GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Mechanical - 4.3L 🢒 Engine Replacement

Tools Required

J 41427 Engine Lift Brackets

Removal Procedure

    Object Number: 310799 Size: SH
  1. Raise the hood to the service position, perform the following:
    2. 1.1. Remove the hood hinge bolts (1).
    1.2. Raise the hood until vertical.
    1.3. Install the hood hinge bolts until snug in the service position (2).
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.
  5. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement in Engine Cooling.
  6. Remove the drive belt. Refer to Drive Belt Replacement .
  7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    8. Object Number: 309158 Size: SH
  8. If equipped, remove the oil pan skid plate bolts and plate.
  9. If equipped, remove the engine shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  10. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    11. Object Number: 869720 Size: SH
  11. Remove the transmission cover.

    12. Object Number: 869722 Size: SH
  12. Remove the positive battery cable clip bolt (2).
  13. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.

    14. Object Number: 310250 Size: SH
  14. Remove the battery cable bracket bolts.

    15. Object Number: 782731 Size: SH
  15. Disconnect the oil level sensor electrical connector (7).
  16. Disconnect the crankshaft position (CKP) sensor electrical connector (5) and remove the harness from the retainer clip.
  17. Remove the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.

    18. Object Number: 9096 Size: SH
  18. If equipped, remove the torque converter bolts.
  19. Remove the transmission bolts.
  20. Lower the vehicle.

    21. Object Number: 367002 Size: SH
  21. Reposition the radiator inlet hose clamp.
  22. Remove the radiator inlet hose from the thermostat housing.

    23. Object Number: 367001 Size: SH
  23. Reposition the radiator outlet hose clamps.
  24. Remove the radiator outlet hose from the surge tank.
  25. Remove the radiator outlet hose from the water pump.

    26. Object Number: 781993 Size: SH
  26. If equipped, disconnect the cruise control cable from the throttle lever.
  27. If equipped, remove the cruise control cable from the accelerator control cable bracket.

    28. Object Number: 781992 Size: SH
  28. Remove the accelerator cable from the throttle body lever.

    29. Object Number: 781990 Size: SH

    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.

  29. Remove the accelerator cable from the accelerator control cable bracket.

    30. Object Number: 325556 Size: SH
  30. Remove the accelerator cable from the throttle body lever.

    31. Object Number: 398030 Size: SH
  31. Remove the accelerator control cable bracket nuts.
  32. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
  33. Reposition and secure the bracket and cable out of the way.
  34. If equipped, remove the air conditioning (A/C) hoses. Refer to Discharge Hose Replacement and Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.

    35. Object Number: 782175 Size: SH
  35. Disconnect the following electrical connectors:
    36. • A/C pressure switch (4), if equipped
    •  A/C compressor clutch (1), if equipped
  36. Remove the positive cable nut and cable from the generator.

    37. Object Number: 782174 Size: SH
  37. Disconnect the following electrical connectors:
    38. • Throttle position (TP) sensor (1)
    • Idle air control (IAC) motor (2)
    • Control port injector module (3)
    • Engine coolant temperature (ECT) sensor (5)
  38. Remove the engine wiring harness clip bolt (4).

    39. Object Number: 782178 Size: SH
  39. Disconnect the following electrical connectors:
    40. • Evaporative emission (EVAP) canister purge solenoid valve (1)
    • Manifold absolute pressure (MAP) sensor (2)

    Object Number: 782177 Size: SH
  40. Disconnect the following electrical connectors:
    41. • Ignition coil (1)
    • Ignition coil driver (2)
    • Generator (3)
  41. Remove the engine wiring harness ground nut and ground wire (4) from the rear of the right cylinder head.

    42. Object Number: 782680 Size: SH
  42. Disconnect the following electrical connectors:
    43. • Knock sensor (1)
    • Camshaft position (CMP) sensor (2)
    • Fuel pump/oil pressure sensor (3)
    • Distributor (2)
  43. Remove the harness ground bolt.
  44. Reposition the harness ground (4) and ground strap (5).

    45. Object Number: 310241 Size: SH
  45. Remove the engine wiring harness bracket nuts.
  46. Remove the engine wiring harness bracket from the studs.

    47. Object Number: 782670 Size: SH
  47. Remove the junction block bracket bolt.
  48. Reposition the bracket and wiring harness aside.

    49. Object Number: 782176 Size: SH
  49. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
  50. Remove the stud holding the engine wiring harness bracket.
  51. Reposition the engine wiring harness with the bracket aside.
  52. Remove the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation, and Air Conditioning.
  53. Remove the distributor cap. Refer to Distributor Replacement in Engine Controls - 4.3L.

    54. Object Number: 869711 Size: SH
  54. Disconnect the EVAP canister harness from the purge solenoid valve.

    55. Object Number: 869713 Size: SH
  55. Disconnect the power brake booster vacuum hose from the vacuum fitting.

    56. Object Number: 340090 Size: SH
  56. Loosen the power steering (P/S) pump rear bracket nut.
  57. Remove the P/S pump rear bracket front nut.
  58. Remove the bolts and the nut for the P/S pump bracket.
  59. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
  60. Slide the P/S pump bracket forward off the stud and set aside.
  61. Remove the thermostat and water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.

    62. Object Number: 33636 Size: SH
  62. Remove the left front and right rear intake manifold lower bolts.
  63. Install J 41427 to the left front and right rear intake manifold bolts, using the following procedure:
    64. 63.1. Install the J 41427 marked RIGHT REAR.

    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.

    63.2. Install the lift bracket bolts.

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

    63.3. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
    63.4. Install the lift bracket bolts.

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

  64. Install a suitable lifting devise to the engine lift brackets.

    65. Object Number: 310259 Size: SH
  65. Remove the engine mount to engine mount bracket nuts.
  66. Support the transmission with a suitable floor jack.
  67. Remove the engine.

Installation Procedure

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

    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 engine mount bracket bolts.

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


    Object Number: 33636 Size: SH
  3. Remove the lifting devise and the J 41427
  4. Apply threadlock GM P/N 12345382, (Canadian P/N 10953489), or equivalent to the threads of the intake manifold lower bolts.
  5. Install the intake manifold bolts.

    6. Tighten

    1. Tighten the bolts a first pass to 3 N·m (27 lb in).
    2. Tighten the bolts a second pass to 12 N·m (106 lb in).
    3. Tighten the bolts a final pass to 15 N·m (11 lb ft).
  6. Install one transmission bolt until snug.
  7. Remove the support jack from under the transmission.
  8. Install the thermostat and water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.

    9. Object Number: 340090 Size: SH
  9. Slide the P/S pump bracket onto the stud.
  10. Install the bolts and the nut for the P/S pump bracket.
  11. Install the P/S pump rear bracket front nut.
  12. Tighten the P/S pump rear bracket nut.

    13. Tighten
    Tighten the bolts and nuts to 41 N·m (30 lb ft).


    Object Number: 869713 Size: SH
  13. Connect the power brake booster vacuum hose to the vacuum fitting.

    14. Object Number: 869711 Size: SH
  14. Connect the EVAP canister harness to the purge solenoid valve.
  15. Install the distributor cap. Refer to Distributor Replacement in Engine Controls - 4.3L.
  16. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation, and Air Conditioning.

    17. Object Number: 782176 Size: SH
  17. Position the engine wiring harness.
  18. Install the stud holding the engine wiring harness bracket.
  19. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

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


    Object Number: 782670 Size: SH
  20. Position the bracket and wiring harness.
  21. Install the junction block bracket bolt.

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


    Object Number: 310241 Size: SH
  22. Install the engine wiring harness bracket to the studs.
  23. Install the engine wiring harness bracket nuts.

    24. Tighten
    Tighten the nuts to 12 N·m (106 lb in).


    Object Number: 782680 Size: SH
  24. Position the harness ground (4) and ground strap (5).
  25. Install the harness ground bolt.

    26. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).

  26. Connect the following electrical connectors:
    27. • Knock sensor (1)
    • CMP sensor (2)
    • Fuel pump/oil pressure sensor (3)
    • Distributor (2)

    Object Number: 782177 Size: SH
  27. Install the engine wiring harness ground nut and ground wire (4) to the rear of the right cylinder head.

    28. Tighten
    Tighten the nut to 16 N·m (12 lb ft).

  28. Connect the following electrical connectors:
    29. • Ignition coil (1)
    • Ignition coil driver (2)
    • Generator (3)

    Object Number: 782178 Size: SH
  29. Connect the following electrical connectors:
    30. • EVAP canister purge solenoid valve (1)
    • MAP sensor (2)

    Object Number: 782174 Size: SH
  30. Install the engine wiring harness clip bolt (4).

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

  31. Connect the following electrical connectors:
    32. • TP sensor (1)
    • IAC motor (2)
    • Control port injector module (3)
    • ECT sensor (5)

    Object Number: 782175 Size: SH
  32. Install the positive cable and nut to the generator.

    33. Tighten
    Tighten the nut to 18 N·m (13 lb ft).

  33. Connect the following electrical connectors:
    34. • A/C pressure switch (4), if equipped
    • A/C compressor clutch (1), if equipped
  34. If equipped, install the A/C hoses. Refer to Discharge Hose Replacement and Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.

    35. Object Number: 398030 Size: SH
  35. Position the bracket and cables.
  36. Install the accelerator control cable bracket with the cables attached, to the throttle body.
  37. Install the accelerator control cable bracket nuts.

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


    Object Number: 325556 Size: SH
  38. Install the accelerator cable to the throttle body lever.

    39. Object Number: 781990 Size: SH

    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.

  39. Install the accelerator cable to the accelerator control cable bracket.

    40. Object Number: 781992 Size: SH
  40. Install the accelerator cable to the throttle body lever.

    41. Object Number: 781993 Size: SH
  41. If equipped, install the cruise control cable to the accelerator control cable bracket.
  42. If equipped, connect the cruise control cable to the throttle body lever.

    43. Object Number: 367001 Size: SH
  43. Install the radiator outlet hose to the water pump.
  44. Install the radiator outlet hose to the surge tank.
  45. Position the radiator outlet hose clamps.

    46. Object Number: 367002 Size: SH
  46. Install the radiator inlet hose to the thermostat housing.
  47. Position the radiator inlet hose clamp.
  48. Install the drive belt. Refer to Drive Belt Replacement .
  49. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement in Engine Cooling.
  50. Install the fuel pipes/hoses. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.

    51. Object Number: 310799 Size: SH
  51. Remove the hood hinge bolt from the service position (2).
  52. Lower the hood to the normal position.
  53. Install the hood hinge bolts.

    54. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  54. Raise the vehicle.

    55. Object Number: 9096 Size: SH
  55. Install the transmission bolts

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

  56. If equipped, Install the torque converter bolts.

    57. Tighten
    Tighten the bolts to 63 N·m (47 lb ft).


    Object Number: 782731 Size: SH
  57. Install the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
  58. Connect the CKP sensor electrical connector (5) and install the harness to the retainer clip.
  59. Connect the oil level sensor electrical connector (7).

    60. Object Number: 310250 Size: SH
  60. Install the battery cable bracket bolts.

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

  61. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.

    62. Object Number: 869722 Size: SH
  62. Install the positive battery cable clip bolt (2).

    63. Object Number: 869720 Size: SH
  63. Install the transmission cover.

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

  64. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  65. If equipped, install the engine shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.

    66. Object Number: 309158 Size: SH
  66. If equipped, install the oil pan skid plate and bolts.

    67. Tighten
    Tighten the bolts to 20 N·m (1 lb ft).

  67. Lower the vehicle.
  68. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  69. Perform the engine prelube procedure. Refer to Engine Prelubing
  70. Add engine oil supplement GM P/N 1052367 (Canadian P/N 992869), or equivalent to the engine oil.
  71. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  72. If equipped, bleed the hydraulic clutch. Refer to Hydraulic Clutch Bleeding in Clutch.
  73. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.

    74. Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

  74. Disable the ignition system.
  75. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
  76. Start the engine and listen for unusual noises.
  77. Check the oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
  78. If necessary, install an oil pressure gauge and measure the oil pressure.
  79. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
  80. Listen for sticking valve lifters, or other unusual noises.
  81. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
  82. Verify that the distributor is properly positioned.
  83. Perform a final inspection for the proper oil and coolant levels.
  84. Close the hood.