Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required

J 41427 Engine Lift Bracket

1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the underbody shields. Refer to Steering Linkage Shield Replacement in Steering Linkage (Non-Rack and Pinion)
4. Remove the braces from the engine to the transmission (manual transmission only). Refer to Transmission Replacement in Manual Transmission - New Venture.
5. Remove the flange nuts holding the exhaust pipe to the exhaust manifolds.
6. Remove the oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.



7. Remove the bolt holding the starter wiring harness and if equipped, transmission cooler lines.
8. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.



9. Remove the transmission cover.
10. Disconnect the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
11. Remove the transfer case. Refer to Transfer Case Replacement in Transfer Case - NVG-236 (Two Speed Automatic).



12. Remove the rear engine mount to crossmember nut.
13. Remove the crossmember.



14. In order to remove the top transmission bolts lower the rear of the transmission after removing the crossmember.
15. Remove the transmission.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - New Venture.




16. Remove the front engine mount through-bolts.
17. Lower the vehicle.



18. Remove the PCV tube.
19. Remove the air inlet duct from the throttle body.
20. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
21. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
22. Remove the inlet and outlet radiator hoses from the engine. Refer to Radiator Hose Replacement in Engine Cooling.
23. Disconnect the heater hoses from the engine.



24. Disconnect the following electrical connectors:

•	The fuel meter body assembly

•	The EVAP canister purge solenoid valve

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The A/C compressor high pressure switch

•	The A/C clutch switch

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor

•	The ignition control module (ICM)

•	The generator

•	The crankcase position (CKP) sensor

•	The engine oil pressure gauge sensor

25. Release the engine wiring harness retainers and move the wiring harness aside.



26. Remove the battery ground cable at the engine.



27. Remove the bolt holding the ground strap to the left cylinder head.



28. Remove the bolt holding the ground wires to the right cylinder head.
29. Remove the bolt holding the wiring harness retainer to the right cylinder head.




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.
30. Remove the accelerator control cable from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
31. Remove the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.



32. Remove the accelerator control cable bracket from the generator mounting bracket.
33. Remove the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.



34. Remove the oil fill tube.
35. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C - Automatic.



36. Remove the nuts holding power steering pump rear bracket to the engine.



37. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement .

•	The power steering pump can remain on the mounting bracket.

•	The hoses do not require removal.

•	Remove the three bolts and the nut.

•	Slide the mounting bracket off of the stud.

•	Secure the mounting bracket out of the way.

38. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.



39. Disconnect the vacuum brake booster hose from the intake manifold.
40. Disconnect the vacuum hose for the A/C system from the intake manifold.
41. Disconnect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
42. Disconnect the EVAP canister purge solenoid valve harness. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.
43. Remove the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.



44. Remove the EGR valve inlet pipe from the intake and exhaust manifold.



45. Install the J 41427 to the right rear and the left front of the intake manifold.

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

46. Use an engine lifting device to remove the engine from the vehicle.

Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required

J 41427 Engine Lift Bracket

1. Install the engine into the vehicle.




Notice: 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.

2. Install the front engine mount through-bolts and nuts.

Tighten
Tighten the bolts to 65 N·m (48 lb ft)

3. Remove the engine lift brackets.
4. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower intake manifold bolts.
5. Install the intake manifold bolts.

Tighten

1. Tighten the bolts the first pass to 3 N·m (27 lb in).
2. Tighten the bolts the second pass to 12 N·m (106 lb in).
3. Tighten the bolts the third pass to 15 N·m (11 lb ft).



6. Install the EGR valve inlet pipe to the intake and exhaust manifold.

Tighten

1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N·m (18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N·m (18 lb ft).
7. Install the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
8. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
9. Connect the EVAP canister purge solenoid valve harness. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.



10. Connect the vacuum brake booster hose to the intake manifold.
11. Connect the vacuum hose for the A/C system to the intake manifold.
12. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.



13. Install the power steering mounting bracket. Refer to Accessory Mounting Brackets Replacement .
14. Install the nuts holding the power steering pump rear bracket to the engine.

Tighten
Tighten the power steering rear bracket nuts to 41 N·m (30 lb ft).

15. Install the A/C compressor, if equipped. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C - Automatic.



16. Install the oil fill tube in the valve rocker arm cover.
17. Install the oil fill tube on the intake manifold stud and install the nut.

Tighten
Tighten the oil fill tube nut to 12 N·m (106 lb in).

18. Install the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.



19. Install the accelerator control cable bracket to the generator mounting bracket.

Tighten
Tighten the bracket bolt to 25 N·m (18 lb ft).





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.
20. Install a NEW accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Control.
21. Install the cruise control cable, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.



22. Install the battery ground cable bolt.

Tighten
Tighten the ground cable bolt to 35 N·m (26 lb ft).




23. Install the bolt holding the ground strap to the left cylinder head.

Tighten
Tighten the ground strap bolt to 35 N·m (26 lb ft).




24. Install the bolt holding the ground wires to the rear of the right cylinder head.

Tighten
Tighten the ground wires bolt to 35 N·m (26 lb ft).

25. Install the bolt holding the wiring harness retainer to the rear of the right cylinder head.

Tighten
Tighten the wiring harness retainer bolt to 35 N·m (26 lb ft).




26. Position the engine wiring harness.
27. Install the wiring harness in the retainers.
28. Connect the following electrical connectors:

•	The fuel meter body assembly

•	The EVAP canister purge solenoid valve

•	The idle air control (IAC) motor

•	The throttle position (TP) sensor

•	The A/C compressor high pressure switch

•	The A/C clutch switch

•	The exhaust gas recirculation (EGR) valve

•	The engine coolant temperature (ECT) sensor

•	The ignition control module (ICM)

•	The generator

•	The crankcase position (CKP) sensor

•	the engine oil pressure gauge sensor

29. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
30. Install the inlet and outlet radiator hose to the engine. Refer to Radiator Hose Replacement in Engine Cooling.
31. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement (4.3L) in HVAC Systems with A/C - Automatic.



32. Raise the vehicle.
33. Install the transmission.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - New Venture.

34. Install the transfer case. Refer to Transfer Case Replacement in Transfer Case - NVG-236 (Two Speed Automatic).
35. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.



36. Install the transmission cover.

Tighten
Tighten the transmission cover bolts to 12 N·m (106 lb in).

37. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.



38. Install the bolt holding the starter wire harness and if equipped, transmission cooler lines.

Tighten
Tighten the bracket bolt to 12 N·m (106 lb in).

39. Install the oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.



40. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.
41. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement .
42. Install the braces from the engine to the transmission (manual transmission only). Refer to Transmission Replacement in Manual Transmission - New Venture.
43. Install the underbody shield. Refer to Steering Linkage Shield Replacement in Steering Linkage (Non-Rack and Pinion).
44. Lower the vehicle.
45. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
46. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
47. Connect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
48. Operate and test the engine. Refer to Engine Set-Up and Testing .