GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 GMC K Sierra - 4WD 🢒 Engine 🢒 Engine Mechanical - 4.3L 🢒 Engine Replacement

Removal Procedure

Tools Required

J 41427 Engine Lift Brackets


    Object Number: 309158 Size: SH
  1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
  2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Evacuate and recover the A/C refrigerant, if equipped. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C - Manual.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove the oil pan skid plate.
  6. Remove the engine protection shield, if equipped. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  7. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    8. Object Number: 391868 Size: SH
  8. Remove the transmission cover.

    9. Object Number: 327996 Size: SH
  9. Remove the bolt holding the bracket for the starter cables and transmission cooler lines, if equipped.

    10. Object Number: 344257 Size: SH
  10. Loosen the nuts (2) at the catalytic converter pipe.
  11. Remove the exhaust pipes from the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.

    12. Object Number: 310250 Size: SH
  12. Remove the bolts holding the brackets to the oil pan for both battery cables.

    13. Object Number: 491824 Size: SH
  13. Disconnect the crankshaft position (CKP) sensor electrical connector (2) and remove the wire harness from the retainer.
  14. Disconnect the low oil level sensor electrical connector (3) and remove the wire harness from the retainer.
  15. Remove the bolt holding the battery negative cable (1) and a ground cable (1) to the engine.

    16. Object Number: 9096 Size: SH
  16. Remove the torque converter to flywheel bolts, if equipped, through the starter opening.
  17. Remove the engine to transmission bolts.
    18. • Refer to Transmission Replacement in Automatic Transmission - 4L60-E.
    • Refer to Transmission Replacement in Manual Transmission - NV3500.
  18. Lower the vehicle.

    19. Object Number: 310799 Size: SH
  19. Move the hood hinge bolts (1) to hold the hood in the service position (2).
  20. Disconnect the PCV hose from the air cleaner outlet duct.
  21. Remove the air cleaner outlet duct from the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
  22. Remove the fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  23. Remove the drive belt. Refer to Drive Belt Replacement .
  24. Remove the engine cooling fan. Refer to Fan Clutch Replacement in Engine Cooling.
  25. Remove the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  26. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.

    27. 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.

  27. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls.
  28. Disconnect the cruise control cable from the throttle body and the bracket on the throttle body and intake manifold, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.

    29. Object Number: 398030 Size: SH
  29. Remove the accelerator control cable bracket from the throttle body.
  30. Disconnect the A/C hoses from the compressor and the accumulator, if equipped. Refer to Compressor Hose Assembly Replacement in HVAC Systems in A/C - Manual.

    31. Object Number: 398868 Size: SH
  31. Remove the secondary air injection (AIR) crossover pipe from the AIR pipe assemblies.

    32. Object Number: 332032 Size: SH
  32. Remove AIR pipe assemblies from the left exhaust manifold, if equipped.

    33. Object Number: 332026 Size: SH
  33. Disconnect the AIR pipe assembly from the AIR pump.
  34. Remove the AIR pipe assembly from the right exhaust manifold, if equipped.

    35. Object Number: 491821 Size: SH
  35. Disconnect the following electrical connectors:
    36. • The A/C pressure switch (4), if equipped
    • The A/C compressor clutch (1), if equipped
    • The exhaust gas recirculation (EGR) valve (2)
    • The generator battery positive cable (3)

    Object Number: 491817 Size: SH
  36. Disconnect the following electrical connectors:
    37. • The fuel meter body assembly (3)
    • The idle air control (IAC) motor (2)
    • The throttle position (TP) sensor (1)
    • The engine coolant temperature (ECT) sensor (4)

    Object Number: 491816 Size: SH
  37. Disconnect the following electrical connectors:
    38. • The EVAP canister purge solenoid valve (1)
    • The manifold absolute pressure (MAP) sensor (2)
    • The ignition control module (ICM) (4)
    • The ignition coil (3)

    Object Number: 491825 Size: SH
  38. Disconnect the following electrical connectors:
    39. • The engine oil pressure gauge sensor (3)
    • The distributor (2)
    • The knock sensor (KS) (1)

    Object Number: 310241 Size: SH
  39. Remove the nuts holding the brackets for the engine wiring harness to the intake studs.
  40. Remove the bolt holding the engine wiring harness to the bracket on the power steering mounting bracket.

    41. Object Number: 394403 Size: SH
  41. Remove the bracket for the battery positive cable junction block from the power steering pump mounting bracket.
  42. Move the battery positive and negative cables aside.

    43. Object Number: 310243 Size: SH
  43. Remove the nut holding the ground wire to the stud at the rear of the right cylinder head.
  44. Remove the stud holding the engine wiring harness bracket to the rear of the right cylinder head.
  45. Remove the nut holding the engine wiring harness bracket to the stud for the EVAP canister purge solenoid valve.

    46. Object Number: 310256 Size: SH
  46. Remove the bolt holding the ground strap and the ground wire to the rear of the left cylinder head.
  47. Move the engine wiring harness aside.
  48. Remove both heater hoses from the engine and the cowl.
    49. • Refer to Heater Hoses Replacement in Heating and Ventilation (Non A/C).
    • Refer to Heater Hoses Replacement in HVAC Systems with A/C - Manual.
  49. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.
  50. Disconnect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
  51. Disconnect the hose to the EVAP purge canister solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.

    52. Object Number: 346148 Size: SH
  52. Disconnect the vacuum brake booster hose from the engine and the vacuum brake booster.

    53. Object Number: 340090 Size: SH
  53. Loosen the nut holding the power steering pump rear bracket to the side of the engine.
  54. Remove the nut holding the power steering pump rear bracket to the front of the engine
  55. Remove the three bolts and the nut holding the power steering pump mounting bracket to the engine.
  56. With the power steering pump and the A/C compressor still attach, slide the power steering pump mount bracket off of the stud and set aside.
  57. Remove the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.

    58. Object Number: 172982 Size: SH
  58. Remove the EGR valve inlet pipe from the intake and exhaust manifold.

    59. Object Number: 33636 Size: SH

    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.

  59. Attach the J 41427 to the left front and right rear intake manifold mounting bolts, using the following procedure:
    60. 59.1. Remove the right rear lower intake manifold bolts.
    59.2. Install the J 41427 marked RIGHT REAR.
    59.3. Install the retaining bolts.

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

    59.4. Remove the left front lower intake manifold bolts.
    59.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
    59.6. Install the retaining bolts.

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

  60. Attach a suitable lifting device to the engine lift brackets.

    61. Object Number: 310259 Size: SH
  61. Remove the engine motor mount to frame bracket bolts.
  62. Support the transmission with a suitable jack.
  63. Remove the engine.

Installation Procedure

Tools Required

J 41427 Engine Lift Brackets


    Object Number: 310259 Size: SH
  1. Install the engine to the vehicle.

    2. 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 engine mount to frame bracket bolts.

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 33636 Size: SH
  3. Remove the J 41427 and the lifting device.
  4. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower intake manifold bolts.
  5. Install the intake manifold bolts.

    6. 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 final pass to 15 N·m (11 lb ft).
  6. Loosely install one transmission to engine bolt.
  7. Remove support jack from under the transmission.

    8. Object Number: 172982 Size: SH
  8. Install the EGR valve inlet pipe to the intake and the exhaust manifold.

    9. Tighten

    1. Tighten the EGR valve inlet pipe intake nut to 25 N·m (18 lb ft).
    2. Tighten the EGR valve inlet pipe exhaust nut to 30 N·m (22 lb ft).
    3. Tighten the EGR valve inlet pipe clamp bolt to 25 N·m (18 lb ft).
  9. Install the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.

    10. Object Number: 340090 Size: SH
  10. Slide the power steering pump mounting bracket with the power steering pump and the A/C compressor on the stud.
  11. Position the power steering pump rear bracket on the studs.
  12. Install the power steering pump mounting bracket three bolts and the nut.
  13. Install the nut for the power steering pump rear bracket to the front of the engine.

    14. Tighten
    Tighten the power steering pump mounting bracket and the power steering pump rear bracket bolts and the nuts to 41 N·m (30 lb ft).

  14. Connect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
  15. Connect the hose to the EVAP purge canister solenoid valve. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.

    16. Object Number: 346148 Size: SH
  16. Connect the vacuum brake booster hose to the engine and the vacuum brake booster.
  17. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
  18. Install both heater hoses to the engine and the cowl.
    19. • Refer to Heater Hoses Replacement in Heating and Ventilation (Non A/C).
    • Refer to Heater Hoses Replacement in HVAC Systems with A/C - Manual.

    Object Number: 332026 Size: SH
  19. Install the AIR pipe assembly with new gaskets to the right exhaust manifold, if equipped.
  20. Install the AIR pipe nuts and bracket bolt.

    21. Tighten

    1. Tighten the AIR nuts to 25 N·m (18 lb ft).
    2. Tighten the AIR bracket bolt to 10 N·m (88 lb in).
  21. Connect the AIR pipe assembly to the AIR pump.

    22. Object Number: 332032 Size: SH
  22. Install the AIR pipe assembly with new gaskets to the left exhaust manifold, if equipped.
  23. Install the AIR pipe nuts and bracket bolt.

    24. Tighten

    1. Tighten the AIR nuts to 25 N·m (18 lb ft).
    2. Tighten the AIR bracket bolt to 10 N·m (88 lb ft).

    Object Number: 398868 Size: SH
  24. Install the AIR crossover pipe to the AIR pipe assemblies.
  25. Position the engine wiring harness.

    26. Object Number: 491816 Size: SH
  26. Connect the following electrical connectors:
    27. • The EVAP canister purge solenoid valve (1)
    • The manifold absolute pressure (MAP) sensor (2)
    • The ignition control module (ICM) (4)
    • The ignition coil (3)

    Object Number: 491825 Size: SH
  27. Connect the following electrical connectors:
    28. • The engine oil pressure gauge sensor (3)
    • The distributor (2)
    • The knock sensor (KS) (1)

    Object Number: 491821 Size: SH
  28. Connect the following electrical connectors:
    29. • The A/C pressure switch (4), if equipped
    • The A/C compressor clutch (1), if equipped
    • The exhaust gas recirculation (EGR) valve (2)
    • The generator battery positive cable (3)

    Object Number: 491817 Size: SH
  29. Connect the following electrical connectors:
    30. • The fuel meter body assembly (3)
    • The idle air control (IAC) motor (2)
    • The throttle position (TP) sensor (1)
    • The engine coolant temperature (ECT) sensor (4)

    Object Number: 310256 Size: SH
  30. Install the bolt holding the ground strap and the ground wire to the rear of the left cylinder head.

    31. Tighten
    Tighten the ground strap and wire bolt to 16 N·m (12 lb ft).


    Object Number: 310243 Size: SH
  31. Position the wiring harness bracket on the EVAP purge canister solenoid valve stud and install the nut.
  32. Install the stud holding the wire harness bracket to the rear of the right cylinder head.

    33. Tighten

        • Tighten the nut on the EVAP solenoid to 9 N·m (80 lb in).
        • Tighten the stud at rear of the cylinder head to 25 N·m (18 lb ft).
  33. Install the nut holding the ground wire on the stud at the rear of the right cylinder head.

    34. Tighten
    Tighten the ground wire nut to 16 N·m (12 lb ft).


    Object Number: 394403 Size: SH
  34. Position the battery positive and negative cables. Refer to Battery Cable Replacement
  35. Install the battery positive cable junction block bracket and bolt to the power steering pump mounting bracket.

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


    Object Number: 310241 Size: SH
  36. Install the bolt holding the engine wiring harness bracket to battery positive cable junction block bracket.
  37. Install the engine wiring harness bracket on the intake manifold studs and install the nuts.

    38. Tighten

        • Tighten the wiring harness bracket nuts to 12 N·m (106 lb in).
        • Tighten the wiring harness bracket bolt to 9 N·m (80 lb ft).
  38. Connect the A/C hoses to the A/C compressor and the accumulator. Refer to Compressor Hose Assembly Replacement in HVAC Systems with A/C - Manual.

    39. Object Number: 398030 Size: SH
  39. Install the accelerator control cable bracket and nuts to the throttle body.

    40. Tighten
    Tighten the nuts to 10 N·m (88 lb in).

    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 the NEW accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls.
  41. Connect the cruse control cable to the throttle body and the accelerator control cable bracket, if equipped. Refer to Cruise Control Cable Replacement in Cruise Control.
  42. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  43. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  44. Install the engine cooling fan. Refer to Fan Clutch Replacement in Engine Cooling.
  45. Install the drive belt. Refer to Drive Belt Replacement .
  46. Install the upper and lower radiator shroud. Refer Fan Shroud Replacement in Engine Cooling.
  47. Install the air cleaner outlet duct to the throttle body and the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
  48. Connect the PCV hose to the air cleaner outlet duct.

    49. Object Number: 310799 Size: SH
  49. Move the hood hinge bolts from the service position (2) to the normal operating position (1).
  50. Raise the vehicle.

    51. Object Number: 102341 Size: SH
  51. Install the remaining transmission to engine bolts except for the one where the transmission cover mounts.
    52. •  Refer to Transmission Replacement in Automatic Transmission - 4L60-E.
    • Refer to Transmission Replacement in Manual Transmission - NV3500.
  52. Install three torque convertor to flywheel bolts, if equipped. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transmission - 4L60-E.

    53. Object Number: 391868 Size: SH
  53. Install the transmission cover and bolts.

    54. Tighten

    1. Tighten the transmission cover to oil pan bolt to 12 N·m (106 lb in).
    2. Tighten the transmission cover to transmission bolt to 47 N·m (34 lb ft).

    Object Number: 327996 Size: SH
  54. Install the bolt holding the bracket for the starter cables and the transmission cooler pipes, if equipped.

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


    Object Number: 310250 Size: SH
  55. Install the bolts holding the positive and negative battery cable brackets to the oil pan.

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


    Object Number: 491824 Size: SH
  56. Install the bolt for the battery negative cable (1) and ground wire (1) to the front of the engine.

    57. Tighten
    Tighten the battery negative cable and ground wire bolt to 16 N·m (12 lb ft).

  57. Connect the CKP sensor (2) and install the wire harness in the retainer.
  58. Connect the low oil level sensor (3) and install the wire harness in the retainer.
  59. Install the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
  60. Tighten the nuts at the catalytic converter flange. Refer to Catalytic Converter Replacement in Engine Exhaust.
  61. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.

    62. Object Number: 309158 Size: SH
  62. Install the oil pan skid plate (RWD vehicle shown).

    63. Tighten
    Tighten the oil pan skid plate bolt to 20 N·m (15 lb ft).

  63. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  64. Lower the vehicle.
  65. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
  66. Fill the engine with the proper quantity and grade of engine oil. Refer to Engine Oil and Oil Filter Replacement .
  67. Fill the engine with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  68. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C - Manual.
  69. Before starting a new engine, or one that has been repaired. Refer to Engine Set-Up and Testing .