LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 4.3L (On-Vehicle) >> Repair Instructions >> Engine Replacement >> Installation Procedure

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.
  1. Attach the J 41427  to the left front and the right rear intake manifold mounting bolts, using the following procedure:
    1. 1.1. Remove the right rear lower intake manifold bolts.
    2. 1.2. Install the J 41427  marked RIGHT REAR.
    3. 1.3. Install the retaining bolts.
    4. 1.4. Remove the left front lower intake manifold bolts.
    5. 1.5. Install the J 41427  marked LEFT FRONT with the arrow pointing to the front of the engine.
    6. 1.6. 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.
    Fig 1: J 41427 Attached To Left Front & Right Rear Intake Manifold Mounting Bolts
    G01661327Courtesy 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. 7.1. Tighten the bolts the first pass to 3 N.m (27 lb in).
    2. 7.2. Tighten the bolts the second pass to 12 N.m (106 lb in).
    3. 7.3. Tighten the bolts the third pass to 15 N.m (11 lb ft).
      Fig 2: Engine Mount Through-Bolt & Nut
      G01661328Courtesy of GENERAL MOTORS CORP.
  8. Install the water outlet. Refer to THERMOSTAT REPLACEMENT (2.2 L) or THERMOSTAT REPLACEMENT (4.3 L) .
  9. Connect the fuel pipes at the rear of the engine.
  10. Install the distributor cap. Refer to DISTRIBUTOR .
  11. Connect the EVAP canister purge solenoid valve pipe.
  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. Fig 3: Power Steering Pump Mounting Bracket & Nuts
    G01661329Courtesy of GENERAL MOTORS CORP.
  13. Install the A/C compressor, if equipped. Refer to COMPRESSOR .
  14. Install the water pump pulley. Refer to WATER PUMP REPLACEMENT (2.2 L) or WATER PUMP REPLACEMENT (4.3 L) .
  15. Install the accelerator control cable bracket to the throttle body.

    Tighten 

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

    Fig 4: Accelerator Control Cable Bracket & Nuts
    G01661330Courtesy 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).

    Fig 5: Ground Wires At Left Cylinder Head, Fuel Pipe Bracket & Bolts
    G01661331Courtesy 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).

    Fig 6: Ground Wires At Right Cylinder Head & Stud
    G01661332Courtesy 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).

    Fig 7: Ground Strap & Bolt
    G01661333Courtesy 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).

    Fig 8: CKP Sensor Electrical Connector, Battery Negative Cable & Engine Wiring Harness Bracket Bolt
    G01661334Courtesy of GENERAL MOTORS CORP.
  26. Install the generator. Refer to GENERATOR .
  27. Connect the following electrical connectors:
    • The distributor (1)
    • The engine oil pressure sensor (2)
    • The knock sensor (3)
    Fig 9: Distributor, Engine Oil Pressure Sensor & Knock Sensor Electrical Connectors
    G01661335Courtesy 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)
    Fig 10: A/C Compressor Clutch, Cutoff Switch, TP Sensor, IAC Valve Motor & ECT Sensor Connectors
    G01661336Courtesy 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)
    Fig 11: Fuel Meter Body, EVAP Canister Purge Solenoid & MAP Sensor Electrical Connectors
    G01661337Courtesy of GENERAL MOTORS CORP.
  30. Connect the following electrical connectors:
    • The ICM (1)
    • The ignition coil (2)
    • The generator (4)
    Fig 12: ICM, Ignition Coil & Generator Electrical Connectors
    G01661338Courtesy 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 (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
    Fig 13: Power Brake Booster Vacuum Hose
    G01661339Courtesy 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.
    Fig 14: Accelerator Cable At Throttle Body
    G01661340Courtesy 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.
    Fig 15: Proper Installation Of Cable Between Hook Tab & Pulley Wall
    G01661341Courtesy of GENERAL MOTORS CORP.
  36. Install the accelerator cable to the accelerator cable control bracket.
    37. Fig 16: Accelerator Cable At Accelerator Cable Control Bracket
    G01661342Courtesy of GENERAL MOTORS CORP.
  37. Install the radiator. Refer to RADIATOR REPLACEMENT (2.2 L) or RADIATOR REPLACEMENT (4.3 L) .
  38. Install the inlet and outlet radiator hoses to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (2.2L) or RADIATOR HOSE REPLACEMENT - INLET (4.3L) and RADIATOR HOSE REPLACEMENT - OUTLET (2.2L) or RADIATOR HOSE REPLACEMENT - OUTLET (4.3L) .
  39. Connect the heater hoses to the engine.
  40. Raise the vehicle.
  41. Install the transmission.
  42. Install the transmission cover.

    Tighten 

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

  43. Install the starter. Refer to STARTER MOTOR .
    Fig 17: Transmission Cover & Bolts
    G01661343Courtesy 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. Fig 18: Transmission Oil Cooler Lines, Starter Wiring Harness Bracket & Stud
    G01661344Courtesy of GENERAL MOTORS CORP.
  45. Install the engine oil cooler pipes. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT (2WD) or ENGINE OIL COOLER HOSE/PIPE REPLACEMENT (4WD) .
  46. Install the exhaust pipe to the exhaust manifolds. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT .
  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. 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 .
  53. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
    Fig 19: PCV Tube
    G01661345Courtesy of GENERAL MOTORS CORP.
    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.
  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).

    Fig 20: Air Cleaner Outlet Duct
    G01661346Courtesy of GENERAL MOTORS CORP.
  56. Connect the intake air temperature (IAT) sensor harness connector.
    Fig 21: IAT Sensor Harness Connector
    G01661347Courtesy of GENERAL MOTORS CORP.
  57. Install the air cleaner outlet duct retaining wingnut.

    Tighten 

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

    Fig 22: Air Cleaner Outlet Duct Retaining Wingnut
    G01661348Courtesy of GENERAL MOTORS CORP.
  58. Install the breather tube to the air cleaner outlet duct.
    59. Fig 23: Breather Tube
    G01661349Courtesy of GENERAL MOTORS CORP.
  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 RECOVERY/EVACUATION & RECHARGING .
  61. Install the hood. Refer to HOOD REPLACEMENT .
  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.
scientia non olet · About LEMON Manuals