove the transmission oil level indicator tube nut, if equipped.
    Fig 26: Removing Transmission Oil Level Indicator Tube Nut
    G02116559Courtesy of GENERAL MOTORS CORP.
  56. Remove the transmission oil level indicator tube, if equipped.
    Fig 27: Removing Transmission Oil Level Indicator Tube
    G02116560Courtesy of GENERAL MOTORS CORP.
  57. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.
    Fig 28: Removing Transmission Bolt & Stud On Right Side
    G02116561Courtesy of GENERAL MOTORS CORP.
  58. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.
    Fig 29: Removing Transmission Converter Cover Bolts
    G02116562Courtesy of GENERAL MOTORS CORP.
  59. Remove the automatic transmission bolt/studs, if equipped.
  60. Separate the engine from the automatic transmission.

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

  61. Lower the vehicle.
  62. Install an engine hoist to the J 41798  .
  63. 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.
  64. Remove the engine.
  65. Install the engine to an engine stand.
  66. Remove the engine hoist.
    Fig 30: Removing Automatic Transmission Bolt/Studs
    G02116563Courtesy of GENERAL MOTORS CORP.
  67. Remove the J 41798  from the engine.
    Fig 31: Removing J 41798 From Engine
    G02116564Courtesy of GENERAL MOTORS CORP.
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