LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1814 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Powertrain Assembly On Engine Support Table
    GM952078Courtesy of GENERAL MOTORS CORP.
  1. With the powertrain supported on the jacking table, raise the powertrain into position.
    2. NOTE: If the radiator assembly is not properly positioned to the cradle, damage could occur.
  2. Raise the powertrain assembly into position. Align the lower radiator alignment pins with the cradle assembly. Be sure all the hoses and the electrical harnesses are correctly routed and free from the loading path of the powertrain assembly.
  3. Raise the transaxle into the vehicle to align the input shaft to the center of clutch. Guide the transaxle into position, rotate back and forth to align the input shaft splines to the clutch disc manual transmission only.
    4. NOTE: Refer to Fastener Notice .
    IMPORTANT: The body to cradle bolts are a one time use fastener and should be discarded after removal.
  4. Position the cradle guide pins into the location and install the new cradle-to-body bolts.

    Tighten:  Tighten the frame-to-body bolts to 155 N.m (114 lb ft).

    5. Fig 2: Removing/Installing Right Hand Engine Mount Bracket
    GM928024Courtesy of GENERAL MOTORS CORP.
  5. Lower the vehicle.
  6. Install the RH engine mount-to-engine bracket bolts.

    Tighten:  Tighten the engine mount-to-engine bracket bolts to 50 N.m (37 lb ft).

  7. Install the RH engine mount assembly and the nuts.

    Tighten:  Tighten the wheel nuts to 125 N.m (92 lb ft).

    8. Fig 3: Left Transmission Mount & Bolts
    GM928777Courtesy of GENERAL MOTORS CORP.
  8. Install the LH transaxle mount-to-transaxle bolts.

    Tighten:  Tighten the LH transaxle mount-to-engine bracket bolts to 50 N.m (37 lb ft).

  9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  10. Remove the wood blocks between the cradle and the powertrain.
    11. IMPORTANT: Do not damage the transaxle and the bearing races when the axles are seated.
  11. Swing the axle shafts into position and fully seat the axles into the transaxle.
  12. Position the strut assemblies onto the lower control arms.
  13. Install the lower control arm nut.

    Tighten:  Tighten the lower control arm-to-knuckle nut to 10 N.m (89 lb in) +150 degrees.

  14. Verify the axles are fully seated.
  15. Position the stabilizer link into position and install the nut.
  16. Install the stabilizer nut.

    Tighten:  Tighten the stabilizer link to strut to 65 N.m (48 lb ft).

    17. Fig 4: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  17. Install tie rod end into strut knuckle assembly.

    Tighten:  Tighten the tie rod knuckle assembly to 50 N.m (37 lb ft).

    18. Fig 5: Removing/Installing Steering Shaft To Intermediate Shaft
    GM927947Courtesy of GENERAL MOTORS CORP.
  18. Install the steering shaft to the intermediate shaft.
  19. Install the steering shaft-to-intermediate shaft bolt.

    Tighten:  Tighten the steering shaft-to-rack bolt to 34 N.m (25 lb ft).

  20. Install the propshaft into position. Hand-tighten the center bearing nuts - AWD Only.
  21. Install the propshaft into position - AWD only.
  22. Install the propshaft-to-PTU bolts - AWD only.

    Tighten:  Tighten the propshaft-to-PTU bolts to 25 N.m (19 lb ft).

  23. Install the propshaft into the rear axle assembly - AWD Only.
  24. Install the propshaft to rear module bolts - AWD Only.

    Tighten:  Tighten the propshaft-to-rear module bolts to 50 N.m (37 lb ft).

  25. Tighten the propshaft support bearing bolts - AWD only.

    Tighten:  Tighten the propshaft support bearing bolts to 25 N.m (19 lb ft).

  26. Install the propshaft support strap - AWD only.

    Tighten:  Tighten the propshaft guard strap to 25 N.m (19 lb ft).

    27. Fig 6: Disconnecting/Connecting Transaxle Lines
    GM949017Courtesy of GENERAL MOTORS CORP.
  27. Connect the transaxle lines-to-transaxle.

    Tighten

    • Tighten the transaxle cooler lines-to-transaxle stud 20 N.m (15 lb ft) - Automatic Only.
    • Tighten the transaxle cooler lines-to-transaxle nut 10 N.m (89 lb in) - Automatic Only.
  28. Install the gasket and down pipe-to-intermediate pipe assembly.
  29. Hand tighten the nuts.
  30. Install the gasket and down pipe-to-exhaust manifold.

    Tighten:  Tighten the down pipe-to-intermediate pipe nuts to 50 N.m (37 lb ft).

  31. Route the O2 harness into position at heat shield.
    32. Fig 7: A/C Compressor & Mounting Bolt
    GM952094Courtesy of GENERAL MOTORS CORP.
  32. Install the A/C compressor to the engine block.

    Tighten:  Tighten the A/C compressor-to-block bolt to 25 N.m (18 lb ft).

  33. Connect the A/C compressor harness-to-compressor.
  34. Connect the A/C pressure transducer-to-sensor.
    35. Fig 8: View Of Drive Belt Tensioner Tool
    GM951829Courtesy of GENERAL MOTORS CORP.
  35. Install the route belt around alternator and the A/C compressor.
  36. Install the J 39914  onto the tensioner and unload the spring tension from the tensioner while positioning the belt. See Special Tools .
  37. Release the tensioner and remove the tool.
  38. Attach the front air deflector to the cradle assembly.
  39. Route and install the shifter cable onto the bracket.
  40. Install the right engine inner splash shield.
  41. Install the right wheel and hand tighten the wheel nuts.
  42. Install the LH inner splash shield.
  43. Install the left wheel and hand tighten the wheel nuts.

    Tighten:  Tighten the wheel nuts to 125 N.m (92 lb ft).

  44. Lower the vehicle.
  45. Connect the shifter cable to the transaxle range switch. Adjustment is required. Refer to Floor Shift Control Cable Replacement .
    46. Fig 9: Disconnecting/Connecting Clutch Hydraulic Line
    GM986882Courtesy of GENERAL MOTORS CORP.
  46. Connect the clutch hydraulic line to the actuator cylinder by inserting and pushing in the C-clip until it stops manual transmission only.
  47. Connect the shift cables into the shift cable bracket manual transmission only.
  48. Connect the shift cable ends to the transaxle manual transmission only.
  49. Connect the heater hoses to the heater core at the front of the dash.
  50. Connect the purge hose at the purge solenoid.
  51. Connect the fuel transfer line to the quick connect to the fuel line.
  52. Connect the surge hose at the bottom of the surge tank.
  53. Connect the degas hose at the surge tank.
    54. Fig 10: Disconnecting/Connecting Radiator Hose And Clamp From Thermostat Pipe Assembly
    GM931384Courtesy of GENERAL MOTORS CORP.
  54. Connect the lower radiator hose at the coolant pipe.
  55. Connect the upper radiator hose at the engine cylinder head.
  56. Cut the radiator support straps and remove.
    57. Fig 11: View Of Battery Tray Bracket Bolts
    GM951487Courtesy of GENERAL MOTORS CORP.
  57. Install the headlamp assemblies and the torque bolts.
  58. Route the engine ground under the A/C line.
  59. Install the engine ground-to-body bolt.

    Tighten:  Tighten the engine ground-to-body bolt to 20 N.m (15 lb ft).

  60. Install the UHFB and the battery tray.
  61. Install the UHFB and the battery tray bolts.

    Tighten:  Tighten the battery tray bolts to 16 N.m (11 lb ft).

  62. Route the engine harness into position and install the main engine and the body harness connectors into the UHFB housing.
    63. Fig 12: Identifying Bolts On Top Of Fuse Block
    GM934982Courtesy of GENERAL MOTORS CORP.
  63. Snap the connectors into position in the UHFB.
  64. Connect both electrical connectors (2) underneath the UHFB.
    65. IMPORTANT: Make sure the engine and body harnesses are properly positioned to avoid damage to the harness.
  65. Install the UHFB while aligning the UHFB with the connectors.
  66. Snap the UHFB into position.
  67. Tighten the UHFB connector bolts (1).

    Tighten:  Tighten the UHFB connector bolts to 4 N.m (35 lb in).

  68. Install the battery and electronic power steering (EPS) feed wire to the UHFB stud and tighten the nut.

    Tighten:  Tighten the battery positive-to-UHFB stud to 10 N.m (89 lb in).

  69. Install the UHFB fuse cover into position.
  70. Connect the electrical connectors to the transmission control module (TCM), if equipped.
  71. Install the battery cable and the harness attachment clips on the side of the battery tray/UHFB bracket assembly.
  72. Install the battery and the cover.
  73. Install the brake vacuum hose into the booster.
  74. Connect the rear O2S connector.
  75. Secure the rear O2S to the body clips, near air cleaner assembly.
  76. Remove the shop towel from the throttle body opening.
    77. Fig 13: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  77. Position the outlet resonator/duct assembly into position.
  78. Connect the PCV fresh air vent hose assembly.
  79. Tighten the clamp at the throttle body assembly.
  80. Position the outlet resonator/duct assembly up with the support bracket and install the pushpin.
  81. Tighten the clamp at air the cleaner assembly.
  82. Connect the IAT sensor connector.
  83. Connect the negative battery cable.

    Tighten:  Tighten the battery terminal bolt to 17 N.m (13 lb ft).

    84. Fig 14: Removing & Installing Surge Tank Cap
    GM931323Courtesy of GENERAL MOTORS CORP.
    NOTE: All entrapped air must be purged from the powertrain cooling system before the final coolant level can be determined. Proper coolant level is critical to avoid engine damage.
  84. Fill the coolant system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (GE 47716 Fill) .
  85. Start the engine and fill the transaxle fluid. Refer to Transmission Fluid Checking .
  86. Check for leaks.
  87. If excessive engine idle vibration is noticed, mount adjustment procedure can be performed. Refer to Powertrain Mount Balance - Total Mounts .
  88. Verify the wheel alignment is within specifications.
scientia non olet · About LEMON Manuals