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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1496 (Engine Mechanical - 5.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Envoy XL and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the hood. Refer to HOOD REPLACEMENT  in Body Front End.
  2. Place fender covers over both fenders.
  3. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE  in Engine Electrical.
  4. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING  in Heating, Ventilation, and Air Conditioning.
  5. Remove the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6)  or RADIATOR REPLACEMENT (BODY VIN TYPE 3)  in Engine Cooling.
  6. Remove the radiator support brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL  in Body Front End.
  7. Remove the front differential drive axle, if equipped with 4-wheel drive (4WD). Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT (4.8L, 5.3L, 6.0L V-8)  in Front Drive Axle.
  8. Remove the wheel drive shafts. Refer to AXLE SHAFTS .
  9. Remove the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT   .
  10. Disconnect the following electrical connectors:
    • Oil pressure sensor (1)
    • Oxygen sensors (2, 3)
    • Camshaft position (CMP) sensor (4)
    Fig 1: Disconnecting Electrical Connectors At Rear Of Engine
    G02129276Courtesy of GENERAL MOTORS CORP.
  11. Remove the air conditioning (A/C) compressor hose. Refer to COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 3)  or COMPRESSOR HOSE ASSEMBLY REPLACEMENT (BODY VIN TYPE 6)  in Heating, Ventilation, and Air Conditioning.
  12. Disconnect the rear auxiliary A/C compressor pipe fitting (7).
  13. Remove the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
  14. Tie the pipe assembly out of the way.
    Fig 2: Removing Rear Auxiliary A/C Compressor Pipe Nut And Bolt
    G02129277Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the engine coolant temperature (ECT) sensor (1).
  16. Remove the ground terminal bolt (2).
  17. Remove the retaining clips from the brackets.
    Fig 3: Removing Ground Terminal Bolt
    G02129278Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the A/C pressure switch electrical connector (2).
  19. Remove the retaining clip (1) from the cylinder head.
  20. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
    Fig 4: Removing Retaining Clip From Cylinder Head
    G02129279Courtesy of GENERAL MOTORS CORP.
  21. Remove the ground terminal bolts (2, 4).
  22. Remove the starter. Refer to STARTING SYSTEM  in Engine Electrical.
    Fig 5: Removing Ground Terminal Bolts
    G02129280Courtesy of GENERAL MOTORS CORP.
  23. Remove the battery cable channel bolt.
  24. Remove the battery cable channel from the oil pan.
    Fig 6: Removing Battery Cable Channel Bolt
    G02129281Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the A/C compressor electrical connector.
  26. Lower the vehicle.
  27. Gather all branches of the engine wiring harness and reposition the harness off to the side.
    Fig 7: Disconnecting A/C Compressor Electrical Connector
    G02129282Courtesy of GENERAL MOTORS CORP.
  28. Remove the generator cable from the generator, perform the following:
    • Slide the boot down revealing the terminal stud.
    • Remove the generator cable nut from the terminal stud.
    • Remove the generator cable.
      Fig 8: Removing Generator Cable
      G02129283Courtesy of GENERAL MOTORS CORP.
  29. Remove the generator bracket bolts.
  30. Position the bracket with generator aside.
    Fig 9: Removing Generator Bracket Bolts
    G02129284Courtesy of GENERAL MOTORS CORP.
  31. Using J 38185  , reposition the inlet hose clamp.
  32. Remove the inlet hose from the water outlet.
    Fig 10: Removing Inlet Hose From Water Outlet
    G02129285Courtesy of GENERAL MOTORS CORP.
  33. Using J 38185  , reposition the inlet hose clamp.
  34. Remove the outlet hose from the water outlet.
    Fig 11: Removing Outlet Hose From Water Outlet
    G02129286Courtesy of GENERAL MOTORS CORP.
  35. Disconnect the auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes.
    Fig 12: Disconnecting Auxiliary Heater Inlet And Outlet Hose/Pipe Assembly From Heater Water Shutoff Valve Pipes
    G02129287Courtesy of GENERAL MOTORS CORP.
  36. Using J 38185  , reposition the auxiliary heater inlet and outlet hose clamps.
  37. Remove the auxiliary heater inlet and outlet hoses/pipes from the water pump.
    Fig 13: Removing Auxiliary Heater Inlet And Outlet Hoses/Pipes From Water Pump
    G02129288Courtesy of GENERAL MOTORS CORP.
  38. Remove the ignition coil(s) (as required) for the proper fit of the J 41798  before lifting the engine. Refer to IGNITION COILS in Engine Controls - 4.8L, 5.3L, and 6.0L.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  39. 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).
  40. Raise the vehicle.
  41. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (5.3L ENGINE)  in Engine Exhaust.
    Fig 14: Installing J 41798 Tool To Cylinder Heads
    G02129289Courtesy of GENERAL MOTORS CORP.
  42. Remove the 3 frame engine mount bracket bolts from both the right and left sides.
    Fig 15: Removing Frame Engine Mount Bracket Bolts
    G02129290Courtesy of GENERAL MOTORS CORP.
  43. Remove the torque converter bolts.
    Fig 16: Removing Torque Converter Bolts
    G02129291Courtesy of GENERAL MOTORS CORP.
  44. Remove the transmission oil level indicator tube nut.
    Fig 17: Removing Transmission Oil Level Indicator Tube Nut
    G02129292Courtesy of GENERAL MOTORS CORP.
  45. Remove the transmission oil level indicator tube.
    Fig 18: Removing Transmission Oil Level Indicator Tube
    G02129293Courtesy of GENERAL MOTORS CORP.
  46. Remove the transmission bolt and stud on the right side.
    Fig 19: Removing Transmission Bolt And Stud (Right Side)
    G02129294Courtesy of GENERAL MOTORS CORP.
  47. Remove the lower transmission bolt/studs.
  48. Lower the vehicle.
  49. Remove the 3 upper transmission bolts/studs.
  50. Install an engine hoist to the J 41798  .
  51. Install a floor jack under the transmission for support.
  52. Separate the engine from the transmission.
  53. Remove the engine.
  54. Install the engine to an engine stand.
  55. Install J 21366  to the transmission in order to hold the torque converter.
    Fig 20: Removing Transmission Bolt/Studs
    G02129295Courtesy of GENERAL MOTORS CORP.
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