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Home >> GMC Truck >> 2000 >> Safari Van AWD V6-4.3L VIN W >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Removal

Engine Removal

Removal Procedure

- Tools Required
- J 41427 Engine Lift Bracket
- J 41602 Body Protection Hoist Adapter Set
- J 39580 Universal Engine Support Table





Important: This procedure must be performed on a side lift hoist. The engine and front frame assembly will be removed out of the bottom of the vehicle, therefore, a single post hoist or a twin post hoist cannot be used to perform this procedure.

Notice: Failure to flush out the oil cooling system or the engine cooling system may result in premature failure of the replacement engine.

If the engine is damaged internally and a new engine is installed, make sure that all foreign material is completely flushed out of the cooling system.
The oil cooler system should be also be flushed out, if equipped.
1. Disconnect the battery negative cable. Refer to Battery Replacement in Starting and Charging.
2. Remove the engine cover. Refer to Engine Cover Replacement.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
4. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Powertrain Management.
5. Remove the following:
- Upper fan shroud
- Fan and clutch
- Lower fan shroud
- Both radiator hoses
- Oil cooler lines
- Transmission cooler lines
6. Disconnect the air conditioning hose at the accumulator and the condenser, if equipped.
- Refer to Compressor/Condenser Hose Replacement - Auxiliary (RPO C60)
- Refer to Compressor/Condenser Hose Replacement - Auxiliary (RPO C69)
- Refer to Compressor/Condenser Hose Replacement - Auxiliary (RPO YF7) in Heating and Air Conditioning.
7. Remove the bolts holding the condenser to the radiator.
8. Remove the radiator. Refer to Radiator 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.

9. Remove the accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
10. Remove the cruise control cable, if equipped from the throttle shaft. Refer to Cruise Control Cable Replacement in Cruise Control.
11. Remove the cruise control cable from the accelerator control cable bracket.
12. Remove the power steering reservoir and drain the fluid. Refer to Remote Power Steering Fluid Reservoir Replacement in Steering and Suspension.
13. Disconnect the pipes from the hydro boost unit. Refer to Hydraulic Brake Booster Replacement in Brakes and Traction Control.
14. Disconnect the master cylinder from the hydro boost unit. Refer to Master Cylinder Replacement in Brakes and Traction Control.
15. Tie the master cylinder to the oil fill tube.
16. Disconnect the steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
17. Disconnect the heater hoses from the engine. Refer to Hot Water Bypass Valve Replacement (Standard) or Hot Water Bypass Valve Replacement (RPO C60) in Heating and Air Conditioning.
18. Disconnect the vacuum hose to the vacuum tank from the intake manifold.
19. Disconnect the engine wiring harness from the VCM. Refer to Vehicle Control Module Wiring in Diagrams/Diagnostic Aids.
20. Disconnect the fuse box and the wiring harness from the bulkhead connector. Refer to Bulkhead/Underhood Fuse-Relay Center Wiring in Diagrams/Diagnostic Aids.
21. Disconnect the battery negative cable from the battery and the battery cable assembly from the fender and the radiator support. Refer to Battery Cable Replacement in Starting and Charging.
22. Secure the battery cable assembly to the engine.
23. Disconnect all related electrical connectors that connect the wiring harness to the body under the hood including the following: Refer to Engine/Center of Front of Dash Wiring (Components) in Diagrams/Diagnostic Aids.
- The ground wires
- The A/C module
- The differential pressure input switch
24. Remove the wiring harness from the retainers and lay the harness on the engine.





25. Remove the front section of the running boards, if equipped.
26. Install the J 41602 to the pinch weld area on both sides of the vehicle.
27. Position the front hoist arms under the J 41602. Refer to Vehicle Lifting for proper position of the rear hoist arms.
28. Make sure the rear of the vehicle is slightly higher than the front.
29. Raise the vehicle.





30. Remove the oil pan drain plug and drain the engine oil into a suitable container.
31. Remove the engine oil cooler pipes from the oil filter adapter. Refer to Engine Oil Cooler Line Replacement in Cooling System.
32. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Transmission and Drivetrain.





33. Remove the starter. Refer to Starter Motor Replacement in Starting and Charging.
34. Remove the transmission cover.





35. Remove the torque converter bolts through the starter opening.
36. Disconnect the shift cable from the transmission. Refer to Shift Cable Replacement in Transmission and Drivetrain.
37. Remove the heat shield.
38. Disconnect the exhaust system at the main flange behind the catalytic converter.
- Refer to Catalytic Converter Replacement (Rear Wheel Drive)
- Refer to Catalytic Converter Replacement (Automatic Four Wheel Drive) in Powertrain Management.
39. Remove the muffler and tail pipe section from the hangers and remove from the vehicle.





40. Remove the park brake bracket from the frame.
41. Disconnect the rear brake pipe from the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Brakes and Traction Control.
42. Remove the front bumper.
43. Disconnect the power steering cooler from the front air deflector. Refer to Power Steering Cooler Pipe/Hose Replacement in Steering and Suspension.
44. Disconnect the inflatable restraint front end discriminating sensor electrical connector. Refer to Inflatable Restraint Front End Discriminating Sensor Replacement in Restraint System.
45. Disconnect the fender wheelhouse extensions from the chassis to the frame.
46. Disconnect the rear air conditioning pipes at the rear crossmember, if equipped.
Leave the air conditioning pipes attached to the powertrain assembly. Refer to Accumulator Tube Replacement - Auxiliary Side in Heating and Air Conditioning.
47. Disconnect the fuel pipes at the fuel filter. Refer to Fuel Hose/Pipe Assembly Replacement (Fuel Tank) in Powertrain Management.
48. Pull the fuel pipes through the crossmember (forward). Lay the fuel pipes on the transmission.
49. Disconnect the fuel tank electrical connector. Refer to Undercarriage Wiring in Diagrams/Diagnostic Aids.
50. Disconnect the EVAP vent valve electrical connector.
51. Remove the bolt and the ground wire at the chassis by the EVAP vent valve.
52. Make sure all the connections are disconnected between the chassis and the frame.
53. Remove the engine wiring harness clips from the frame and the cross sills.





54. Position the J 39580 under the engine/frame assembly.
55. Lower the vehicle.
56. Adjust J 39580 to properly support the frame assembly with the engine, transmission, front suspension components, and front differential carrier assembly, if equipped.





57. Remove the body mount bolts (1), (2) and (3).
58. Place a jack stand under the transmission crossmember to prevent the engine/frame assembly from tipping off of the J 39580.
59. Raise the hoist in order to separate the body from the engine/frame assembly.
60. Install support stands under the rear axle.
61. Move the engine/frame assembly from under the vehicle.





62. Remove the bolt holding the starter wiring harness and the transmission oil cooler pipe bracket to the oil pan.
63. Remove the generator. Refer to Generator Replacement in Starting and Charging.





64. Remove the nut and the A/C pipe bracket, if equipped from the fuel pipe bracket stud.
65. Remove the stud holding the fuel pipe bracket to the rear of the left cylinder head.
66. Remove the fuel pipe stud nut on the side of the transmission.
67. Move the fuel pipes back to clear the engine.
68. Disconnect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) in Powertrain Management.





69. Remove the ground wire bolt and ground wire from the rear of the left cylinder head.
70. Remove the bolt holding the engine wiring harness clip to the rear of the right cylinder head.





71. Disconnect the crankcase position (CKP) sensor electrical connector (4).
72. Remove the CKP sensor wiring harness clip (3) from the bracket.
73. Remove the engine wiring harness clip (1) from the negative battery cable stud (2).
74. Remove the negative battery cable stud (1) and the cable.





75. Remove the bolt holding the engine wiring harness bracket to the generator mounting bracket.





76. Disconnect the EGR valve electrical connector (1).
77. Remove the ground wire (2) from the stud at the water outlet.





78. Disconnect the following electrical connectors:
- The manifold absolute pressure (MAP) sensor(4)
- The EVAP canister purge solenoid valve (1)
- The ignition coil (2)
- The ignition coil module (ICM) (3)





79. Disconnect the following electrical connectors:
- The A/C compressor clutch, if equipped (1)
- The A/C high pressure cutoff switch, if equipped (5)
- The throttle position (TP) sensor (2)
- The idle air control (IAC) motor (3)
- The fuel meter body assembly connector (4)





80. Disconnect the following electrical connectors:
- The knock (KS) sensor (1)
- The distributor (2)
- The engine oil pressure sensor (3)
81. Remove the engine wiring harness from the brackets.
82. Remove the bolts holding the transmission fluid fill tube from the oil indicator and the bell housing bolt.
83. Move the transmission fluid tube to the side.
84. Position the engine wiring harness out of the way.
85. Remove the transfer case to engine block brace, if equipped. Refer to Transfer Case Replacement in Transmission and Drivetrain.
86. Remove the exhaust pipe from the exhaust manifolds.
- Refer to Catalytic Converter Replacement (Rear Wheel Drive)
- Refer to Catalytic Converter Replacement (Automatic Four Wheel Drive) in Powertrain Management.





87. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
88. Remove the clamp bolt for the EGR valve inlet pipe.
89. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
90. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
91. Remove the distributor cap with the spark plug wire harness.
92. Remove the air conditioning pipe bracket nut from the intake manifold stud.
93. Remove the air conditioning compressor and the power steering pump, leaving the pump and the compressor on the bracket. Refer to Accessory Mounting Brackets Replacement (PS Pump) or Accessory Mounting Brackets Replacement (Generator).





94. Install the J 41427 using the following procedure:
94.1. Remove the two right rear lower intake manifold bolts.
94.2. Install the J 41427 marked RIGHT REAR.

Notice: Refer to Fastener Notice in Service Precautions.

94.3. Install the retaining bolts.
Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
94.4. Remove the two left front lower intake manifold bolts.
94.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
94.6. Install the retaining bolts
Tighten the retaining bolts to 15 Nm (11 ft. lbs.).





95. Remove the engine mount through bolts.
96. Raise the engine slightly. Support the front of the transmission with suitable floor stand and a block of wood. Do not support the transmission under the oil pan.





97. Remove the transmission to engine bolts.
98. Disconnect the engine from the transmission.
99. Remove the engine from the frame.

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