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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1619 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE .
  1. Install the J 41798  to the engine.

    Tighten 

    • Tighten the M8 bolts to 25 N.m (18 lb ft).
    • Tighten the M10 bolts to 50 N.m (37 lb ft).
  2. Install an engine hoist to the J 41798  .
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
    Fig 1: Installing J 41798
    G02106849Courtesy of GENERAL MOTORS CORP.
  6. Install the left and right engine mount to engine mount bracket bolts.

    Tighten 

    Tighten the bolts to 65 N.m (48 lb ft).

  7. Install the upper transmission bolts until snug.
  8. Remove the floor jack from under the transmission.
  9. Remove the engine hoist.
    Fig 2: Installing Left & Right Engine Mount To Engine Mount Bracket Bolts
    G02106850Courtesy of GENERAL MOTORS CORP.
  10. Remove the J 41798  from the engine.
    Fig 3: Removing J 41798
    G02106851Courtesy of GENERAL MOTORS CORP.
  11. Install the ignition coil(s) and the spark plug wire(s). Refer to REMOVAL (4.8L, 5.3L, 6.0L & 8.1L) .
  12. Raise the vehicle.
    Fig 4: Installing Ignition Coils & Spark Plug Wires
    G02106852Courtesy of GENERAL MOTORS CORP.
  13. Install the disc and clutch pressure plate and bolts until snug, if equipped.
  14. Using J 5824-01  , align the clutch disc splines with the pilot bearing.
  15. Align the marks made during removal.
    Fig 5: Installing Disc, Clutch Pressure Plate & Bolts
    G02106853Courtesy of GENERAL MOTORS CORP.
  16. Tighten the clutch pressure plate bolts in the sequence shown, evenly over 3 increments with the fourth increment to the final specification.

    Tighten 

    Tighten the bolts to 70 N.m (52 lb ft).

    Fig 6: Tightening Sequence For Clutch Pressure Plate Bolts
    G02106854Courtesy of GENERAL MOTORS CORP.
  17. Install the clutch line to the concentric slave cylinder.
    Fig 7: Installing Clutch Line
    G02106855Courtesy of GENERAL MOTORS CORP.
  18. Install the manual transmission bolt/studs, if equipped.
    Fig 8: Installing Manual Transmission Bolt/Studs
    G02106856Courtesy of GENERAL MOTORS CORP.
  19. Install the manual transmission stud on the right side of the transmission, if equipped.

    Tighten 

    Tighten the bolt/studs to 50 N.m (37 lb ft).

    Fig 9: Installing M/T Stud On Right Side Of Transmission
    G02106857Courtesy of GENERAL MOTORS CORP.
  20. Remove the J 21366  from the transmission.
  21. Install the automatic transmission, if equipped.
    Fig 10: Installing Automatic Transmission
    G02106858Courtesy of GENERAL MOTORS CORP.
  22. If equipped with a 4L80E transmission, install the transmission converter cover bolts.
    Fig 11: Installing Transmission Converter Cover Bolts
    G02106859Courtesy of GENERAL MOTORS CORP.
  23. If equipped with a 4L60E transmission, install the transmission bolt and stud on the right side.

    Tighten 

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

    Fig 12: Installing Transmission Bolt & Stud On Right Side
    G02106860Courtesy of GENERAL MOTORS CORP.
  24. Install the automatic transmission oil level indicator tube, if equipped.
    Fig 13: Installing A/T Oil Level Indicator Tube
    G02106861Courtesy of GENERAL MOTORS CORP.
  25. Install the automatic transmission oil level indicator tube nut, if equipped.

    Tighten 

    Tighten to nut to 18 N.m (13 lb ft).

    Fig 14: Installing Automatic Transmission Oil Level Indicator Tube Nut
    G02106862Courtesy of GENERAL MOTORS CORP.
  26. Install the torque converter bolts, if equipped.

    Tighten 

    • If equipped with a 4L60E, tighten the bolts to 63 N.m (47 lb ft)
    • If equipped with a 4L80E, tighten the bolts to 60 N.m (44 lb ft).
    Fig 15: Installing Torque Converter Bolts
    G02106863Courtesy of GENERAL MOTORS CORP.
  27. Install the positive cable clip and bolt.

    Tighten 

    Tighten the bolt to 9 N.m (80 lb in).

  28. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (4.3L, 4.8L, AND 5.3L ENGINES)
  29. Install the starter motor. Refer to STARTER MOTOR .
    Fig 16: Installing Positive Cable Clip & Bolt
    G02106864Courtesy of GENERAL MOTORS CORP.
  30. Install the oil pan skid plate and bolts, if equipped.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

    Fig 17: Installing Oil Pan Skid Plate & Bolts
    G02106865Courtesy of GENERAL MOTORS CORP.
  31. Install the engine shield and bolts.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

  32. Lower the vehicle.
    Fig 18: Installing Engine Shield & Bolts
    G02106866Courtesy of GENERAL MOTORS CORP.
  33. Install the vacuum brake booster hose.
    Fig 19: Installing Vacuum Brake Booster Hose
    G02106867Courtesy of GENERAL MOTORS CORP.
  34. Position the generator bracket to the front of the engine.
  35. Install the generator bracket bolts until snug.
  36. Install the rear power steering pump to engine block bolt, until snug.

    Tighten 

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

  37. Route the engine wiring harness to the lower engine area.
  38. Raise the vehicle.
    Fig 20: Installing Generator Bracket Bolts
    G02106868Courtesy of GENERAL MOTORS CORP.
  39. Slide the channel pin into the oil pan tab.
  40. Install the battery cable channel bolt.

    Tighten 

    Tighten the bolt to 12 N.m (106 lb in).

    Fig 21: Installing Battery Cable Channel Bolt
    G02106869Courtesy of GENERAL MOTORS CORP.
  41. Connect the following electrical connectors:
    • CKP sensor (1)
    • Engine oil level sensor (6)
    • Coolant heater, if equipped.
  42. Lower the vehicle.
  43. Connect the fuel pipes. Refer to REMOVAL & INSTALLATION (METAL COLLAR) .
    Fig 22: Connect Engine Oil Level Sensor & CKP Sensor Electrical Connectors
    G02106870Courtesy of GENERAL MOTORS CORP.
  44. Install the EVAP purge solenoid vent tube to the solenoid (1).
  45. Install the EVAP tube to the vapor pipe (2).
    Fig 23: Solenoid & Vapor Pipe
    G02106871Courtesy of GENERAL MOTORS CORP.
  46. Install the battery cable junction block to the junction block bracket.
  47. Clip all of the engine wiring harness clips to their correct location.
    Fig 24: Installing Battery Cable Junction Block Bracket
    G02106872Courtesy of GENERAL MOTORS CORP.
  48. Connect the following electrical connectors:
    • Oil pressure sensor (1)
    • CMP sensor (2)
  49. Position the harness ground and the engine ground strap to the block.
  50. Install the harness ground bolt at the left rear of the engine block.
  51. Position the harness ground, and auxiliary negative battery cable, if equipped, to the block.
  52. Install the harness ground bolt at the right rear of the engine block.

    Tighten 

    Tighten the bolts Oil pressure sensor and to 16 N.m (12 lb ft).

    Fig 25: Connect CMP Sensor & Oil Pressure Sensor Electrical Connectors
    G02106873Courtesy of GENERAL MOTORS CORP.
  53. Connect the following electrical connectors:
    • ECT sensor (1)
    • Electronic variable orifice switch (2)
  54. Position the harness ground and negative battery cable to the block.
  55. Install the harness ground bolt.

    Tighten 

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

    Fig 26: Connect ECT Sensor & Electronic Variable Orifice Switch Electrical Connectors
    G02106874Courtesy of GENERAL MOTORS CORP.
  56. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    Fig 27: Connect MAP Sensor & Knock Sensor Electrical Connectors
    G02106875Courtesy of GENERAL MOTORS CORP.
  57. Connect the following electrical connectors:
    • Main coil harness (1)
    • Fuel injectors (2)
    • ETC (3)
    Fig 28: Connect, Main Coil Harness, Fuel Injectors & ETC Electrical Connectors
    G02106876Courtesy of GENERAL MOTORS CORP.
  58. Connect the main coil harness (2) and fuel injector electrical connectors on the left side.
    Fig 29: Connect Main Coil Harness & Fuel Injector Electrical Connectors On Left Side
    G02106877Courtesy of GENERAL MOTORS CORP.
  59. Install the generator cable to the generator; perform the following:
    1. 59.1. Install the generator cable.
    2. 59.2. Install the generator cable nut to the terminal stud.

      Tighten 

      Tighten the nut to 9 N.m (80 lb in).

    3. 59.3. Slide the boot over the terminal stud.
    Fig 30: Installing Generator Cable & Nut
    G02106878Courtesy of GENERAL MOTORS CORP.
  60. Install the radiator vent inlet hose to the throttle body.
  61. Position the vent inlet hose clamp at the throttle body.
    Fig 31: Installing Radiator Vent Inlet Hose
    G02106879Courtesy of GENERAL MOTORS CORP.
  62. Install the engine wiring harness bracket and nut (2)

    Tighten 

    Tighten the nut to 5 N.m (44 lb in).

  63. Connect the following electrical connector:
    • EVAP canister purge solenoid (1)
    • Generator (3)
  64. Install the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET (LR4, LM7, LQ4) and HEATER HOSE REPLACEMENT - INLET (LR4, LM7, LQ4) .
    Fig 32: Engine Wiring Harness Bracket Nut, EVAP Canister Purge Solenoid & Generator
    G02106880Courtesy of GENERAL MOTORS CORP.
  65. Open the hose clamp and install the radiator outlet hose to the water pump.
    Fig 33: Installing Radiator Outlet Hose
    G02106881Courtesy of GENERAL MOTORS CORP.
  66. Open the hose clamp and install the radiator inlet hose to the water pump.
  67. Install the radiator support. Refer to RADIATOR SUPPORT REPLACEMENT .
  68. Install the A/C compressor. Refer to COMPRESSOR REPLACEMENT (LR4, LM7, AND LQ4) .
    Fig 34: Installing Radiator Inlet Hose
    G02106882Courtesy of GENERAL MOTORS CORP.
  69. Remove the hood hinge bolts from the service position (2).
  70. Lower the hood to the normal position.
  71. Install the hood hinge bolts.

    Tighten 

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

  72. Remove the fender covers.
  73. Fill the crankcase with the proper quantity and grade of engine oil.
  74. Bleed the hydraulic clutch, if equipped. Refer to HYDRAULIC CLUTCH BLEEDING .
    Fig 35: Removing Hood Hinge Bolts From Service Position
    G02106883Courtesy of GENERAL MOTORS CORP.
  75. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE .
    IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is install in the vehicle.
  76. Test the vehicle using the following procedure:
    1. 76.1. Disable the ignition system.
    2. 76.2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    3. 76.3. Enable the ignition system.
    4. 76.4. Start the engine and listen for unusual noises.
    5. 76.5. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
    6. 76.6. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
    7. 76.7. Listen for sticking lifters and other unusual noises.
    8. 76.8. Inspect for fuel, oil and/or coolant leaks while the engine is running.
    9. 76.9. Perform a final inspection for the proper engine oil an coolant levels.
  77. Install the engine 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) .
  78. Close the hood.
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