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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1194 (Automatic Transmission - 4L60-E/4L65-E (Service & Replacement)) >> Repair Instructions >> Oil Cooler Line Replacement (Front) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the TOC front pipes to the vehicle (through the top of the vehicle).

    Finesse the pipes into position.

  2. Raise the vehicle.
  3. Remove the caps from the rear of the TOC front pipes and remove the plugs from the junction fittings at the engine flywheel housing.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper and lower pipe fittings to the junction fittings at the engine flywheel housing.

    Tighten 

    Tighten the transmission oil cooler front upper and lower pipe fittings to the junction at the engine flywheel housing to 27 N.m (20 lb ft).

    Fig 1: TOC Front Pipe Rear Retaining Clamp & Bolt
    G01972958Courtesy of GENERAL MOTORS CORP.
  5. Install the TOC front pipe rear retaining clamp and bolt.

    Tighten 

    Tighten the transmission oil cooler front pipe rear retaining clamp bolt to 2.2 N.m (19 lb in).

  6. Install the TOC front pipe front retaining clamp and bolt.

    Tighten 

    Tighten the transmission oil cooler front pipe front retaining clamp bolt to 12 N.m (106 lb in).

    Fig 2: TOC Front Pipe Front Retaining Clamp & Bolt
    G01972959Courtesy of GENERAL MOTORS CORP.
  7. Install the TOC front pipe front clip.
    Fig 3: TOC Front Pipe Front Clip
    G01972960Courtesy of GENERAL MOTORS CORP.
  8. Install the right hand engine mount (and bracket).

    Refer to ENGINE MOUNT REPLACEMENT--RIGHT in Engine Mechanical - 5.7L.

  9. Lower the vehicle; leave the vehicle on the hoist.
  10. Remove the J 41803  and the J 28467-B  .
  11. Install the generator. Refer to GENERATOR in Engine Electrical.
  12. Install the A/C compressor bracket. Refer to COMPRESSOR MOUNTING BRACKET REPLACEMENT in Heating, Ventilation, and Air Conditioning.
  13. Position the PS gear and cooler to the front suspension crossmember.
  14. Install the BPMV bracket. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) REPLACE in Antilock Brake System.
    Fig 4: PS Gear Mounting Bolts & Nuts
    G01972961Courtesy of GENERAL MOTORS CORP.
  15. Install the PS gear mounting bolts and nuts.

    Tighten 

    Tighten the power steering gear mounting nuts to 100 N.m (74 lb ft).

  16. Install the PS cooler retaining bolts.

    Tighten 

    Tighten the power steering cooler retaining bolts to 11 N.m (97 lb in).

    Fig 5: PS Cooler Retaining Bolts
    G01972962Courtesy of GENERAL MOTORS CORP.
  17. Connect the intermediate shaft lower coupling to the PS gear; be sure that the intermediate shaft and the PS gear steering shaft are orientated as marked prior to disconnecting them.

    Slide the intermediate shaft lower coupling onto the PS gear steering shaft.

  18. Install the intermediate shaft lower coupling bolt.

    Tighten 

    Tighten the steering column intermediate shaft lower coupling bolt to 34 N.m (25 lb ft).

  19. Install the intermediate shaft lower coupling shield.
  20. Lower the vehicle.
    Fig 6: Intermediate Shaft Lower Coupling Bolt
    G01972963Courtesy of GENERAL MOTORS CORP.
  21. Remove the tie-off retainer and carefully pivot the AC condenser and the radiator back into position.
    Fig 7: Pivoting AC Condenser & Radiator Back Into Position
    G01972964Courtesy of GENERAL MOTORS CORP.
  22. Install the radiator outlet hose to the radiator outlet.
  23. Using J 38185  , position the radiator outlet hose clamp onto the radiator outlet.
    Fig 8: Installing Radiator Outlet Hose To Radiator Outlet
    G01972965Courtesy of GENERAL MOTORS CORP.
  24. Install the radiator inlet hose to the radiator inlet.
  25. Using J 38185  , position the radiator inlet hose clamp onto the radiator inlet.
    Fig 9: Installing Radiator Inlet Hose To Radiator Inlet
    G01972966Courtesy of GENERAL MOTORS CORP.
  26. Install the surge tank upper hose to the radiator inlet.
  27. Using J 38185  , position the coolant surge tank upper hose clamp onto the radiator inlet.
    Fig 10: Installing Surge Tank Upper Hose To Radiator Inlet
    G01972967Courtesy of GENERAL MOTORS CORP.
  28. Install the compressor hose to the condenser.
    Fig 11: Installing Compressor Hose To Condenser
    G01972968Courtesy of GENERAL MOTORS CORP.
  29. Using a back-up wrench on the condenser fitting (2), tighten the compressor hose fitting (1) to the condenser.

    Tighten 

    Tighten the fitting to 24 N.m (17 lb ft).

    Fig 12: Tightening Compressor Hose Fitting To Condenser
    G01972969Courtesy of GENERAL MOTORS CORP.
  30. Connect the front evaporator tube to the condenser.
  31. Install the front evaporator tube to condenser bolt.

    Tighten 

    Tighten the front evaporator tube bolt to 27 N.m (20 lb ft).

  32. Install the upper and lower radiator support. Refer to RADIATOR SUPPORT REPLACEMENT in Engine Cooling.
  33. Install the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT in Engine Controls.
    Fig 13: Connecting Front Evaporator Tube To Condenser
    G01972970Courtesy of GENERAL MOTORS CORP.
  34. Connect the upper TOC line to the oil cooler using the following steps:
    1. 34.1. Push the TOC pipe into the quick connect fitting, until a click is heard.
    2. 34.2. Tug gently in the TOC line to ensure a proper connection.
  35. Position the plastic retainer over the connection.
  36. Raise the vehicle.
  37. Connect the lower TOC line to the oil cooler using the following steps:
    1. 37.1. Push the TOC pipe into the quick connect fitting, until a click is heard.
    2. 37.2. Tug gently in the TOC line to ensure a proper connection.
  38. Position the plastic retainer over the connection.
  39. Lower the vehicle.
    Fig 14: Connecting Lower TOC Line To Oil Cooler
    G01972971Courtesy of GENERAL MOTORS CORP.
  40. Connect the negative battery cable.

    Tighten 

    Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

  41. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  42. Recharge the AC system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation, and Air Conditioning.
  43. Check the transmission fluid level. Add if necessary.
    Fig 15: Connecting Negative Battery Cable
    G01972972Courtesy of GENERAL MOTORS CORP.
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