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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1923 (Engine Mechanical - 2.4L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

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    Fig 1: Transaxle To Engine Bolts
    GM1847526Courtesy of GENERAL MOTORS CORP.
  1. Install a suitable lifting devise to the engine.
  2. Using the lifting devise, position and install the engine to the transaxle.
    3. CAUTION: Refer to Fastener Caution .
  3. Install the transaxle bolts to the engine and tighten the bolts to 75 N.m (55 lb ft).
    4. Fig 2: Torque Converter To Flexplate Bolts
    GM1847524Courtesy of GENERAL MOTORS CORP.
  4. Install the torque converter to flexplate bolts (1) and tighten to 60 N.m (44 lb ft).
  5. Remove the engine lifting devise.
    6. Fig 3: Identifying Starter Motor Bolts & Starter
    GM1814106Courtesy of GENERAL MOTORS CORP.
  6. Install the starter motor and bolts and tighten the bolts to 53 N.m (39 lb ft).
    7. Fig 4: Engine Wiring Harness Ground Bolt
    GM1847502Courtesy of GENERAL MOTORS CORP.
  7. Gather all branches of the engine wiring harness and position the harness to the engine.
  8. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt (1).

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

    9. Fig 5: Identifying Engine Wiring Harness Electrical Connector
    GM1812206Courtesy of GENERAL MOTORS CORP.
  9. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
  10. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector.
  11. Install the engine wiring harness clip (5) to the stud.
    12. Fig 6: Locating Exhaust CMP Sensor Connector
    GM1815153Courtesy of GENERAL MOTORS CORP.
  12. Connect the engine wiring harness electrical connector (1) to the exhaust CMP sensor.
    13. Fig 7: Locating Intake Camshaft Position (CMP) Sensor And Intake Camshaft Position (CMP) Sensor Connectors
    GM1815154Courtesy of GENERAL MOTORS CORP.
  13. Connect the engine wiring harness electrical connector (1) to the intake CMP sensor.
  14. Connect the engine wiring harness electrical connector (2) to the EVAP emission canister purge solenoid valve.
    15. Fig 8: View Of Starter And Engine Electrical Connectors
    GM1809558Courtesy of GENERAL MOTORS CORP.
  15. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
  16. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
  17. Connect the engine wiring harness electrical connector (3) to the knock sensor.
    18. Fig 9: Identifying Engine Wiring Harness Electrical Connectors
    GM1811485Courtesy of GENERAL MOTORS CORP.
  18. Connect the engine wiring harness electrical connectors (1) to the ignition coils.
  19. Connect the engine wiring harness electrical connectors (2, 3) to the camshaft actuators.
    20. Fig 10: Identifying Engine Electrical Connectors Left Side
    GM1810743Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
  21. Connect the engine wiring harness electrical connector (8) to the fuel injector wiring harness electrical connector (7).
  22. Install the engine wiring harness clip (3) to the oil level indicator tube bracket.
    23. Fig 11: Powertrain Assembly On Engine Support Table
    GM952078Courtesy of GENERAL MOTORS CORP.
  23. Position the powertrain and support table under the vehicle.
  24. Raise the powertrain into position under the vehicle.
  25. With the table positioned, if required, lower the vehicle over the powertrain.
  26. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
  27. Install the NEW frame to body bolts and tighten to 155 N.m (114 lb ft).
  28. Lower the vehicle.
    29. Fig 12: Left Transmission Mount & Bolts
    GM928777Courtesy of GENERAL MOTORS CORP.
  29. Install the transaxle mount to transaxle adapter bolts and tighten to 55 N.m (41 lb ft).
    30. Fig 13: Engine Mount To Bracket Bolts
    GM1810250Courtesy of GENERAL MOTORS CORP.
  30. Install the engine mount to engine mount bracket bolts (2).
  31. Tighten the engine mount to bracket bolts in the following sequence:
    1. Middle
    2. Rear
    3. Front

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

  32. Raise and support the vehicle.
  33. Install the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement .
    34. Fig 14: Lower Control Arm Ball Stud, Nut And Cotter Pin
    GM1847531Courtesy of GENERAL MOTORS CORP.
  34. Install the control arm ball studs into the steering knuckles.
  35. Install the ball stud nuts and tighten to 40 N.m (30 lb ft).
  36. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.
    37. Fig 15: Stabilizer Link To Stabilizer Shaft Nut
    GM1829576Courtesy of GENERAL MOTORS CORP.
  37. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts.

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

    38. Fig 16: View Of Tie Rod, Knuckle & Tapered Ball Stud
    GM891579Courtesy of GENERAL MOTORS CORP.
  38. Connect the outer tie rods to the steering knuckles.
  39. Use the J 44015 
  40. Remove the J 44015  .
    41. Fig 17: Outer Tie Rod To Steering Knuckle Nut
    GM1829556Courtesy of GENERAL MOTORS CORP.
  41. Install NEW outer tie rod to steering knuckle nuts and tighten to 25 N.m (48 lb ft) plus 90 degrees.
    42. Fig 18: View Of Intermediate Shaft To Steering Gear Pinch Bolt
    GM1829617Courtesy of GENERAL MOTORS CORP.
  42. Position the intermediate shaft to the steering gear and install a NEW pinch bolt.

    Tighten the bolt to 34 N.m (25 lb ft).

  43. Install the catalytic converter. Refer to Catalytic Converter Replacement .
    44. Fig 19: Transaxle Oil Cooler Line To Transaxle Nut
    GM1847469Courtesy of GENERAL MOTORS CORP.
  44. Install the transaxle oil cooler lines to the transaxle.
  45. Install the transaxle oil cooler line to transaxle nut (1) and tighten to 4 N.m (27 lb in).
    46. Fig 20: View Of Tire/Wheel Assembly & Wheel Lug Nuts
    GM933764Courtesy of GENERAL MOTORS CORP.
  46. Remove the wood from between the oil pan and the engine cradle.
  47. Remove the wood from between the transaxle and the engine cradle.
  48. Install the front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement .
  49. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
  50. Lower the vehicle.
    51. Fig 21: View Of Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  51. Unsecure and position the radiator/condenser/fan assembly.
    52. Fig 22: Transaxle Shift Cable And Range Select Lever
    GM1834362Courtesy of GENERAL MOTORS CORP.
  52. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
  53. Install the transaxle shift cable to the range select lever.
  54. Raise and support the vehicle.
  55. Install the oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Sensor 1 and Heated Oxygen Sensor Replacement - Sensor 2 .
  56. Instal the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LAT or LE5) .
    57. Fig 23: Auxiliary Heater Water Pump Bolt And Pump
    GM1814527Courtesy of GENERAL MOTORS CORP.
  57. On LAT engine, install the auxiliary heater water pump and bolt and tighten the bolt to 9 N.m (80 lb in).
    58. Fig 24: Identifying Engine Wiring Harness Electrical Connector
    GM1812206Courtesy of GENERAL MOTORS CORP.
  58. Connect the engine wiring harness electrical connector (2) to the auxiliary heater water pump.
  59. Install the engine control module. Refer to Engine Control Module Replacement .
    60. Fig 25: View Of Starter And Electrical Connectors
    GM1813964Courtesy of GENERAL MOTORS CORP.
  60. On all engines, position and install the positive battery cable between the starter and the engine.
  61. Install the positive battery cable lead (1) to the starter motor.
  62. Install the positive battery cable to starter motor nut (4) and tighten the nut to 9 N.m (80 lb in).
    63. Fig 26: Engine Wiring Harness Ground Lead Nut And Stud
    GM1813437Courtesy of GENERAL MOTORS CORP.
  63. Position the negative battery cable and install the negative battery cable lead (2) to the transaxle stud.
  64. Install the engine wiring harness ground lead nut (1) to the transaxle stud and tighten the nut to 50 N.m (37 lb ft).
    65. Fig 27: Compressor Bolts
    GM1811970Courtesy of GENERAL MOTORS CORP.
  65. Position the A/C compressor and install the bolts and tighten to 50 N.m (37 lb ft).
    66. Fig 28: Generator Control Module Coolant Pump
    GM1811960Courtesy of GENERAL MOTORS CORP.
  66. On LAT engine, install the generator control module coolant pump and bolt and tighten the bolt to 25 N.m (18 lb ft).
    67. Fig 29: Engine Wiring Harness Electrical Connector
    GM1811958Courtesy of GENERAL MOTORS CORP.
  67. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump.
  68. On all engines, connect the engine wiring harness electrical connector (2) to the A/C compressor.
  69. Lower the vehicle.
    70. Fig 30: View Of Auxiliary Heater Water Pump & Heater Hoses
    GM1812209Courtesy of GENERAL MOTORS CORP.
  70. Install the coolant recovery reservoir/heater inlet hose (2) to the thermostat housing.
  71. Position the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.
  72. Install the heater inlet hose (3) to the thermostat housing.
  73. Position the heater inlet hose clamp at the thermostat housing.
  74. Install the auxiliary heater water pump hose clip (1) to the heater outlet hose.
    75. Fig 31: Locating Engine Wiring Harness Electrical Connector
    GM1816297Courtesy of GENERAL MOTORS CORP.
  75. On LAT engine, connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump module.
    76. Fig 32: Generator Control Module Coolant Hose And Clamp
    GM1816290Courtesy of GENERAL MOTORS CORP.
  76. Install the generator control module coolant hose to the generator control module.
  77. Position the generator control module coolant hose clamp (1) at the generator control module.
    78. Fig 33: View Of Radiator Inlet Hose To Engine
    GM1656126Courtesy of GENERAL MOTORS CORP.
  78. On all engines, reposition the radiator inlet hose clamp using the J 38185  . See Special Tools .
  79. Remove the radiator inlet hose from the cylinder head.
  80. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LAT) or Radiator Outlet Hose Replacement (LE5) or Radiator Outlet Hose Replacement (HP5) .
    81. Fig 34: Coolant Recovery Inlet Hose And Clamp
    GM1812505Courtesy of GENERAL MOTORS CORP.
  81. Position and install the coolant recovery inlet hose (1) to the cylinder head.
  82. Install the coolant recovery inlet pipe clip to the fuel rail.
  83. Install the coolant recovery inlet hose clamp (2) at the cylinder head.
    84. Fig 35: Vacuum Brake Booster Hose And Clamp
    GM1810786Courtesy of GENERAL MOTORS CORP.
  84. Position and install the vacuum brake booster hose (2) to the intake manifold.
  85. Position the vacuum brake booster hose clamp (1) at the intake manifold.
  86. Install the generator starter. Refer to Generator with Starter Replacement .
  87. For the LAT, install the battery tray. Refer to Battery Tray Replacement (HP7) .
  88. For the LE5, install the battery box. Refer to Battery Box Replacement .
    89. Fig 36: Transaxle Shift Cable Clip
    GM1834359Courtesy of GENERAL MOTORS CORP.
  89. Install the transaxle shift cable clip (1) to the fuel line bracket.
    90. Fig 37: View Of Fuel Feed Pipe Retainer & Fuel Pipe Bracket
    GM1683133Courtesy of GENERAL MOTORS CORP.
  90. Install the throttle body. Refer to Throttle Body Assembly Replacement .
  91. Install the fuel feed pipe clip (2) to the fuel line bracket.
  92. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  93. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  94. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  95. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  96. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) or Cooling System Draining and Filling (Static Fill Without HP5) or Cooling System Draining and Filling (GE 47716 Fill With HP5) or Cooling System Draining and Filling (GE 47716 Fill Without HP5) .
  97. For the LAT engine, reconnect the hybrid battery. Refer to Hybrid Battery Service Disconnect/Connect .
  98. Fill the transaxle with fluid. Refer to Transmission Fluid Check .
  99. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  100. Recharge the A/C system with refrigerant. Refer to Refrigerant Recovery and Recharging (With HP5) or Refrigerant Recovery and Recharging (Without HP5) .
  101. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
  102. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.
  103. Install the hood. Refer to Hood Replacement .
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