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Home >> Chevy Truck >> 2000 >> Express 1/2 Ton Van V6-4.3L VIN W >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement

Removal and Replacement


^ Tools Required
- J 41427 Engine Lift Bracket

Removal Procedure





1. Remove the radiator support. Refer to Radiator Support Replacement.
2. Remove the engine cover. Refer to Engine Cover Replacement.
3. Remove the engine cooling fan. Refer to Fan Clutch Replacement in Cooling System.

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.

4. Remove the accelerator control cable. Refer to Accelerator Controls Cable Replacement.
5. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement.
6. Remove the stud and bolt holding the ground wires to the rear of both cylinder heads.
7. Remove the nut holding the wiring harness at the transmission to engine stud.





8. Disconnect the following electrical connectors:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) gauge sensor (3)
^ The A/C high pressure switch (4), if equipped





9. 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)





10. Disconnect the following electrical connectors:
^ The distributor (2)
^ The engine oil pressure sensor (3)
^ The Knock (KS) Sensor (1)





11. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The Engine Coolant Temperature (ECT) sensor (3)
12. Remove the ground wire (4) from the stud at the water outlet.





13. Disconnect the Crankshaft Position (CKP) sensor (3).
14. Remove the engine wiring harness clip (1) from the stud on the generator mounting bracket.
15. Remove the engine wiring harness clip (2) at the front of the engine.
16. Move the engine wiring harness aside.





17. Remove the bolt holding the battery negative cable and the ground strap to the front of the engine.
18. Remove the generator mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).
19. Remove the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating and Ventilation (Non-A/C).
20. Remove the radiator inlet and outlet hoses. Refer to Radiator Hose Replacement in Cooling System.
21. Remove the A/C compressor pipes from the vehicle. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
22. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).





23. Remove the power steering pump rear mounting bracket from the engine. Set the pump aside.
24. Remove the distributor. Refer to Distributor Replacement.
25. In order to allow access for the lifting device, remove the upper intake manifold. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower).
26. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
27. Remove the clamp bolt for the EGR valve inlet pipe.





28. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.





29. Remove the transmission control cable bracket from the rear of the left cylinder head.

Notice: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.

30. Remove both AIR pipes from the engine. Refer to AIR Check Valve/Pipe Replacement - Bank 1 and AIR Check Valve/Pipe Replacement - Bank 2.
31. Raise the vehicle. Refer to Vehicle Lifting.
32. Remove both exhaust manifolds. Refer to Exhaust Manifold Replacement (Left) or Exhaust Manifold Replacement (Right).
33. Remove the oil pan drain plug and drain the engine oil into a suitable container.
34. Remove the engine oil filter.
35. Remove the engine oil cooler pipes from the engine. Refer to Engine Oil Cooler Line Replacement in Cooling System.
36. Remove the starter motor. Refer to Starter Motor Replacement.





37. Remove the transmission cover.





38. Remove the torque converter bolts from the flywheel through the transmission cover opening.





39. Remove the transmission cooler pipes from the engine.





40. Remove the bolts holding the transmission to the engine except the top two bolts.
41. Lower the vehicle.
42. Support the transmission with a strap between the frame rails or use a suitable transmission jack.





Notice: Refer to Fastener Notice in Service Precautions.

43. Install the J 41427 using the following procedure:
43.1. Remove the two right rear lower intake manifold bolts.
43.2. Install the J 41427 marked RIGHT REAR.
43.3. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
43.4. Remove the two left front lower intake manifold bolts.
43.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
43.6. Install the retaining bolts.
^ Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
44. Attach a suitable engine lifting device to the J 41427.
45. Remove the engine mounts from the engine mount frame brackets. Refer to Engine Mount Replacement (Mount) or Engine Mount Replacement (Frame Bracket).
46. Remove the two remaining engine to transmission bolts.
47. Remove the engine assembly from the vehicle.


Installation Procedure





1. Install the engine assembly to the vehicle.
2. Loosely install the two upper transmission to engine bolts.
3. Install the engine mounts to the engine mount frame brackets. Refer to Engine Mount Replacement (Mount) or Engine Mount Replacement (Frame Bracket).
4. Remove the engine lifting device.
5. Remove the J41427 from the engine.
6. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the lower intake manifold bolts.
7.1. Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
7.2. Tighten the bolts the second pass to 12 Nm (106 inch lbs.).
7.3. Tighten the bolts the third pass to 15 Nm (11 ft. lbs.).
8. Raise the vehicle. Refer to Vehicle Lifting.
9. Install the remaining bolts from the transmission to the engine. Refer to Transmission Replacement in Transmission and Drivetrain for location of the proper bolts and tightening specifications.





10. Install the bolt holding the transmission cooler pipes bracket to the oil pan.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
11. Install the torque converter bolts to the flywheel. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.





12. Install the transmission cover.
^ Tighten the transmission cover bolts to 12 Nm (106 inch lbs.).
13. Install the starter motor. Refer to Starter Motor Replacement.
14. Install the engine oil cooler pipes to the engine. Refer to Engine Oil Cooler Line Replacement in Cooling System.
15. Install the exhaust manifolds. Refer to Exhaust Manifold Replacement (Left) or Exhaust Manifold Replacement (Right).
16. Lower the vehicle.
17. Install the AIR pipes to the engine. Refer to AIR Check Valve/Pipe Replacement- Bank 1 and AIR Check Valve/Pipe Replacement - Bank 2.
18. Install the upper intake manifold to the engine. Refer to Intake Manifold Replacement (Upper) or Intake Manifold Replacement (Lower).
19. Install the EGR valve inlet pipe. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement.
20. Install the spark plug wire harness retainer on the EGR valve inlet pipe.





21. Install the transmission control cable bracket to the rear of the left cylinder head.
^ Tighten the transmission control cable bracket bolts to 40 Nm (30 ft. lbs.).
22. Install the distributor. Refer to Distributor Replacement.
23. Install the power steering pump with the rear bracket to the engine. Refer to Power Steering Pump Replacement in Steering and Suspension.
24. Install the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).
25. Install the A/C compressor pipes to the vehicle. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
26. Install the radiator inlet and outlet hoses to the engine. Refer to Radiator Hose Replacement in Cooling System.
27. Install the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
28. Install the generator mounting bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).





29. Install the stud and bolt holding the ground wires to the rear of both cylinder heads.
^ Tighten the bolt and the stud to 10 Nm (88 inch lbs.).
30. Install the nut holding the engine wiring harness at the transmission to engine stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).





31. Connect the Crankshaft Position (CKP) sensor (3).
32. Install the engine wiring harness clip (1) from the stud on the generator mounting bracket.
33. Install the engine wiring harness clip (2) at the front of the engine.





34. Connect 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)





35. Connect the following electrical connectors:
^ The distributor (2)
^ The engine oil pressure sensor (3)
^ The Knock (KS) Sensor (1)





36. Connect the following electrical connectors:
^ The Throttle Position (TP) sensor (1)
^ The Idle Air Control (IAC) motor (2)
^ The Engine Coolant Temperature (ECT) gauge sensor (3)
^ The A/C high pressure switch (4), if equipped





37. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The EGR valve (2)
^ The Engine Coolant Temperature (ECT) sensor (3)
38. Install the nut holding the ground wire (4) to the water outlet stud.
^ Tighten the nut to 10 Nm (88 inch lbs.).





39. Install the bolt holding the battery negative cable and the ground strap to the front of the engine.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).

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.

40. Install a NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement.
41. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement.
42. Install the fan clutch to the water pump. Refer to Fan Clutch Replacement in Cooling System.
43. Install the radiator support. Refer to Radiator Support Replacement.
44. Install the oil filter and fill the engine with engine off. Refer to Engine Oil and Oil Filter Replacement
45. Fill the cooling system with the proper quantity and type of coolant. Refer to Draining and Filling Cooling System in Cooling System.
46. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
47. Operate the engine and check for proper operation. Refer to Engine Set-Up and Testing.
48. Install the engine cover. Refer to Engine Cover Replacement.
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