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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 >> Removal Procedure

Removal 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. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  4. Remove the hood. Refer to HOOD REPLACEMENT .
  5. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  6. Remove the underbody shields, if equipped.
  7. Remove the exhaust pipe from the exhaust manifolds. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT .
  8. Remove the engine oil cooler pipes. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT (2WD) or ENGINE OIL COOLER HOSE/PIPE REPLACEMENT (4WD) .
  9. Remove the stud holding the starter wire harness and if equipped, transmission oil cooler lines.
    10. Fig 1: Transmission Oil Cooler Lines, Starter Wire Harness Bracket & Stud
    G01661305Courtesy of GENERAL MOTORS CORP.
  10. Remove the starter. Refer to STARTER MOTOR .
  11. Remove the transmission cover.
  12. Remove the transmission.
    Fig 2: Transmission Cover & Bolts
    G01661306Courtesy of GENERAL MOTORS CORP.
  13. Remove the front engine mount through bolts.
  14. Lower the vehicle.
    Fig 3: Front Engine Mount Through Bolt
    G01661307Courtesy of GENERAL MOTORS CORP.
  15. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
    Fig 4: PCV Tube
    G01661308Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the breather tube at the air cleaner outlet duct.
    Fig 5: Breather Tube
    G01661309Courtesy of GENERAL MOTORS CORP.
  17. Remove the air cleaner outlet duct retaining wingnut.
    Fig 6: Air Cleaner Outlet Duct Retaining Wingnut
    G01661310Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the intake air temperature (IAT) sensor harness connector.
    Fig 7: IAT Sensor Harness Connector
    G01661311Courtesy of GENERAL MOTORS CORP.
  19. Remove the air cleaner outlet duct from the throttle body.
    Fig 8: Air Cleaner Outlet Duct
    G01661312Courtesy 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.
  20. Disconnect the accelerator cable from the throttle body.
    Fig 9: Accelerator Cable At Throttle Body
    G01661313Courtesy of GENERAL MOTORS CORP.
  21. Remove the accelerator cable from the accelerator control cable bracket.
    22. Fig 10: Accelerator Cable At Accelerator Control Cable Bracket
    G01661314Courtesy of GENERAL MOTORS CORP.
  22. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to CRUISE CONTROL CABLE REPLACEMENT (4.3L) or CRUISE CONTROL CABLE REPLACEMENT (2.2L) .
  23. Remove the radiator. Refer to RADIATOR REPLACEMENT (2.2 L) or RADIATOR REPLACEMENT (4.3 L) .
  24. Remove the inlet and outlet radiator hoses from 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) .
  25. Disconnect the heater hoses from the engine.
  26. Disconnect the power brake booster vacuum hose from the intake manifold.
  27. Disconnect the vacuum hose for the A/C system, if equipped from the intake manifold.
    Fig 11: Power Brake Booster Vacuum Hose
    G01661315Courtesy of GENERAL MOTORS CORP.
  28. Disconnect 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 12: A/C Compressor Clutch, Cutoff Switch, TP Sensor, IAC Valve Motor & ECT Sensor Connectors
    G01661316Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the following electrical connectors:
    • The fuel meter body (1)
    • The EVAP canister purge solenoid (2)
    • The MAP sensor (3)
    Fig 13: Fuel Meter Body, EVAP Canister Purge Solenoid & MAP Sensor Connectors
    G01661317Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the following electrical connectors:
    • The ICM (1)
    • The ignition coil (2)
    • The generator (4)
    Fig 14: ICM, Ignition Coil & Generator Electrical Connectors
    G01661318Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the following electrical connectors:
    • The distributor (1)
    • The engine oil pressure sensor (2)
    • The knock sensor (3)
    Fig 15: Distributor, Engine Oil Pressure Sensor & Knock Sensor Electrical Connectors
    G01661319Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the CKP sensor (2) electrical connector.
  33. Remove the bolt and the battery negative cable (1).
  34. Remove the engine wiring harness bracket bolt (3).
  35. Remove the engine wiring harness clips from the front of the engine.
  36. Remove the engine wiring harness clips from the brackets.
  37. Move the engine wiring harness aside.
  38. Remove the generator. Refer to GENERATOR .
    Fig 16: CKP Sensor Electrical Connector, Battery Negative Cable & Engine Wiring Harness Bracket Bolt
    G01661320Courtesy of GENERAL MOTORS CORP.
  39. Remove the bolt holding the ground wires to the left cylinder head.
  40. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.
    Fig 17: Ground Wires At Left Cylinder Head, Fuel Pipe Bracket & Bolts
    G01661321Courtesy of GENERAL MOTORS CORP.
  41. Remove the bolts holding the ground wires to the right cylinder head.
    Fig 18: Ground Wires At Right Cylinder Head & Bolts
    G01661322Courtesy of GENERAL MOTORS CORP.
  42. Remove the bolt holding the ground strap to the right cylinder head.
    Fig 19: Ground Strap & Bolt
    G01661323Courtesy of GENERAL MOTORS CORP.
  43. Remove the accelerator control cable bracket from the throttle body.
  44. Remove the water pump pulley. Refer to WATER PUMP REPLACEMENT (2.2 L) or WATER PUMP REPLACEMENT (4.3 L) .
  45. Remove the A/C compressor, if equipped. Refer to COMPRESSOR .
    Fig 20: Accelerator Control Cable Bracket & Nuts
    G01661324Courtesy of GENERAL MOTORS CORP.
  46. Remove the nuts holding the power steering pump rear bracket to the engine.
  47. Remove the power steering pump mounting bracket.
    • The power steering pump can remain on the mounting bracket.
    • The hoses do not require removal.
    • Remove the three bolts and the nut.
    • Slide the mounting bracket off of the stud.
    • Secure the mounting bracket out of the way.
    48. Fig 21: Power Steering Pump Rear Bracket & Nuts
    G01661325Courtesy of GENERAL MOTORS CORP.
  48. Remove the distributor cap. Refer to DISTRIBUTOR .
  49. Disconnect the fuel pipes at the rear of the intake manifold.
  50. Disconnect the EVAP canister purge solenoid valve pipe.
  51. Remove the water outlet. Refer to THERMOSTAT REPLACEMENT (2.2 L) or THERMOSTAT REPLACEMENT (4.3 L) .
    NOTE: Refer to FASTENER NOTICE .
  52. Attach the J 41427  to the left front and the right rear intake manifold mounting bolts, using the following procedure:
    1. 52.1. Remove the right rear lower intake manifold bolts.
    2. 52.2. Install the J 41427  marked RIGHT REAR.
    3. 52.3. Install the retaining bolts.
    4. 52.4. Remove the left front lower intake manifold bolts.
    5. 52.5. Install the J 41427  marked LEFT FRONT with the arrow pointing to the front of the engine.
    6. 52.6. Install the retaining bolts.

      Tighten 

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

  53. Install a engine lifting device to the engine lift brackets.
  54. Remove the engine.
    Fig 22: J 41427 Attached To Left Front & Right Rear Intake Manifold Mounting Bolts
    G01661326Courtesy of GENERAL MOTORS CORP.
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