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Home >> GMC >> 2005 >> Jimmy Part Time, Standard >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 4.3L >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure
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Installation Procedure

NOTE: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.
    Fig 1: Engine Lift Brackets J 41427
    GM33636Courtesy of GENERAL MOTORS CORP.
  1. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:
    1. Remove the right rear lower intake manifold bolts.
    2. Install the J 41427 marked RIGHT REAR.
    3. Install the retaining bolts.
    4. Remove the left front lower intake manifold bolts.
    5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
    6. Install the retaining bolts.

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

  2. Install a engine lifting device to the engine lift brackets.
  3. Install the engine into the vehicle.
    4. Fig 2: View Of Engine Mount Bolt
    GM4564Courtesy of GENERAL MOTORS CORP.
  4. Install the engine mount through-bolts and nuts.

    Tighten:  Tighten the engine mount through-bolts or the nuts to the following:

    • Tighten the through-bolts to 74 N.m (55 lb ft)
    • Tighten the nuts to 63 N.m (46 lb ft)
  5. Remove the J 41427 and the engine lifting device.
  6. Apply thread lock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
  7. Install the intake manifold bolts.

    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 third pass to 15 N.m (11 lb ft).

  8. Install the water outlet. Refer to Thermostat Replacement (4.3L) in Engine Cooling.
  9. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 4.3L.
  10. Install the distributor cap. Refer to Distributor Replacement in Engine Controls - 4.3L.
  11. Connect the EVAP canister purge solenoid valve pipe. Refer to Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine in Engine Controls - 4.3L.
    12. Fig 3: Removing Power Steering Rear Mounting Bracket Nut From Engine Stud (4.3L)
    GM288833Courtesy of GENERAL MOTORS CORP.
  12. Install the power steering pump mounting bracket.
    • Slide the power steering pump mounting bracket on the stud.
    • Position the power steering pump rear bracket on the studs.
    • Install the power steering pump mounting bracket three bolts and the nut.
    • Install the nut for the power steering pump rear bracket to the front of the engine.

      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).

  13. Install the A/C compressor, if equipped. Refer to Compressor Replacement in Heating, Ventilation and Air Conditioning.
  14. Install the water pump pulley. Refer to Water Pump Replacement (4.3L) in Engine Cooling.
    15. Fig 4: View Of Accelerator & Cruise Control Cable Bracket
    GM339439Courtesy of GENERAL MOTORS CORP.
  15. Install the accelerator control cable bracket to the throttle body.

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

    16. Fig 5: Locating Bolts For Ground Wire & Fuel Pipe Bracket
    GM555709Courtesy of GENERAL MOTORS CORP.
  16. Install the bolt holding the ground wires to the left cylinder head.

    Tighten:  Tighten the ground wire bolt to 35 N.m (26 lb ft).

  17. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.

    Tighten:  Tighten the fuel pipe bracket bolt to 30 N.m (22 lb ft).

    18. Fig 6: Rear Of Cylinder Head Ground Wires
    GM375426Courtesy of GENERAL MOTORS CORP.
  18. Install the stud holding the ground wires to the right cylinder head.

    Tighten:  Tighten the ground wire stud to 35 N.m (26 lb ft).

    19. Fig 7: View Of Ground Strap
    GM395663Courtesy of GENERAL MOTORS CORP.
  19. Install the bolt and the ground strap to the rear of the right cylinder head.

    Tighten:  Tighten the ground strap bolt to 35 N.m (26 lb ft).

    20. Fig 8: Locating Engine Wiring Harness Components
    GM517077Courtesy of GENERAL MOTORS CORP.
  20. Position the engine wiring harness.
  21. Install the engine wiring harness clips to the brackets.
  22. Install the engine wiring harness clips to the front of the engine.
  23. Connect the CKP sensor electrical connector (2).
  24. Install the bolt and the battery negative cable (1).

    Tighten:  Tighten the bolt to 17 N.m (13 lb ft).

  25. Install the engine wiring harness bracket bolt (3) to the generator mounting bracket.

    Tighten:  Tighten the stud to 25 N.m (18 lb ft).

  26. Install the generator. Refer to Generator Replacement (4.3L) in Engine Electrical.
    27. Fig 9: Locating Electrical Connectors
    GM516981Courtesy of GENERAL MOTORS CORP.
  27. Connect the following electrical connectors:
    • The distributor (1)
    • The engine oil pressure sensor (2)
    • The knock sensor (3)
    28. Fig 10: Locating Electrical Connectors
    GM516898Courtesy of GENERAL MOTORS CORP.
  28. Connect the following electrical connectors:
    • The A/C compressor clutch (1), if equipped
    • The A/C compressor cutoff switch (5), if equipped
    • The TP sensor (2)
    • The IAC valve motor (3)
    • The ECT sensor (4)
    29. Fig 11: Locating Electrical Connectors
    GM516916Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors:
    • The fuel meter body (1)
    • The EVAP canister purge solenoid (2)
    • The MAP sensor (3)
    30. Fig 12: Locating Electrical Connectors
    GM516938Courtesy of GENERAL MOTORS CORP.
  30. Connect the following electrical connectors:
    • The ICM (1)
    • The ignition coil (2)
    • The generator (4)
    31. Fig 13: Disconnecting Vacuum Brake Booster Hose (4.3L)
    GM346148Courtesy of GENERAL MOTORS CORP.
  31. Connect the power brake booster vacuum hose to the intake manifold.
  32. Connect the vacuum hose for the A/C system, if equipped.
  33. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement (LU3) in Cruise Control.
    34. Fig 14: Identifying Accelerator Cable/Throttle Body Lever
    GM325556Courtesy of GENERAL MOTORS CORP.
    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.
  34. Install the NEW accelerator cable onto the throttle body.
    35. Fig 15: Locating Cable
    GM616716Courtesy of GENERAL MOTORS CORP.
  35. Wrap the cable in between the finger of the hook tab and the pulley wall. Make sure that the cable is fully seated in the pulley groove. The cable must not lie outside of the hook tab.
    36. Fig 16: View Of Accelerator Control Cable Bracket
    GM616725Courtesy of GENERAL MOTORS CORP.
  36. Install the accelerator cable to the accelerator cable control bracket.
  37. Install the radiator. Refer to Radiator Replacement (4.3L) in Engine Cooling.
  38. Install the inlet and outlet radiator hoses to the engine. Refer to Radiator Hose Replacement - Inlet (4.3L) and Radiator Hose Replacement - Outlet (4.3L) in Engine Cooling.
  39. Connect the heater hoses to the engine. Refer to Heater Hose Replacement - Inlet (4.3L) and Heater Hose Replacement - Outlet (4.3L) in Heating, Ventilation and Air Conditioning.
  40. Raise the vehicle.
  41. Install the transmission.
    42. Fig 17: View Of Transmission Cover
    GM334324Courtesy of GENERAL MOTORS CORP.
  42. Install the transmission cover.

    Tighten:  Tighten the nut to 12 N.m (106 lb in).

  43. Install the starter. Refer to Starter Motor Replacement (4.3L) in Engine Electrical.
    44. Fig 18: Locating Bracket For Starter Wire Harness & Transmission Oil Cooler Pipes
    GM449304Courtesy of GENERAL MOTORS CORP.
  44. Install the stud holding the bracket for the starter wiring harness and if equipped, the transmission oil cooler lines.

    Tighten:  Tighten the bracket stud to 9 N.m (80 lb in).

  45. Install the engine oil cooler pipes. Refer to Engine Oil Cooler Hose/Pipe Replacement (2WD) or Engine Oil Cooler Hose/Pipe Replacement (4WD) in Engine Cooling.
  46. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.
  47. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement .
  48. Add engine oil supplement GM P/N 1052367 (Canadian P/N 992869) or equivalent to the engine oil.
  49. Install the underbody shields, if equipped.
  50. Lower the vehicle.
    51. Fig 19: View Of PCV Tube
    GM172994Courtesy of GENERAL MOTORS CORP.
  51. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  52. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  53. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
    54. NOTE:
    • Handle the MAF sensor carefully.
    • Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
    • Do not damage the screen located on the air inlet end of the MAF.
    • Do not touch the sensing elements.
    • Do not allow solvents and lubricants to come in contact with the sensing elements.
    • Use a small amount of a soap based solution in order to aid in the installation.
    Fig 20: Air Intake Tube Routing
    GM424556Courtesy of GENERAL MOTORS CORP.
  54. Install air cleaner outlet duct to throttle body.
  55. Install air cleaner outlet duct to MAF sensor.

    Tighten:  Tighten the hose clamp to 4 N.m (32 lb in).

    56. Fig 21: Locating IAT Sensor Harness Connector
    GM10940Courtesy of GENERAL MOTORS CORP.
  56. Connect the intake air temperature (IAT) sensor harness connector.
    57. Fig 22: Locating Cleaner Outlet Duct Retaining Wingnut
    GM312278Courtesy of GENERAL MOTORS CORP.
  57. Install the air cleaner outlet duct retaining wingnut.

    Tighten:  Tighten the wingnut to 2 N.m (18 lb in).

    58. Fig 23: View Of Breather Tube At Air Cleaner Outlet Duct
    GM444792Courtesy of GENERAL MOTORS CORP.
  58. Install the breather tube to the air cleaner outlet duct.
  59. Install the PCV tube to the right valve rocker arm cover and the air cleaner outlet duct.
  60. Recharge the air conditioning system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  61. Install the hood. Refer to Hood Replacement in Body Front End.
  62. 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.
  63. Start the engine and listen for unusual noises.
  64. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.

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

  65. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
  66. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
  67. Inspect for oil and/or coolant leaks while the engine is operating.
  68. Verify that the distributor is properly positioned.
  69. Perform a final inspection for the proper engine oil and coolant levels.
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