GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 GMC K Sierra - 4WD 🢒 Engine 🢒 Engine Mechanical - 4.8L, 5.3L, and 6.0L 🢒 Engine Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the battery negative cable.
  2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Evacuate and recover theair conditioning (A/C) refrigerant, if equipped. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C -- Manual.

    4. Object Number: 310799 Size: SH
  4. Raise the hood to the servicing position. Refer to Hood Replacement in Body Front End.

    5. Object Number: 308983 Size: SH
  5. Remove the upper and the lower radiator hoses from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  6. Remove the air cleaner duct from the engine. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.
  7. Remove the A/C condenser mounting bolts, if equipped. Refer to Condenser Replacement in HVAC Systems with A/C -- Manual.

    8. Object Number: 373069 Size: SH
  8. Remove the upper radiator support and the radiator from the vehicle.

    9. Remove the following from body front end.

    • Remove grille
    • Remove front bumper bolts and bumper
    • Remove hood latch cable from hood latch assembly
    • Disconnect engine vent hose from radiator
    • Disconnect engine surge tank hose from radiator
    • Remove engine oil cooler lines from radiator
    • Remove transmission oil cooler lines from radiator
    • Remove radiator mounting bolts and radiator
    • Remove lines from auxiliary transmission cooler
    • Remove power steering cooler retaining bolts
    • Remove hood latch assembly bolts and bracket assembly
    • Remove left front fender diagonal brace from upper radiator support
    • Remove upper radiator support bolts and support
    • Disconnect A/C lines from condenser
    • Remove A/C lines from compressor and position aside
    • Remove A/C compressor
    • Refer to Radiator Support Replacement in Body Front End.
  9. Remove the A/C pressure hose from the A/C compressor, if equipped. Set the A/C pressure hose aside. Refer to Compressor Hose Assembly Replacement in HVAC Systems with A/C -- Manual.

    10. Object Number: 412343 Size: SH
  10. Remove the coolant hose from the throttle body.

    11. Object Number: 310811 Size: SH
  11. Remove bothof the heater hoses from the engine and the cowl. Refer to Heater Hoses Replacement in HVAC Systems with A/C -- Manual.
  12. Remove the engine sight shield from the intake manifold. Refer to Upper Intake Manifold Sight Shield Replacement .
  13. Remove the accelerator control cable mounting bracket from the intake manifold.

    14. 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.

  14. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.

    15. Object Number: 310125 Size: SH
  15. Open the large electrical harness retainer. Remove one 10 mm nut in order to release the engine harness from the intake manifold.

    16. Object Number: 310126 Size: SH
  16. Disconnect the following electrical connectors:
    17. • The eight injector connectors
    • The idle air control (IAC) motor
    • The throttle position (TP) sensor
    • The evaporative emissions (EVAP) canister purge solenoid
    • The manifold absolute pressure (MAP) sensor
    • The camshaft position (CMP) sensor
    • The ground splice at the rear of the right side of the block
    • The ground splice and the ground strap at the rear of the left side of the block
    • The coolant temperature (CTS) sensor
    • The oil pressure sensor/switch
    • The A/C compressor clutch, if equipped
    • the electrical connector from intake and disconnect from harness
    • junction block bracket from genorator bracket
  17. Set the electrical harness aside.
  18. Disconnect the EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.
  19. Remove the battery negative cable from the engine block.
  20. Remove the drive belt. Refer to Drive Belt Replacement .
  21. Generator Replacement in Engine Electrical.

    22. Object Number: 310813 Size: SH
  22. Remove the generator mounting bracket from the engine using the following steps:
    23. • Remove the bolts holding the generator mounting bracket to the cylinder head and block.
    • Remove the bolt behind the power steering pump to engine block.
    • Remove the generator mounting bracket.
  23. Position the bracket aside.

    24. Object Number: 310129 Size: SH
  24. Disconnect the fuel pipes from the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls -- 4.8L, 5.3L, 6.0L.
  25. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    26. Object Number: 310119 Size: SH
  26. Remove the steering linkage under body shield, if equipped.

    27. Object Number: 309158 Size: SH
  27. Remove the engine oil pan under body shield, if equipped.
  28. Drain the engine oil. Refer to Engine Oil and Oil Filter Change .
  29. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.

    30. Object Number: 310817 Size: SH
  30. Disconnect the engine wiring harness from the following components:
    31. • The crankshaft position (CKP) sensor
    • The engine oil level sensor
    • The A/C pressure switch, if equipped
    • The block heater, if equipped
    • The wiring harness to oil pan
    • Unrout wiring from lower engine area
  31. Remove the exhaust pipes from the exhaust manifolds. Refer to the appropriate procedure in Engine Exhaust from the following list:
    32. •  Catalytic Converter Replacement and Front Pipe Replacement
    •  Catalytic Converter Replacement
    •  Front Pipe Replacement

    Object Number: 310672 Size: SH
  32. Remove the transmission cooler pipe retainer from the right side of the engine block, if equipped.

    33. Object Number: 310627 Size: SH
  33. Remove the torque converter shield from the engine.
  34. Remove the torque converter bolts.
  35. Remove the nut and the transmission oil level indicator tube from the bellhousing stud.

    36. Object Number: 310823 Size: SH
  36. Remove the lower bellhousing studs from the engine. Refer to the appropriate procedure from the following list:
    37. •  Transmission Replacement in Manual Transmission -- NV 3500
    •  Transmission Replacement in Manual Transmission -- NV 4500
    •  Transmission Replacement in Automatic Transmission -- 4L60-E
    •  Transmission Replacement in Automatic Transmission -- 4L80-E
  37. Lower the vehicle.
  38. Remove remaining bellhousing bolts.

    39. Object Number: 310126 Size: SH
  39. Position the engine electrical harness aside.

    40. Object Number: 339300 Size: SH
  40. Remove ignition coil(s) (as required) for the proper fit of the J 41798 before lifting the engine. Refer to Ignition Coil Replacement in Engine Electrical.

    41. Object Number: 309151 Size: SH
  41. Install the J 41798 engine lift brackets to the cylinder heads.

    42. 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.

  42. Tighten the engine lift bracket bolts to 55 N·m (41 lb ft).
  43. Install a lifting device onto the J 41798 engine lift brackets.

    44. Object Number: 307275 Size: SH
  44. Install floor jack or stands to transmission for support.
  45. Remove the engine mount bolts. Refer to Engine Mount Replacement .

    46. Notice: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

  46. Remove the engine from the vehicle.

Installation Procedure

    Notice: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

  1. Install the engine to the vehicle.

    2. Object Number: 307275 Size: SH
  2. Install the engine mount bolts. Refer to Engine Mount Replacement
  3. Install upper bellhousing bolts.
  4. Remove transmission support apparatus
  5. Remove the lifting device from the J 41798 lift brackets.

    6. Object Number: 309151 Size: SH
  6. Remove the J 41798 lift brackets from both cylinder heads.

    7. Object Number: 339300 Size: SH
  7. Install the ignition coil(s) and the spark plug wire(s) after removing the J 41798 . Refer to Ignition Coil Replacement in Engine Electrical.

    8. Object Number: 310126 Size: SH
  8. Route the engine wiring harness to the lower right hand side of the engine.
  9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  10. Install remaining bellhousing bolts.
  11. Install torque converter bolts.
  12. Install torque converter shield
  13. Install transmission oil level indicator tube and nut to bellhousing stud.
  14. Install transmission cooler pipe retainer to right side of engine block.

    15. Refer to the appropriate procedure from the following list:

    •  Transmission Replacement in Manual Transmission -- NV 3500
    •  Transmission Replacement in Manual Transmission -- NV 4500
    •  Transmission Replacement in Automatic Transmission -- 4L60-E
    •  Transmission Replacement in Automatic Transmission -- 4L80-E
  15. Install the engine exhaust pipes to the exhaust manifolds. Refer to the appropriate procedure in Engine Exhaust from the following list:
    16. •  Catalytic Converter Replacement
    •  Front Pipe Replacement
  16. Reroute wiring to lower engine area and install bolt to oil pan.
  17. Connect electrical connectors to the crankshaft position (CKP) sensor.
  18. The engine oil level sensor
  19. The A/C pressure switch, if equipped
  20. The block heater, if equipped
  21. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.

    22. Object Number: 309158 Size: SH
  22. Install the engine oil pan under body shield, if equipped.

    23. Object Number: 310119 Size: SH
  23. Install the steering linkage under body shield.
  24. Lower the vehicle.
  25. Install the A/C compressor hose to the A/C compressor, if equipped. Refer to Compressor Hose Assembly Replacement in HVAC Systems with A/C -- Manual.
  26. Connect the fuel pipes to the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls -- 4.8L, 5.3L, 6.0L.

    27. Object Number: 310813 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.

  27. Install the generator mounting bracket to the cylinder head using the nuts and the bolts.

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


    Object Number: 540287 Size: SH
  28. Install the bolt at the rear of the power steering pump to engine block.

    29. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).

  29. Install the generator to the engine. Refer to Generator Replacement in Engine Electrical.
  30. Install the drive belt. Refer to Drive Belt Replacement
  31. Install the battery negative cable to the engine block. Refer to Fastener Tightening Specifications .
  32. Install the EVAP canister purge solenoid to the intake manifold. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.

    33. Object Number: 310126 Size: SH
  33. Route the engine harness over the top of the engine. Connect the following components:
    34. • The eight injector connectors
    • The idle air control (IAC) motor
    • The throttle position (TP) sensor
    • The EVAP canister purge solenoid.
    • The manifold absolute pressure (MAP) sensor
    • The camshaft position (CMP) sensor
    • The ground splice at the rear of the right side of engine block
    • The ground splice and the ground strap at the rear of the left side of engine block
    • The coolant temperature (CTS) sensor
    • The oil pressure sensor/switch
    • A/C compressor clutch electrical connector to harness and reclip to intake manifold

    Object Number: 310125 Size: SH
  34. Install the nut to the engine wiring harness bracket.

    35. Tighten
    Tighten the nut to 10 N·m (89 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.

  35. Install a NEW accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.

    36. Install cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement . in Engine Controls -- 4.8L, 5.3L, 6.0L.

  36. Install the bolts for the accelerator control cable mounting bracket.

    37. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  37. Install the engine sight shield to the intake manifold. Refer to Upper Intake Manifold Sight Shield Replacement .

    38. Object Number: 310811 Size: SH
  38. Install both heater hoses to the cowl and the engine. Refer to Heater Hoses Replacement in HVAC Systems with A/C -- Manual.

    39. Object Number: 412343 Size: SH
  39. Install the coolant hose to the throttle body.

    40. Object Number: 373069 Size: SH
  40. Install the upper radiator support and the radiator. Refer to Radiator Support Replacement in Body Front End.
  41. Install the A/C condenser mounting bolts, if equipped. Refer to Condenser Replacement in HVAC Systems with A/C -- Manual.
  42. Install the air cleaner duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 4.8L, 5.3L, 6.0L.
  43. Install the upper and the lower radiator hoses to the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.

    44. Object Number: 310799 Size: SH
  44. Lower the hood. Refer to Hood Replacement in Body Front End.
  45. Fill the engine with oil. Refer to Engine Oil and Oil Filter Change .
  46. Fill the engine with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  47. Connect the negative battery cable.