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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) >> Removal Procedure

Removal 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. Open the hood.
  2. Place the fender covers over both fenders.
  3. Raise the hood to the service position. Perform the following procedure:
    1. Remove the hood hinge bolts (1).
    2. Raise the hood until vertical.
    3. Install the hood hinge bolts until snug in the service position (2).
    4. Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the energy storage box (ESB). Refer to Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2) in Engine Electrical.
  5. Remove 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) .
  6. Remove the radiator support. Refer to Radiator Support Replacement in Body Front End.
  7. Remove the A/C drive belt. Refer to Drive Belt Replacement - Air Conditioning .
  8. Remove the discharge hose bolt and hose from the compressor.
  9. Remove the suction hose bolt and hose from the compressor.
  10. Discard the sealing washers. Cap the compressor and line openings.
  11. Disconnect the compressor electrical connections.
  12. Remove the A/C compressor bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
  13. Remove the A/C compressor (2).
    14. Fig 2: View of A/C Compressor & Bolts
    GM648141Courtesy of GENERAL MOTORS CORP.
  14. Open the hose clamp and remove the radiator inlet hose from the water pump.
    15. Fig 3: View Of Radiator Inlet Hose
    GM846666Courtesy of GENERAL MOTORS CORP.
  15. Open the hose clamp and remove the radiator outlet hose from the water pump.
    16. Fig 4: View Of Radiator Outlet Hose (5.3L Engine w/RPO HP2)
    GM1288138Courtesy of GENERAL MOTORS CORP.
  16. Remove 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.
  17. Remove the auxiliary heater water pump. Refer to Water Pump Replacement - Auxiliary in Engine Cooling.
  18. Disconnect the evaporative emission (EVAP) canister purge solenoid (1).
  19. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.
    20. Fig 5: View Of EVAP Canister Purge Solenoid & Generator Electrical Connectors & Bracket Nut
    GM1235683Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.
    21. Fig 6: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  21. Remove the connector position assurance (CPA) retainer (1) from the main coil harness connector.
  22. Disconnect the main coil harness (4) and fuel injector (2) electrical connectors on the left side.
  23. Remove the harness clips (3, 5) from the fuel rail.
    24. Fig 7: View of CPA Retainer, Fuel Injector, Main Coil Harness & Harness Clips (5.3L Engine w/RPO HP2)
    GM1237555Courtesy of GENERAL MOTORS CORP.
  24. Remove the CPA retainer (1) from the main coil harness connector.
  25. Disengage the CPA retainer on the electronic throttle control (ETC).
  26. Disconnect the main coil harness (4), fuel injectors (3), and ETC (2) electrical connectors on the right side.
  27. Remove the harness clips (1) from the fuel rail.
    28. Fig 8: View Of CPA Retainer, Harness Clips, ETC, Coil Harness & Fuel Injectors Electrical Connectors
    GM1235686Courtesy of GENERAL MOTORS CORP.
  28. Remove the engine wiring harness ground bolt (4).
  29. Reposition the harness ground (2) and negative battery cable (3) from the block.
  30. Disconnect the engine coolant temperature (ECT) sensor (5) electrical connector.
    31. Fig 9: 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.
  31. Remove the harness ground bolt at the right rear of the engine block.
  32. Reposition the harness ground (2) and auxiliary negative battery cable, if equipped, from the block.
  33. Remove the harness ground bolt at the left rear of the engine block.
  34. Reposition the harness ground, and engine ground strap from the block.
  35. Disconnect the following electrical connectors:
    • The oil pressure sensor (1)
    • The camshaft position (CMP) sensor (3)
    36. Fig 10: View Of Oil Pressure Sensor, Harness Ground & CMP Sensor Electrical Connector (5.3L Engine w/RPO HP2)
    GM1236366Courtesy of GENERAL MOTORS CORP.
  36. Unclip any missed engine harness clips from the engine.
  37. Disconnect the EVAP purge solenoid vent tube from the solenoid (1) and vapor pipe (2).
    38. Fig 11: View Of EVAP Tube To Solenoid & Vapor Pipe (5.3L Engine w/RPO HP2)
    GM1285743Courtesy of GENERAL MOTORS CORP.
  38. Remove the EVAP tube.
  39. Disconnect the fuel feed line. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 4.8L, 5.3L, and 6.0L.
  40. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  41. Disconnect the following electrical connectors from the engine:
    • The crankshaft position (CKP) sensor (1)
    • The engine oil level sensor (3)
    • The coolant heater, if equipped
    42. Fig 12: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  42. Remove the battery cable channel bolt.
    43. Fig 13: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  43. Slide the channel pin out of the oil pan tab.
  44. Reposition the lower engine wiring harness off to the side.
  45. Lower the vehicle.
  46. Reposition the upper portion of the engine wiring harness off to the side.
  47. Reposition the vent inlet hose clamp at the throttle body.
  48. Remove the radiator vent inlet hose from the throttle body.
    49. Fig 14: View Of Vent Inlet Hose At Throttle Body
    GM659465Courtesy of GENERAL MOTORS CORP.
  49. Remove the 3-phase cable bracket cover bolt (1).
    50. Fig 15: View Of 3-Phase Cable Bracket Cover Bolt (5.3L Engine w/RPO HP2)
    GM1237060Courtesy of GENERAL MOTORS CORP.
  50. Remove the starter/generator control module (SGCM) cover bolts and cover.
  51. Remove the 3-phase cable nuts.
  52. Remove the 3-phase cable from the SGCM studs.
    53. Fig 16: View Of SGCM, Cover & Bolts (5.3L Engine w/RPO HP2)
    GM1237061Courtesy of GENERAL MOTORS CORP.
  53. Tie the cable out of the way.
  54. Disconnect the engine harness electrical connector (3) from the power steering pump.
    55. Fig 17: View of Engine Harness Electrical Connector (5.3L Engine w/RPO HP2)
    GM1237574Courtesy of GENERAL MOTORS CORP.
  55. Remove the power steering pump harness 42-volt connector (5) from the wheelhouse panel.
  56. Disconnect the power steering pump harness 42-volt electrical connectors (3, 5).
    57. Fig 18: View Of Power Steering Pump Harness Electrical Connectors (5.3L Engine w/RPO HP2)
    GM1237065Courtesy of GENERAL MOTORS CORP.
  57. Remove the power steering pump harness bolt (3).
  58. Remove the power steering pump harness clip (2) from the bracket.
    59. Fig 19: View of Power Steering Pump Harness Clip & Bolt (5.3L Engine w/RPO HP2)
    GM1237063Courtesy of GENERAL MOTORS CORP.
  59. Remove the power steering pump harness clip (1) from the bracket.
  60. Remove the ground bolt (3).
  61. Disconnect the power steering pump harness electrical connector (4) from the power steering pump.
    62. Fig 20: View Of Power Steering Pump Harness Clip, Ground Bolt & Harness Electrical Connector (5.3L Engine w/RPO HP2)
    GM1237572Courtesy of GENERAL MOTORS CORP.
  62. Remove the power steering pump harness from the vehicle.
  63. Remove the battery cable clip bolt (1).
  64. Remove the battery cable junction block bracket bolts (2) from the power steering pump bracket.
    65. Fig 21: View Of Battery Cable Clip Bolt & Cable Junction Block Bracket Bolt (5.3L Engine w/RPO HP2)
    GM1237043Courtesy of GENERAL MOTORS CORP.
  65. Remove the power steering pump bolts (2).
  66. Reposition the power steering pump (1) with the lines attached, off to the side.
    67. Fig 22: View Of Power Steering Pump & Bolt (5.3L Engine w/RPO HP2)
    GM1202279Courtesy of GENERAL MOTORS CORP.
  67. Remove the power steering pump bracket bolts (1, 2) and bracket (3).
    68. Fig 23: View Of Power Steering Pump Bracket & Bolts (5.3L Engine w/RPO HP2)
    GM1202281Courtesy of GENERAL MOTORS CORP.
  68. Remove the vacuum brake booster hose.
    69. Fig 24: View Of Vacuum Brake Booster Hose To Intake Manifold Rear (5.3L Engine w/RPO HP2)
    GM1236362Courtesy of GENERAL MOTORS CORP.
  69. Remove the ignition coils, as required, for the proper fit of the J 41798  . Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
    70. NOTE: Refer to Fastener Notice in Cautions and Notices.
  70. 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).

    71. Fig 25: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
  71. Remove the left and right engine mount to engine mount bracket bolts.
    72. Fig 26: View Of Engine Mount-To-Engine Mount Bracket
    GM307275Courtesy of GENERAL MOTORS CORP.
  72. Raise the vehicle.
  73. Remove the engine shield bolts and shield, if equipped.
    74. Fig 27: View Of Engine Protection Shield
    GM349061Courtesy of GENERAL MOTORS CORP.
  74. Remove the oil pan skid plate bolts and plate, if equipped.
    75. Fig 28: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  75. Drain the engine oil.
  76. Remove 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.
  77. Remove the positive battery cable clip bolt and clip.
    78. Fig 29: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  78. Remove the passenger side closeout cover bolt and cover.
    79. Fig 30: View Of Passenger Side Closeout & Bolt
    GM1195704Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: It is highly recommended to use a 3/8 inch, 6-point shallow thin wall socket and a wobble extension to loosen the torque converter bolts, and a 8 mm ball end hex key to remove the bolts, in order to prevent possibly stripping the bolts.
  79. Remove the torque converter bolts.
    80. Fig 31: View Of Torque Converter Bolts (5.3L Engine w/RPO HP2)
    GM1195705Courtesy of GENERAL MOTORS CORP.
  80. Install J 46093  to the engine block.

    The flange of J 46093  should locate into a hole in the flexplate. Use 2 M10 1.5 x 40 mm bolts for proper tool operation.

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

    81. Fig 32: View Of J 46093 & Bolt
    GM1277133Courtesy of GENERAL MOTORS CORP.
  81. Remove the transmission oil level indicator tube bolt.
    82. Fig 33: View Of Transmission Oil Level Indicator Tube Bolt
    GM1284303Courtesy of GENERAL MOTORS CORP.
  82. Remove the transmission oil level indicator tube from the transmission.
    83. Fig 34: View Of Transmission Oil Level Indicator Tube At Transmission
    GM1284302Courtesy of GENERAL MOTORS CORP.
  83. Remove the transmission studs (1) and bolts (2).
    84. Fig 35: View Of Transmission Studs & Bolts
    GM1195707Courtesy of GENERAL MOTORS CORP.
  84. Remove the transmission nuts.
    85. Fig 36: View Of Transmission Nuts
    GM1195708Courtesy of GENERAL MOTORS CORP.
  85. Install an engine hoist to the J 41798  .
  86. Install a floor jack under the transmission bellhousing for support.
    87. NOTE: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.
  87. Separate the engine from the transmission. Install the J 21366  to the transmission in order to hold the torque converter.
  88. Position or remove the transmission fill tube while removing the engine.
  89. Remove the engine from the vehicle.
  90. Once the engine is out of the vehicle, set the engine down.
  91. Remove the stator studs.
  92. Remove the stator.
    93. Fig 37: View Of Stator
    GM1195710Courtesy of GENERAL MOTORS CORP.
  93. Remove the flexplate bolts and flexplate.
    94. Fig 38: View Of Flexplate & Bolts
    GM1281915Courtesy of GENERAL MOTORS CORP.
  94. Remove the rotor.
    95. Fig 39: View Of Rotor
    GM1195711Courtesy of GENERAL MOTORS CORP.
  95. Install the engine onto an engine stand.
  96. Remove the engine hoist.
  97. Remove the J 41798  from the engine.
    98. Fig 40: View Of J 41798
    GM309151Courtesy of GENERAL MOTORS CORP.
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