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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1019 (Engine Mechanical - 4.8L, 5.3L & 6.0L (Repair Instructions - 1 Of 3)) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Engine Replacement (5.3L Engine w/RPO HP2) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the J 41798  to the cylinder heads.

    Tighten: 

    • Tighten the M8 bolts to 25 N.m (18 lb ft).
    • Tighten the M10 bolts to 50 N.m (37 lb ft).

  2. Install an engine hoist to the J 41798  .
    3. Fig 1: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  3. Remove the engine from the engine stand.
  4. Set the engine down.
  5. Install the rotor.
    6. Fig 2: View Of Rotor
    GM1195711Courtesy of GENERAL MOTORS CORP.
  6. Install the flexplate and bolts.

    Tighten:  Tighten the bolts to 100 N.m (74 lb ft).

    7. Fig 3: View Of Flexplate & Bolts
    GM1281915Courtesy of GENERAL MOTORS CORP.
  7. Install the stator.
    8. Fig 4: View Of Stator
    GM1195710Courtesy of GENERAL MOTORS CORP.
  8. Install the stator studs.

    Tighten:  Tighten the studs to 16 N.m (12 lb ft).

  9. Install the engine to the vehicle.
  10. Remove the J 21366  from the transmission.
  11. Position or install the transmission fill tube while installing the engine.
  12. Install the left and right engine mount to engine mount bracket bolts.

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

    13. Fig 5: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  13. Install the upper transmission stud until snug.
  14. Remove the floor jack from under the transmission bellhousing.
  15. Remove the engine hoist.
  16. Remove the J 41798  from the engine.
    17. Fig 6: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  17. Install the ignition coils, as required. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
  18. Raise the vehicle.
  19. Install the transmission nuts.

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

    20. Fig 7: View Of Transmission Nuts
    GM1195708Courtesy of GENERAL MOTORS CORP.
  20. Install the transmission studs (1) and bolts (2).

    Tighten:  Tighten the studs/bolts to 50 N.m (37 lb ft).

    21. Fig 8: View Of Transmission Studs & Bolts
    GM1195707Courtesy of GENERAL MOTORS CORP.
  21. Install the transmission oil level indicator tube to the transmission.
    22. Fig 9: View Of Transmission Oil Level Indicator Tube At Transmission
    GM1284302Courtesy of GENERAL MOTORS CORP.
  22. Install the transmission oil level indicator tube bolt.

    Tighten:  Tighten the bolt to 18 N.m (13 lb ft).

    23. Fig 10: View Of Transmission Oil Level Indicator Tube Bolt
    GM1284303Courtesy of GENERAL MOTORS CORP.
  23. Remove the J 46093  from the engine block.
    24. Fig 11: View Of J 46093 & Bolt
    GM1277133Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: It is highly recommended to use a 8 mm ball end hex key to install and hand tighten the torque converter bolts. Then use a 3/8 inch, 6-point shallow thin wall socket and a wobble extension to torque the torque converter bolts in order to prevent possibly stripping the bolts.
  24. Install the torque converter bolts.

    Tighten:  Tighten the bolts to 63 N.m (46 lb ft).

    25. Fig 12: View Of Torque Converter Bolts
    GM1195705Courtesy of GENERAL MOTORS CORP.
  25. Install the passenger side closeout cover and bolt.

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

    26. Fig 13: View Of Passenger Side Closeout & Bolt
    GM1195704Courtesy of GENERAL MOTORS CORP.
  26. Install the positive battery cable clip and bolt.

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

    27. Fig 14: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  27. Install the catalytic converter. Refer to Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) or Catalytic Converter Replacement (6.0L and 8.1L Engines) or Catalytic Converter Replacement (6.6L Engine) in Engine Exhaust.
  28. Install the oil pan skid plate and bolts, if equipped.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    29. Fig 15: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  29. Install the engine shield and bolts, if equipped.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    30. Fig 16: View Of Engine Protection Shield
    GM349061Courtesy of GENERAL MOTORS CORP.
  30. Lower the vehicle.
  31. Install the vacuum brake booster hose.
    32. Fig 17: View Of Vacuum Brake Booster Hose To Intake Manifold Rear (5.3L Engine w/RPO HP2)
    GM1236362Courtesy of GENERAL MOTORS CORP.
  32. Install the power steering pump bracket (3) and bolts (1, 2).

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

    33. Fig 18: View Of Power Steering Pump Bracket & Bolts (5.3L Engine w/RPO HP2)
    GM1202281Courtesy of GENERAL MOTORS CORP.
  33. Position the power steering pump (1) with the lines attached to the bracket.
  34. Install the power steering pump bolts (2).

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

    35. Fig 19: View Of Power Steering Pump & Bolt (5.3L Engine w/RPO HP2)
    GM1202279Courtesy of GENERAL MOTORS CORP.
  35. Install the battery cable junction block bracket bolts (2) to the power steering pump bracket.

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

  36. Install the battery cable clip bolt (1).

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

    37. Fig 20: View Of Battery Cable Clip Bolt & Cable Junction Block Bracket Bolt (5.3L Engine w/RPO HP2)
    GM1237043Courtesy of GENERAL MOTORS CORP.
  37. Install the power steering pump harness to the vehicle.
  38. Connect the power steering pump harness electrical connector (4) to the power steering pump.
  39. Install the ground bolt (3).

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

  40. Install the power steering pump harness clip (1) to the bracket.
    41. Fig 21: View Of Power Steering Pump Harness Clip, Ground Bolt & Harness Electrical Connector (5.3L Engine w/RPO HP2)
    GM1237572Courtesy of GENERAL MOTORS CORP.
  41. Install the power steering pump harness clip (2) to the bracket.
  42. Install the power steering pump harness bolt (3).

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

    43. Fig 22: View of Power Steering Pump Harness Clip & Bolt (5.3L Engine w/RPO HP2)
    GM1237063Courtesy of GENERAL MOTORS CORP.
  43. Connect the power steering pump harness 42-volt electrical connectors (3, 5).
  44. Install the power steering pump harness 42-volt connector (5) to the wheelhouse panel.
    45. Fig 23: View Of Power Steering Pump Harness Electrical Connectors (5.3L Engine w/RPO HP2)
    GM1237065Courtesy of GENERAL MOTORS CORP.
  45. Connect the engine harness electrical connector (3) to the power steering pump.
    46. Fig 24: View of Engine Harness Electrical Connector (5.3L Engine w/RPO HP2)
    GM1237574Courtesy of GENERAL MOTORS CORP.
  46. Position the cable.
  47. Install the 3-phase cable to the SGCM studs.
  48. Install the 3-phase cable nuts.

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

  49. Install the SGCM cover and bolts.

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

    50. Fig 25: View Of SGCM, Cover & Bolts (5.3L Engine w/RPO HP2)
    GM1237061Courtesy of GENERAL MOTORS CORP.
  50. Install the 3-phase cable bracket cover bolt (1).

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

    51. Fig 26: View Of 3-Phase Cable Bracket Cover Bolt (5.3L Engine w/RPO HP2)
    GM1237060Courtesy of GENERAL MOTORS CORP.
  51. Install the radiator vent inlet hose to the throttle body.
  52. Position the vent inlet hose clamp at the throttle body.
    53. Fig 27: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  53. Position the upper portion of the engine wiring harness.
  54. Raise the vehicle.
  55. Position the lower engine wiring harness.
  56. Slide the channel pin into the oil pan tab.
  57. Install the battery cable channel bolt.

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

    58. Fig 28: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  58. Connect the following electrical connectors to the engine:
    • The CKP sensor (1)
    • The engine oil level sensor (3)
    • The coolant heater, if equipped
    59. Fig 29: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  59. Lower the vehicle.
  60. Connect the fuel feed line. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 4.8L, 5.3L, and 6.0L.
  61. Install the EVAP tube.
  62. Connect the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).
    63. Fig 30: View Of EVAP Tube To Solenoid & Vapor Pipe (5.3L Engine w/RPO HP2)
    GM1285743Courtesy of GENERAL MOTORS CORP.
  63. Connect the following electrical connectors:
    • The oil pressure sensor (1)
    • The CMP sensor (3)
  64. Position the harness ground and engine ground strap to the block.
  65. Install the harness ground bolt at the left rear of the engine block.

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

  66. Position the harness ground (2) and auxiliary negative battery cable, if equipped, to the block.
    67. Fig 31: View Of Oil Pressure Sensor, Harness Ground & CMP Sensor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1236366Courtesy of GENERAL MOTORS CORP.
  67. Install the harness ground bolt at the right rear of the engine block.

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

  68. Connect the ECT sensor (5) electrical connector.
  69. Position the harness ground (2) and negative battery cable (3) to the block.
  70. Install the engine wiring harness ground bolt (4).

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

    71. Fig 32: View Of Engine Wiring Harness Ground Bolt, ECT Sensor Electrical Connector, Negative Battery Cable & Harness Ground (5.3L Engine w/RPO HP2)
    GM1235684Courtesy of GENERAL MOTORS CORP.
  71. Install the harness clips (1) to the fuel rail.
  72. Connect the main coil harness (4), fuel injectors (3), and ETC (2) electrical connectors on the right side.
  73. Engage the CPA retainer on the ETC.
  74. Install the CPA retainer (1) to the main coil harness connector.
    75. Fig 33: View Of CPA Retainer, Harness Clips, ETC, Coil Harness & Fuel Injectors Electrical Connectors
    GM1235686Courtesy of GENERAL MOTORS CORP.
  75. Install the harness clips (3, 5) to the fuel rail.
  76. Connect the main coil harness (4) and fuel injector (2) electrical connectors on the left side.
  77. Install the CPA retainer (1) to the main coil harness connector.
    78. Fig 34: View of CPA Retainer, Fuel Injector, Main Coil Harness & Harness Clips (5.3L Engine w/RPO HP2)
    GM1237555Courtesy of GENERAL MOTORS CORP.
  78. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    79. Fig 35: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  79. Install the harness bracket nut (2).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  80. Connect the EVAP canister purge solenoid (1).
    81. Fig 36: View Of EVAP Canister Purge Solenoid & Generator Electrical Connectors & Bracket Nut
    GM1235683Courtesy of GENERAL MOTORS CORP.
  81. Install the auxiliary heater water pump. Refer to Water Pump Replacement - Auxiliary in Engine Cooling.
  82. Install the heater hoses. Refer to Heater Hose Replacement - Inlet (LR4,LM7,LQ4) or Heater Hose Replacement - Inlet (W/ HP2 Front) or Heater Hose Replacement - Inlet (W/ HP2 Rear) and Heater Hose Replacement - Outlet (LR4,LM7,LQ4) in Heating, Ventilation and Air Conditioning.
  83. Install the radiator outlet hose to the water pump and close the hose clamp.
    84. Fig 37: View Of Radiator Outlet Hose (5.3L Engine w/RPO HP2)
    GM1288138Courtesy of GENERAL MOTORS CORP.
  84. Install the radiator inlet hose to the water pump and close the hose clamp.
    85. Fig 38: View Of Radiator Inlet Hose
    GM846666Courtesy of GENERAL MOTORS CORP.
  85. Install the A/C compressor (2).
  86. Install the A/C compressor bolts.

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

    87. Fig 39: View of A/C Compressor & Bolts
    GM648141Courtesy of GENERAL MOTORS CORP.
  87. Connect the compressor electrical connections.
  88. Remove the caps from the compressor and line openings. Install NEW sealing washers.
  89. Install the suction hose and bolt to the compressor.

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

  90. Install the discharge hose and bolt to the compressor.

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

  91. Install the A/C drive belt. Refer to Drive Belt Replacement - Air Conditioning .
  92. Install the radiator support. Refer to Radiator Support Replacement in Body Front End.
  93. Connect the ESB. Refer to Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2) in Engine Electrical.
  94. Remove the hood hinge bolts from the service position.
  95. Lower the hood to the normal position.
  96. Install the hood hinge bolts.

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

    97. Fig 40: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  97. Remove the fender covers.
  98. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Capacities - Approximate Fluid or Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  99. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 4.8L, 5.3L, and 6.0L.
  100. Test the vehicle using the following procedure:
    1. Disable the ignition system.
    2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    3. Enable the ignition system.
    4. Start the engine and listen for unusual noises.
    5. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
    6. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
    7. Listen for sticking lifters and other unusual noises.
    8. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
    9. Perform a final inspection for the proper engine oil and coolant levels.
  101. Install the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)  or Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88) .
  102. Close the hood.
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