Tools Required

J 41427 Engine Lift Bracket

1. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 4.3L engine.
5. Remove the front bumper. Refer to Front Bumper Replacement in Bumpers.
6. Remove the grille. Refer to Grille Replacement 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 in Heating, Ventilation, and Air Conditioning.
9. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.

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.
10. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement for the 4.3L engine.
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.



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 air conditioning (A/C) high pressure switch (4), if equipped




15. Disconnect the following electrical connectors:

•	The fuel meter body assembly connector (1)

•	The evaporative emission (EVAP) canister purge solenoid valve (2)

•	The manifold absolute pressure (MAP) sensor (3)




16. Disconnect the following electrical connectors:

•	The distributor (2)

•	The engine oil pressure sensor (3)

•	The knock (KS) sensor (1)




17. Disconnect the following electrical connectors:

•	The A/C compressor clutch (1), if equipped

•	The exhaust gas recirculation (EGR) valve (2)

•	The ECT sensor (3)

18. Remove the ground wire (4) from the stud at the water outlet.



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.



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.
25. Remove the heater hoses from the engine . Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation, and Air Conditioning.
26. Remove the radiator inlet and outlet hoses. Refer to the following procedures:

•	Radiator Inlet Hose Replacement in Engine Cooling

•	Radiator Outlet Hose Replacement in Engine Cooling

27. Remove the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement in Heating, Ventilation, and Air Conditioning.
28. Remove the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
29. Remove the power steering pump mounting bracket.



30. Remove the power steering pump rear mounting bracket from the engine. Set the pump aside.
31. Remove the distributor. Refer to Distributor Replacement for the 4.3L engine.
32. In order to allow access for the lifting device, remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .



33. Remove the transmission control cable bracket from the rear of the left cylinder head.
34. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
35. Remove both exhaust manifolds. Refer to the following procedures:

•	Exhaust Manifold Replacement - Left Side in Engine Exhaust

•	Exhaust Manifold Replacement - Right Side in Engine Exhaust

36. Remove the oil pan drain plug and drain the engine oil into a suitable container.
37. Remove the engine oil filter.
38. Remove the engine oil cooler pipes from the engine. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
39. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.



40. Remove the transmission cover.



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



42. Remove the transmission cooler pipes from the engine.



43. Remove the bolts holding the transmission to the engine except the top 2 bolts.
44. Lower the vehicle.
45. Support the transmission with a strap between the frame rails or use a suitable transmission jack.



46. Install the J 41427 using the following procedure:

46.1.

Remove the 2 right rear lower intake manifold bolts.

46.2.

Install the J 41427 marked RIGHT REAR.

Notice: Refer to Fastener Notice in the Preface section.

46.3.

Install the retaining bolts.

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

46.4.

Remove the 2 left front lower intake manifold bolts.

46.5.

Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.

46.6.

Install the retaining bolts.

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

47. Attach a suitable engine lifting device to the J 41427 .
48. Remove the engine mounts from the engine mount frame brackets. Refer to the following procedures:

•	Engine Mount Replacement - Left Side

•	Engine Mount Replacement - Right Side

49. Remove the 2 remaining engine to transmission bolts.
50. Remove the engine assembly from the vehicle.

1. Install the engine assembly to the vehicle.
2. Loosely install the 2 upper transmission to engine bolts.
3. Install the engine mounts to the engine mount frame brackets. Refer to the following procedures:

•	Engine Mount Replacement - Left Side

•	Engine Mount Replacement - Right Side

4. Remove the engine lifting device.



5. Remove the J 41427 from the engine.
6. Apply thread lock to the threads of the lower intake manifold bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
7. Install the lower intake manifold bolts.

Tighten

1. Tighten the bolts to 3 N·m (27 lb in).
2. Tighten the bolts to 12 N·m (106 lb in).
3. Tighten the bolts to 15 N·m (11 lb ft).
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Install the remaining bolts from the transmission to the engine. Refer to Transmission Replacement for the 4L60-E/4L65-E transmission for location of the proper bolts and tightening specifications.



10. Install the bolt holding the transmission cooler pipes bracket to the oil pan.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

11. Install the torque converter bolts to the flywheel.

Tighten
Tighten the bolts to 62 N·m (46 lb ft).




12. Install the transmission cover.

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

13. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
14. Install the engine oil cooler pipes to the engine. Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
15. Install the exhaust manifolds. Refer to the following procedures:

•	Exhaust Manifold Replacement - Left Side in Engine Exhaust

•	Exhaust Manifold Replacement - Right Side in Engine Exhaust

16. Lower the vehicle.
17. Install the upper intake manifold to the engine. Refer to Upper Intake Manifold Replacement .



18. Install the transmission control cable bracket to the rear of the left cylinder head.

Tighten
Tighten the transmission control cable bracket bolts to 40 N·m (30 lb ft).

19. Install the distributor. Refer to Distributor Replacement for the 4.3L engine.
20. Install the power steering pump with the rear bracket to the engine. Refer to Power Steering Pump Replacement in Power Steering System.
21. Install the power steering pump mounting bracket.
22. Install the A/C compressor discharge hose from the vehicle. Refer to Discharge Hose Replacement in Heating, Ventilation, and Air Conditioning.
23. Install the A/C compressor suction hose from the vehicle. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
24. Install the radiator inlet and outlet hoses to the engine. Refer to the following procedures:

•	Radiator Inlet Hose Replacement in Engine Cooling

•	Radiator Outlet Hose Replacement in Engine Cooling

25. Install the heater hoses to the engine. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation, and Air Conditioning.
26. Install the generator mounting bracket.



27. Install the stud and bolt holding the ground wires to the rear of both cylinder heads.

Tighten
Tighten the bolt and the stud to 10 N·m (88 lb in).

28. Install the nut holding the engine wiring harness at the transmission to engine stud.

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




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



32. Connect the following electrical connectors:

•	The fuel meter body assembly connector (1)

•	The EVAP canister purge solenoid valve (2)

•	The MAP sensor (3)




33. Connect the following electrical connectors:

•	The distributor (2)

•	The engine oil pressure sensor (3)

•	The KS (1)




34. Connect the following electrical connectors:

•	The TP sensor (1)

•	The IAC motor (2)

•	The ECT gage sensor (3)

•	The A/C high pressure switch (4), if equipped




35. Disconnect the following electrical connectors:

•	The A/C compressor clutch (1), if equipped

•	The EGR valve (2)

•	The ECT sensor (3)

36. Install the nut holding the ground wire (4) to the water outlet stud.

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




37. Install the bolt holding the battery negative cable and the ground strap to the front of the engine.

Tighten
Tighten the 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.
38. Install a NEW accelerator control cable. Refer to Accelerator Control Cable Replacement for the 4.3L engine.
39. Install the cruise control cable, if equipped, to the throttle shaft and the accelerator control cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
40. Install the fan clutch to the water pump. Refer to Fan Clutch Replacement in Engine Cooling.
41. Install the radiator support. Refer to Radiator Support Replacement in Body Front End.
42. Install the oil filter and fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement .
43. Fill the cooling system with the proper quantity and type of coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
44. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
45. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
46. Start the engine and listen for unusual noises.
47. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.

If necessary, install an oil pressure gage and measure the engine oil pressure.

48. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
49. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
50. Inspect for oil and/or coolant leaks while the engine is operating.
51. Verify that the distributor is properly positioned.
52. Perform a final inspection for the proper engine oil and coolant levels.
53. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.