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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 992 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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).
    2. Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  3. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  4. Remove the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.
  5. Remove the lower fan shroud. Refer to Fan Shroud Replacement - Lower in Engine Cooling.
  6. Remove the drive belt. Refer to Drive Belt Replacement .
  7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. If equipped, remove the oil pan skid plate bolts and plate.
    9. Fig 2: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  9. If equipped, remove the engine shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  10. Remove the starter. Refer to Starter Motor Replacement (4.3L Engine) in Engine Electrical.
  11. Remove the transmission cover.
    12. Fig 3: Removing Transmission Cover
    GM869720Courtesy of GENERAL MOTORS CORP.
  12. Remove the positive battery cable clip bolt (2).
    13. Fig 4: Removing Positive Battery Cable Clip Bolt
    GM869722Courtesy of GENERAL MOTORS CORP.
  13. Remove the catalytic converter. Refer to Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) in Engine Exhaust.
  14. Remove the battery cable bracket bolts.
    15. Fig 5: Removing Battery Cable Bracket Bolts
    GM310250Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the crankshaft position (CKP) sensor electrical connector (5) and remove the harness from the retainer clip.
  16. Remove the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
    17. Fig 6: View Of Oil Level Sensor Electrical Connector, CKP Electrical Connector & Battery Ground Bolt
    GM782731Courtesy of GENERAL MOTORS CORP.
  17. If equipped, remove the torque converter bolts.
    18. Fig 7: Flywheel-To-Torque Converter Bolts
    GM9096Courtesy of GENERAL MOTORS CORP.
  18. Remove the transmission bolts.
  19. Lower the vehicle.
  20. Reposition the radiator inlet hose clamp.
  21. Remove the radiator inlet hose from the thermostat housing.
    22. Fig 8: Removing Radiator Inlet Hose
    GM367002Courtesy of GENERAL MOTORS CORP.
  22. Reposition the radiator outlet hose clamps.
  23. Remove the radiator outlet hose from the surge tank.
  24. Remove the radiator outlet hose from the water pump.
    25. Fig 9: Removing Radiator Outlet Hose
    GM367001Courtesy of GENERAL MOTORS CORP.
  25. If equipped, disconnect the cruise control cable from the throttle lever.
  26. If equipped, remove the cruise control cable from the accelerator control cable bracket.
    27. Fig 10: Removing Cruise Control Cable
    GM781993Courtesy of GENERAL MOTORS CORP.
  27. Remove the accelerator cable from the throttle body lever.
    28. Fig 11: Disconnecting Accelerator Cable From Throttle Body Lever
    GM781992Courtesy of GENERAL MOTORS CORP.
    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.
  28. Remove the accelerator cable from the accelerator control cable bracket.
    29. Fig 12: View Of Accelerator Cable To Accelerator Control Cable Bracket
    GM781990Courtesy of GENERAL MOTORS CORP.
  29. Remove the accelerator cable from the throttle body lever.
    30. Fig 13: Identifying Accelerator Cable/Throttle Body Lever
    GM325556Courtesy of GENERAL MOTORS CORP.
  30. Remove the accelerator control cable bracket nuts.
  31. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
    32. Fig 14: View Of Accelerator Control Cable Bracket
    GM398030Courtesy of GENERAL MOTORS CORP.
  32. Reposition and secure the bracket and cable out of the way.
  33. If equipped, remove the air conditioning (A/C) hoses. Refer to Discharge Hose Replacement (LB7) or Discharge Hose Replacement (LR4,LM7,LQ4,L18) and Suction Hose Replacement (LB7 w/Denso) or Suction Hose Replacement (LR4, LM7, LQ4, L18 w/Denso) in Heating, Ventilation, and Air Conditioning.
  34. Disconnect the following electrical connectors:
    • A/C pressure switch (4), if equipped
    • A/C compressor clutch (1), if equipped
    35. Fig 15: A/C Pressure Switch & Compressor Clutch
    GM782175Courtesy of GENERAL MOTORS CORP.
  35. Remove the positive cable nut and cable from the generator.
  36. Disconnect the following electrical connectors:
    • Throttle position (TP) sensor (1)
    • Idle air control (IAC) motor (2)
    • Control port injector module (3)
    • Engine coolant temperature (ECT) sensor (5)
  37. Remove the engine wiring harness clip bolt (4).
    38. Fig 16: View Of TP Sensor, IAC Motor, ECT Sensor, Control Port Injector Module & Engine Harness Clip Bolt
    GM782174Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the following electrical connectors:
    • Evaporative emission (EVAP) canister purge solenoid valve (1)
    • Manifold absolute pressure (MAP) sensor (2)
    39. Fig 17: EVAP Canister Purge Solenoid Valve & MAP Sensor
    GM782178Courtesy of GENERAL MOTORS CORP.
  39. Disconnect the following electrical connectors:
    • Ignition coil (1)
    • Ignition coil driver (2)
    • Generator (3)
    40. Fig 18: Ignition Coil, Ignition Coil Driver, Ground Nut/Cable & Generator Electrical Connectors
    GM782177Courtesy of GENERAL MOTORS CORP.
  40. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.
  41. Disconnect the following electrical connectors:
    • Knock sensor (1)
    • Camshaft position (CMP) sensor (2)
    • Fuel pump/oil pressure sensor (3)
    • Distributor (2)
  42. Remove the harness ground bolt.
  43. Reposition the harness ground (4) and ground strap (5).
    44. Fig 19: View Of Ground Strap And CMP & Fuel Pump/Oil Pressure Sensor Connectors
    GM782680Courtesy of GENERAL MOTORS CORP.
  44. Remove the engine wiring harness bracket nuts.
    45. Fig 20: Removing Engine Wiring Harness Bracket Nuts
    GM310241Courtesy of GENERAL MOTORS CORP.
  45. Remove the engine wiring harness bracket from the studs.
  46. Remove the junction block bracket bolt.
    47. Fig 21: Removing Junction Block Bracket Bolt
    GM782670Courtesy of GENERAL MOTORS CORP.
  47. Reposition the bracket and wiring harness aside.
  48. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
  49. Remove the stud holding the engine wiring harness bracket.
    50. Fig 22: Removing Wiring Harness Bracket Stud & Engine wiring Harness Rear Bracket Nut
    GM782176Courtesy of GENERAL MOTORS CORP.
  50. Reposition the engine wiring harness with the bracket aside.
  51. Remove the heater hoses. Refer to Heater Hose Replacement - Inlet (LU3) and Heater Hose Replacement - Outlet (LU3) in Heating, Ventilation, and Air Conditioning.
  52. Remove the distributor cap. Refer to Distributor Replacement in Engine Controls - 4.3L.
  53. Disconnect the EVAP canister harness from the purge solenoid valve.
    54. Fig 23: Disconnecting EVAP Canister Harness
    GM869711Courtesy of GENERAL MOTORS CORP.
  54. Disconnect the power brake booster vacuum hose from the vacuum fitting.
    55. Fig 24: Disconnecting Power Brake Booster Vacuum Hose
    GM869713Courtesy of GENERAL MOTORS CORP.
  55. Loosen the power steering (P/S) pump rear bracket nut.
  56. Remove the P/S pump rear bracket front nut.
  57. Remove the bolts and the nut for the P/S pump bracket.
  58. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
  59. Slide the P/S pump bracket forward off the stud and set aside.
    60. Fig 25: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS CORP.
  60. Remove the thermostat and water outlet. Refer to Thermostat Replacement (4.3L Engine) in Engine Cooling.
  61. Remove the left front and right rear intake manifold lower bolts.
  62. Install J 41427 to the left front and right rear intake manifold bolts, using the following procedure:
    1. Install the J 41427 marked RIGHT REAR.
      NOTE: Refer to Fastener Notice in Cautions and Notices.
    2. Install the lift bracket bolts.

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

    3. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
    4. Install the lift bracket bolts.

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

    63. Fig 26: Engine Lift Brackets J 41427
    GM33636Courtesy of GENERAL MOTORS CORP.
  63. Install a suitable lifting devise to the engine lift brackets.
  64. Remove the engine mount to engine mount bracket nuts.
    65. Fig 27: Removing Engine Mount To Engine Mount Bracket Nuts
    GM310259Courtesy of GENERAL MOTORS CORP.
  65. Support the transmission with a suitable floor jack.
  66. Remove the engine.
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