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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1443 (Engine Mechanical - 4.2L (Ll8)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Oldsmobile Bravada, 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 GMC Envoy, and 2004 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine from the engine stand.
  2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
  3. Install the AIR pipes to the engine.
  4. Install the fasteners securing the AIR pipes to the back of the engine head.
  5. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.
    6. Fig 1: View Of Upper Engine Mount Nuts
    GM754322Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Lower the engine onto the mounts and install the upper engine mount nuts (1).

    Tighten:  Tighten the nuts to 70 N.m (51 lb ft).

  7. Remove the engine hoist.
  8. Lay the radiator into the radiator support, but do not install the radiator completely.
  9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    10. Fig 2: View Of Bell Housing Bolts
    GM727330Courtesy of GENERAL MOTORS CORP.
  10. Install all of the lower bell housing bolts, excluding the top 4.
  11. Remove the 2 through bolts securing the transmission support.
  12. Lower the transmission.
  13. Install the top 4 bell housing bolts.

    Tighten:  Tighten all 11 bell housing bolts to 50 N.m (37 lb ft).

  14. Raise the transmission.
  15. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
  16. Install the 3 torque converter bolts.

    Tighten:  Tighten the torque converter bolts to 60 N.m (44 lb ft).

  17. Install the torque converter bolt cover.
  18. Install the fuel tank shield, if removed. Refer to Fuel Tank Shield Replacement (TrailBlazer, Envoy) or Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL) in Frame and Underbody.
    19. Fig 3: Disconnecting/Connecting Secondary AIR Pipes
    GM1297763Courtesy of GENERAL MOTORS CORP.
  19. Connect the secondary AIR pipes to the secondary AIR pump.
  20. Install the engine protection shield. Refer to Engine Protection Shield Replacement .
  21. Install the propeller shaft to the front axle pinion yoke. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
    22. Fig 4: Disconnecting/Connecting Exhaust Pipe
    GM750208Courtesy of GENERAL MOTORS CORP.
  22. Connect the exhaust pipe to the manifold and secure the pipe with the bolts.

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

  23. Connect the oil pressure sensor electrical connector.
    24. Fig 5: View Of Oil Pan Drain Plug
    GM637677Courtesy of GENERAL MOTORS CORP.
  24. Install the oil pan drain plug.

    Tighten:  Tighten the plug to 26 N.m (19 lb ft).

    25. Fig 6: View Of Radiator Hose
    GM750179Courtesy of GENERAL MOTORS CORP.
  25. Install the lower radiator hose (1).
  26. Install the left and right wheel drive shafts. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  27. Lower the vehicle.
    28. Fig 7: View Of Left Side Of Block
    GM756989Courtesy of GENERAL MOTORS CORP.
  28. Install the 4 grounds on the left side of the block (1).
  29. Install the camshaft sensor electrical connectors.
  30. Install the crankshaft sensor electrical connector.
  31. Install the knock sensor electrical connector.
    32. Fig 8: Rear Of Generator (Alternator) View
    GM754357Courtesy of GENERAL MOTORS CORP.
  32. Install the generator electrical connector and battery lead (1).

    Tighten:  Tighten the generator battery lead nut to 9 N.m (80 lb in).

  33. Install the A/C pressure sensor and clutch electrical connector.
    34. Fig 9: View Of Starter & Related Components
    GM754358Courtesy of GENERAL MOTORS CORP.
  34. Install starter electrical connectors and battery lead (1).

    Tighten:  Tighten the starter battery lead to 9 N.m (80 lb in).

  35. Install the fuel lines at the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement in Engine Controls - 4.2L.
    36. Fig 10: View Of Engine Harness Bracket & Bolts
    GM761550Courtesy of GENERAL MOTORS CORP.
  36. Install the engine harness bracket and bolt.

    Tighten:  Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).

  37. Install the front differential vent hose, to the engine harness bracket.
  38. Install all the harnesses to the engine harness bracket.
  39. Install the PCM. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 4.2L.
  40. Install the power brake hose at booster
    41. Fig 11: View Of Engine Electrical Harness Housing
    GM750195Courtesy of GENERAL MOTORS CORP.
  41. Install the harness retainer (1) to the original location.
  42. Install the ignition coil harness electrical connectors.
    43. Fig 12: Unclipping/Clipping Transmission Cooler Lines At Engine Block
    GM754348Courtesy of GENERAL MOTORS CORP.
  43. Clip the transmission cooler lines to the right side of the engine block.
  44. Connect the camshaft phaser actuator valve electrical connector.
  45. Connect the front axle actuator electrical connector.
  46. Connect the A/C line at the accumulator.
  47. Install the oxygen sensor electrical connector.
    48. Fig 13: Installing/Removing Lift Hook
    GM750188Courtesy of GENERAL MOTORS CORP.
  48. Remove the lift hook J 44220  . See Special Tools and Equipment .
  49. Install the secondary AIR solenoid valve. Refer to Secondary Air Injection (AIR) Solenoid Valve Replacement in Engine Controls - 4.2L.
  50. Install the heater hoses to the heater core. Refer to Heater Hose Replacement - Inlet (Front System Only) or Heater Hose Replacement - Inlet (Auxiliary System) and Heater Hose Replacement - Outlet (Front Only System) or Heater Hose Replacement - Outlet (Auxiliary System) in Heating, Ventilation, and Air Conditioning.
  51. Install the power steering pump.
    52. Fig 14: Installing Power Steering Pump
    GM687444Courtesy of GENERAL MOTORS CORP.
  52. Install the power steering pump bolts.

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

  53. Install the drive belt. Refer to Drive Belt Replacement  .
  54. Install cooling fan and shroud, tilting the radiator forward for clearance.
  55. Finish installing the radiator. Refer to Radiator Replacement (LL8) in Engine Cooling.
  56. Install transmission cooler lines together.
  57. Install the MAP sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement in Engine Controls - 4.2L.
  58. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L.
  59. Install the hood latch. Refer to Hood Latch Support Replacement in Body Front End.
  60. Install the head lamp housing. Refer to Headlamp Housing Panel Replacement (TrailBlazer) or Headlamp Housing Panel Replacement (Bravada, Envoy, Envoy XUV, Rainier) in Body Front End.
  61. Install the grill. Refer to Grille Replacement (Envoy, Envoy XUV) or Grille Replacement (TrailBlazer) or Grille Replacement (Bravada) or Grille Replacement (Rainier) in Exterior Trim.
  62. Install the washer solvent container. Refer to Washer Solvent Container Replacement (Envoy, TrailBlazer) or Washer Solvent Container Replacement (Rainier) in Wipers/Washer Systems.
  63. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.2L.
  64. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  65. Install the hood. Refer to Hood Replacement in Body Front End.
  66. Service the engine oil.
  67. Fill the cooling system. Refer to Draining and Filling Cooling System (LL8) in Engine Cooling.
  68. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  69. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 4.2L.
      IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
    • Disable the ignition system.
    • Crank the engine several times. Listen for unusual noises or evidence that parts are binding.
    • Enable the ignition system.
    • Start the engine and listen for unusual noises.
    • Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
    • Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
    • Listen for a sticking lifter and other unusual noises.
    • Inspect for fuel, oil and/or coolant leaks while the engine is running.
    • Perform a final inspection for the proper engine oil and coolant levels.
  70. Install the hood. Refer to Hood Replacement in Body Front End.
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