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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 144 (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 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the coolant recovery reservoir. Refer to COOLANT RECOVERY RESERVOIR REPLACEMENT .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim .
  4. Remove air cleaner assembly.
  5. Remove the front bumper.
  6. Remove the grille. Refer to Grille Replacement (Uplevel) or Grille Replacement (Base) in Exterior Trim .
  7. Remove the radiator support. Refer to Radiator Support Replacement in Body Front End .
  8. Remove the A/C condenser. Refer to CONDENSER REPLACEMENT .
  9. Remove the radiator. Refer to RADIATOR REPLACEMENT .
    WARNING: 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.
    CAUTION: 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.
  10. Remove the accelerator control cable.
  11. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control .
  12. Remove the stud and bolt holding the ground wires to the rear of both cylinder heads.
  13. Remove the nut holding the wiring harness at the transmission to engine stud.
    Fig 1: Removing Ground Wires Stud & Bolt
    G02077919Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the following electrical connectors:
    • The throttle position (TP) sensor (1)
    • The idle air control (IAC) motor (2)
    • The engine coolant temperature (ECT) gage sensor (3)
    • The A/C high pressure switch (4), if equipped
      Fig 2: Disconnecting TP Sensor, IAC Motor, ECT Gage Sensor & A/C High Pressure Switch
      G02077920Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the following electrical connectors:
    • The fuel meter body assembly connector (1)
    • The EVAP canister purge solenoid valve (2)
    • The manifold absolute pressure (MAP) sensor (3)
      Fig 3: Disconnecting Fuel Meter Body Assembly, EVAP Canister Purge Solenoid Valve & MAP Sensor
      G02077921Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the following electrical connectors:
    • The distributor (2)
    • The engine oil pressure sensor (3)
    • The knock (KS) sensor (1)
      Fig 4: Disconnecting Distributor, Engine Oil Pressure Sensor & KS Sensor
      G02077922Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The EGR valve (2)
    • The engine coolant temperature (ECT) sensor (3)
  18. Remove the ground wire (4) from the stud at the water outlet.
    Fig 5: Disconnecting A/C Compressor Clutch, EGR Valve, ECT Sensor & Ground Wire
    G02077923Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the crankshaft position (CKP) sensor (3).
  20. Remove the engine wiring harness clip (1) from the stud on the generator mounting bracket.
  21. Remove the engine wiring harness clip (2) at the front of the engine.
  22. Move the engine wiring harness aside.
    Fig 6: Disconnecting CKP Sensor & Removing Engine Wiring Harness Clips
    G02077924Courtesy of GENERAL MOTORS CORP.
  23. Remove the bolt holding the battery negative cable and the ground strap to the front of the engine.
  24. Remove the generator mounting bracket.
    Fig 7: Removing Battery Negative Cable & Ground Strap Bolt
    G02077925Courtesy of GENERAL MOTORS CORP.
  25. Remove the heater hoses from the engine. Refer to HEATER HOSE REPLACEMENT - INLET and HEATER HOSE REPLACEMENT - OUTLET .
  26. Remove the radiator inlet and outlet hoses. Refer to the following procedures:
  27. Remove the A/C compressor Discharge Hose from the vehicle. Refer to DISCHARGE HOSE REPLACEMENT .
  28. Remove the A/C compressor Suction Hose from the vehicle. Refer to SUCTION HOSE REPLACEMENT .
  29. Remove the power steering pump mounting bracket.
  30. Remove the power steering pump rear mounting bracket from the engine. Set the pump aside.
    Fig 8: Removing Power Steering Pump Rear Mounting Bracket
    G02077926Courtesy of GENERAL MOTORS CORP.
  31. Remove the distributor. Refer to DISTRIBUTOR .
  32. In order to allow access for the lifting device, remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper .
  33. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
  34. Remove the clamp bolt for the EGR valve inlet pipe.
  35. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
    Fig 9: Removing EGR Valve Inlet Pipe
    G02077927Courtesy of GENERAL MOTORS CORP.
  36. Remove the transmission control cable bracket from the rear of the left cylinder head.
    Fig 10: Removing Transmission Control Cable Bracket
    G02077928Courtesy of GENERAL MOTORS CORP.
    CAUTION: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.
  37. Remove both AIR pipes from the engine. Refer to the following procedures:
  38. Raise the vehicle.
  39. Remove both exhaust manifolds. Refer to the following procedures:
  40. Remove the oil pan drain plug and drain the engine oil into a suitable container.
  41. Remove the engine oil filter.
  42. Remove the engine oil cooler pipes from the engine. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT .
  43. Remove the starter motor. Refer to STARTER MOTOR REPLACEMENT (4.3L) or STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L) .
  44. Remove the transmission cover.
    Fig 11: Removing Transmission Cover
    G02077929Courtesy of GENERAL MOTORS CORP.
  45. Remove the torque converter bolts from the flywheel through the transmission cover opening.
    Fig 12: Removing Torque Converter Bolts
    G02077930Courtesy of GENERAL MOTORS CORP.
  46. Remove the transmission cooler pipes from the engine.
    Fig 13: Removing Transmission Cooler Pipes
    G02077931Courtesy of GENERAL MOTORS CORP.
  47. Remove the bolts holding the transmission to the engine except the top 2 bolts.
  48. Lower the vehicle.
  49. Support the transmission with a strap between the frame rails or use a suitable transmission jack.
    Fig 14: Removing Transmission Bolts
    G02077932Courtesy of GENERAL MOTORS CORP.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  50. Install the J 41427  using the following procedure:
    1. Remove the 2 right rear lower intake manifold bolts.
    2. Install the J 41427  marked RIGHT REAR.
    3. Install the retaining bolts.

      Tighten 

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

    4. Remove the 2 left front lower intake manifold bolts.
    5. Install the J 41427  marked LEFT FRONT with the arrow pointing to the front of the engine.
    6. Install the retaining bolts.

      Tighten 

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

    Fig 15: Installing J 41427
    G02077933Courtesy of GENERAL MOTORS CORP.
  51. Attach a suitable engine lifting device to the J 41427.
  52. Remove the engine mounts from the engine mount frame brackets. Refer to the following procedures:
  53. Remove the two remaining engine to transmission bolts.
  54. Remove the engine assembly from the vehicle.
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