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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1290 (Engine Mechanical - 1.8L (LV6)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the engine and transaxle assembly.
  2. Temporarily install the 6 crossmember bolts.
    Fig 1: Installing Crossmember Bolts
    G01546832Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the left side mounting insulator bolt and nut.

    Tighten 

    Tighten the left side mounting insulator nut and bolt 80 N.m (60 lb ft).

    Fig 2: Installing Left Side Mounting Insulator Bolt And Nut
    G01546833Courtesy of GENERAL MOTORS CORP.
  4. Install the 5 bolts and 2 nuts from the right side engine mount, then remove the engine lift.

    Tighten 

    Tighten the right side engine mount nuts and bolts to 52 N.m (38 lb ft).

    Fig 3: Installing Bolts To Right Side Engine Mount
    G01546834Courtesy of GENERAL MOTORS CORP.
  5. Align the right side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).
    Fig 4: Aligning Right Side Of Crossmember And Installing Bolt
    G01546835Courtesy of GENERAL MOTORS CORP.
  6. Align the left side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).

    Tighten 

    • Tighten the right and left side bolts (1) to 157 N.m (116 lb ft).
    • Tighten the right and left side bolts (2) to 113 N.m (83 lb ft).
      Fig 5: Aligning Left Side Of Crossmember And Installing Bolt
      G01546836Courtesy of GENERAL MOTORS CORP.
  7. Install the crossmember rear bolts and tighten.

    Tighten 

    Tighten the crossmember rear bolts to 39 N.m (29 lb ft).

    Fig 6: Installing Crossmember Rear Bolts
    G01546837Courtesy of GENERAL MOTORS CORP.
  8. Connect the lower control arm assembly.

    Tighten 

    Tighten the nuts and the bolt to 89 N.m (65.6 lb ft).

  9. Connect the front stabilizer link assembly.

    Tighten 

    Tighten the nut to 74 N.m (54.6 lb ft).

  10. Install the left side tie rod end.

    Tighten 

    Tighten the outer tie rod nut to 49 N.m (36.1 lb ft). Align the cotter pin slot by tightening the outer tie rod nut up to 1/6 additional turn, or 70 N.m (52 lb ft) maximum. Do not loosen the nut in order to insert the cotter pin.

  11. Install the drive shaft lock nut.

    Tighten 

    Tighten the nut to 216 N.m (159 lb ft).

  12. Install the front exhaust pipe. Refer to FRONT PIPE REPLACEMENT in Engine Exhaust.
  13. Connect the power steering lines (1), then refill the power steering system. Refer to CHECKING AND ADDING POWER STEERING FLUID in Power Steering System.
    Fig 7: Connecting Power Steering Lines
    G01546838Courtesy of GENERAL MOTORS CORP.
  14. If equipped with AWD, install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - TWO PIECE in Propeller Shaft.
  15. Connect the oil cooler hoses.
  16. Install the right and left engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - LEFT and SPLASH SHIELD REPLACEMENT - ENGINE - RIGHT in Body Front End.
  17. Lower the vehicle.
  18. Install the steering intermediate shaft assembly. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT (FWD) in Steering Wheel and Column.
  19. Install the shift cable mounting bracket bolt (2) and clip the wire harness (1).

    Tighten 

    Tighten the bolt to 12 N.m (9 lb ft).

    Fig 8: Installing Shift Cable Mounting Bracket Bolt And Clipping Wire Harness
    G01546839Courtesy of GENERAL MOTORS CORP.
  20. If equipped with automatic transaxle, install the shift cable to the transaxle.
    1. Install the shift cable nut.

      Tighten 

      Tighten the nut to 12 N.m (9 lb ft).

    2. Clip the cable to the mounting bracket.
      Fig 9: Installing Shift Cable To Transaxle
      G01546840Courtesy of GENERAL MOTORS CORP.
  21. Pull the engine harness wire through the passenger compartment.
  22. Connect the 3 cowl wire electrical connectors to the connector mounting bracket.
  23. Connect the 2 ECM connectors.
  24. Connect the ground cable to the engine.
  25. Connect the ground cables to the transaxle.
  26. If equipped with manual transaxle, connect the transaxle control cables to the transaxle.
    1. Connect the transaxle control cables (2) to the transaxle.
    2. Clip the cable (1) to the mounting bracket.
    Fig 10: Connecting Transaxle Control Cables To Transaxle
    G01546841Courtesy of GENERAL MOTORS CORP.
  27. Connect the clutch actuator cylinder. Refer to CLUTCH ACTUATOR CYLINDER REPLACEMENT in Clutch.
  28. Connect the 3 engine compartment relay box connectors (1,2,3).
    Fig 11: Connecting Engine Compartment Relay Box Connectors
    G01546842Courtesy of GENERAL MOTORS CORP.
  29. Connect 2 ground cables (1,2) from front left side of engine compartment.

    Tighten 

    Tighten the bolts to 9 N.m (7 lb ft).

    Fig 12: Connecting Ground Cables From Front Left Side Of Engine Compartment
    G01546843Courtesy of GENERAL MOTORS CORP.
  30. Connect the 2 wire harness clamps.
    Fig 13: Connecting Wire Harness Clamps
    G01546844Courtesy of GENERAL MOTORS CORP.
  31. Install the engine relay box cover.
  32. Install the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
  33. Install the generator. Refer to GENERATOR .
  34. Install the radiator inlet hose. Refer to RADIATOR HOSE REPLACEMENT - INLET in Engine Cooling.
  35. Install the radiator outlet hose. Refer to RADIATOR HOSE REPLACEMENT - OUTLET in Engine Cooling.
  36. Connect the brake booster vacuum hose to the brake booster.
  37. Connect the heater hose to the water hose union on the cylinder head.
  38. Connect the heater hose to the water by-pass pipe.
  39. Connect the fuel tube to the fuel pipe
  40. Install the fuel tube clamp.
  41. Connect the cruise control actuator electrical connector.
  42. Install the air cleaner case as follows:
    1. 42.1 Install the air cleaner, then the 3 air cleaner case bolts (2).

      Tighten 

      Tighten the bolts to 7 N.m (62 lb in).

    2. 42.2 Connect the air cleaner wire harness clamp, connector and hose.
    3. 42.3 Install the air filter.
    Fig 14: Installing Air Cleaner Case
    G01546845Courtesy of GENERAL MOTORS CORP.
  43. Install the air cleaner cover as follows:
    1. 43.1 Install the air cleaner cap and air cleaner hose assembly.
    2. 43.2 Connect the air cleaner hose to the throttle body, then tighten the air cleaner hose clamp bolt.
    3. 43.3 Connect the air cleaner cap to the air cleaner case, then latch the two air cleaner clamps.
    4. 43.4 Connect the mass air flow sensor connector.
  44. Connect the intake air temperature (IAT) sensor.
  45. Connect the accelerator cable to the throttle body (1).
  46. Install the accelerator cable to the accelerator cable bracket.
    Fig 15: Connecting Accelerator Cable To Throttle Body
    G01546846Courtesy of GENERAL MOTORS CORP.
  47. If vehicle is equipped with a manual transmission, remove the following components:
  48. If vehicle is equipped with A/C, position the A/C compressor and install the A/C compressor bolts. Refer to COMPRESSOR REPLACEMENT in Heating, Ventilation, and Air Conditioning.
  49. Install the serpentine drive belt. Refer to DRIVE BELT REPLACEMENT  .
  50. Refill the engine oil.
  51. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  52. Connect the negative battery cable.
  53. Position the engine cover (1) to the engine.
    Fig 16: Positioning Engine Cover To Engine
    G01546847Courtesy of GENERAL MOTORS CORP.
  54. Install the 2 engine cover plastic retainers.
  55. Install the 2 engine cover fasteners.
  56. Start the engine and check for fluid leaks.
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