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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 257 (Engine Mechanical - 4.0L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front . .
  2. Carefully position the engine to the supported frame and transaxle assembly, aligning the engine dowels to the transaxle cover.
    CAUTION: Refer toFASTENER NOTICE .
  3. Install the bolts attaching the engine to the transaxle.

    Tighten 

    Tighten the engine to transaxle mounting bolts to 75 N.m (55 ft lbs).

    Fig 1: Installing Engine
    G01819602Courtesy of GENERAL MOTORS CORP.
  4. Install the nut securing the front engine mount to the engine frame.

    Tighten 

    Tighten the front engine mount nut to 70 N.m (52 ft lbs).

  5. Place a block of wood between the front of the engine oil pan and the engine frame.
  6. Remove the engine lift chain from the engine lift brackets.
    Fig 2: Installing Front Engine Mount Nut
    G01819603Courtesy of GENERAL MOTORS CORP.
  7. Remove the J 42504  from the cylinder head.
    Fig 3: Identifying J 42504
    G01819604Courtesy of GENERAL MOTORS CORP.
  8. Install the 4 bolts securing the center transaxle brace to the engine and transaxle.

    Tighten 

    Tighten the center transaxle brace bolts to 50 N.m (37 ft lbs).

    Fig 4: Installing Center Transaxle Brace
    G01819605Courtesy of GENERAL MOTORS CORP.
  9. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.

    Tighten 

    Tighten the vehicle speed sensor heat shield nuts to 50 N.m (37 ft lbs).

    Fig 5: Installing Vehicle Speed Sensor Heat Shield
    G01819606Courtesy of GENERAL MOTORS CORP.
  10. Install the bolts (1, 3) securing the front transaxle brace (2) to the transaxle and right cylinder head.

    Tighten 

    Tighten the front transaxle brace bolts (1, 3) to 50 N.m (37 ft lbs).

    Fig 6: Installing Front Transaxle Brace
    G01819607Courtesy of GENERAL MOTORS CORP.
  11. Position the rear transaxle brace over the studs located at the rear of the right cylinder head.
  12. Loosely install the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
  13. Install the bolt (2) securing the rear transaxle brace (1) to the transaxle.

    Tighten 

    • Tighten the rear transaxle brace bolt (2) to 50 N.m (37 ft lbs).
    • Tighten the rear transaxle brace nuts (3) to 50 N.m (37 ft lbs).
    Fig 7: Installing Rear Transaxle Brace
    G01819608Courtesy of GENERAL MOTORS CORP.
  14. Position the right engine mount bracket (1) to the engine.
  15. Install the 4 bolts securing the right engine mount bracket (1) to the engine.

    Tighten 

    Tighten the right engine mount bracket bolts to 50 N.m (37 ft lbs).

  16. Install the nut (2) securing the power steering pressure hose to the right engine mount bracket (1).

    Tighten 

    Tighten the power steering pressure hose retaining nut to 9 N.m (80 in lbs).

    Fig 8: Installing Right Engine Mount Bracket
    G01819609Courtesy of GENERAL MOTORS CORP.
  17. Install the power steering pressure hose to the power steering pump.

    Tighten 

    Tighten the power steering hose to power steering pump to 30 N.m (22 ft lbs).

    Fig 9: Installing Power Steering Pressure Hose
    G01819610Courtesy of GENERAL MOTORS CORP.
  18. Connect the power steering hose to the power steering pump reservoir.
  19. Install the power steering return hose retaining bolt to the cylinder head.

    Tighten 

    Tighten the power steering return hose retaining bolt to 50 N.m (37 ft lbs).

    Fig 10: Connecting Power Steering Hose To Power steering Pump Reservoir
    G01819611Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine wiring harness to the engine. Refer to COMPONENT LOCATIONS in Engine Controls - 4.0 L
  21. Install the nut (3) securing the coil cassette ground wire to the cylinder head.

    Tighten 

    Tighten the coil cassette ground wire nut to 17 N.m (13 ft lbs).

  22. Install the nut securing the intermediate hose to the secondary AIR valve at bank 1.

    Tighten 

    Tighten the intermediate hose to secondary AIR valve nut to 9 N.m (80 in lbs).

  23. Connect the intermediate hose to the secondary AIR valve at bank 2.
    24. Fig 11: Installing Secondary AIR Valve Hoses & Nuts
    G01819612Courtesy of GENERAL MOTORS CORP.
  24. Install the heater pipes.
  25. Position the engine/transaxle assembly under the vehicle.

    Important:  Ensure clearance is maintained between the engine/transaxle assembly and the following:

    • The A/C accumulator hose
    • The A/C compressor hose
    • The brake pipes
    • The heater hoses
    • The radiator hoses
    • The wheel speed sensor leads
    • The wiring harnesses
  26. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
  27. Install the 6 frame mounting bolts (3) retaining the frame (2) to the vehicle.

    Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.

    Tighten 

    Tighten the frame mounting bolts to 191 N.m (141 ft lbs).

    28. Fig 12: Installing Frame Bolts
    G01819613Courtesy of GENERAL MOTORS CORP.
  28. Install the nut securing the right engine mount to the engine mount bracket.

    Tighten 

    Tighten the right engine mount nut to 80 N.m (59 ft lbs).

  29. Remove the block of wood between the front of the engine oil pan and the engine frame.
    Fig 13: Installing Right Engine Mount Nut
    G01819614Courtesy of GENERAL MOTORS CORP.
  30. Install the nut (1) securing the left transaxle mount to the transaxle mount bracket.

    Tighten 

    Tighten the left transaxle mount nut to 80 N.m (59 ft lbs).

  31. Raise and support the vehicle.
    Fig 14: Installing left Transaxle Nut
    G01819615Courtesy of GENERAL MOTORS CORP.
  32. Remove the J 39580  powertrain support dolly from under the engine frame.
    Fig 15: Identifying J 39580
    G01819616Courtesy of GENERAL MOTORS CORP.

    Important:  Line up the flywheel and converter, using the alignment marks made during disassembly.

  33. Install the bolts securing the flywheel to the torque converter.

    Tighten 

    Tighten the flywheel to torque converter bolts to 60 N.m (44 ft lbs).

  34. Install the torque converter cover. Refer to TRANSAXLE (4T80-E) .
  35. Install the oil pan to transaxle brace.

    Tighten 

    Tighten the oil pan to transaxle brace bolts to 50 N.m (37 ft lbs).

  36. Connect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS HEAT SHIELD REPLACEMENT .
    Fig 16: Installing Brace Between Engine Oil Pan & Transaxle Case
    G01819617Courtesy of GENERAL MOTORS CORP.
    WARNING: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
  37. Connect the intermediate shaft to the steering gear.
  38. Install the pinch bolt.

    Tighten 

    Tighten the intermediate shaft to steering gear pinch bolt to 45 N.m (33 ft lbs).

    Fig 17: Installing Steering Gear From Intermediate Shaft
    G01819618Courtesy of GENERAL MOTORS CORP.
  39. Connect the A/C suction hose to the compressor.

    Tighten 

    Tighten the A/C suction hose nut to 20 N.m (15 ft lbs).

    Fig 18: Connecting A/C Suction Hose
    G01819619Courtesy of GENERAL MOTORS CORP.
  40. Connect the A/C discharge hose to the compressor.

    Tighten 

    Tighten the A/C discharge hose nut to 20 N.m (15 ft lbs).

  41. Connect the A/C pressure sensor.
    Fig 19: Connecting A/C Discharge Hose
    G01819620Courtesy of GENERAL MOTORS CORP.
  42. Connect the 2 rear brake pipes at the rear of the engine frame.

    Tighten 

    Tighten the brake pipes to 15 N.m (11 ft lbs).

    Fig 20: Connecting Rear Brake Pipes
    G01819621Courtesy of GENERAL MOTORS CORP.
  43. Connect the front brake pipes to the retainers at the body frame rails.
  44. Install the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.

    Tighten 

    Tighten the brake pipe frame bracket nuts to 15 N.m (11 ft lbs).

    Fig 21: Locating Front Brake Pipe Frame Bracket Bolts
    G01819622Courtesy of GENERAL MOTORS CORP.
  45. Connect the secondary AIR inlet hose to the secondary AIR pump.
  46. Install the front fascia extensions. Refer to FASCIA EXTENSION REPLACEMENT -- FRONT .
  47. Install the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT -- FRONT .
    Fig 22: Connecting Secondary AIR Inlet Hose
    G01819623Courtesy of GENERAL MOTORS CORP.
  48. Attach the front wheel speed sensor electrical leads (2) to the body frame rail.
    49. Fig 23: Installing Front Wheel Speed Sensor Electrical Leads
    G01819624Courtesy of GENERAL MOTORS CORP.
  49. Install the rear exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT - REAR (L47) .
  50. Install the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
  51. Lower the vehicle ONLY enough to allow the threaded holes in the strut to align with the holes in the strut towers.
  52. Install the right and left side strut tower bolts.

    Tighten 

    Tighten the strut tower bolts to 45 N.m (33 ft lbs).

  53. Lower the vehicle.
    Fig 24: Installing Strut Tower Bolts
    G01819625Courtesy of GENERAL MOTORS CORP.
  54. Remove the J 42640  from the steering column.
    Fig 25: Removing J 42640
    G01819626Courtesy of GENERAL MOTORS CORP.

    Important:  Ensure the transaxle oil cooler pipe is positioned upwards while tightening.

  55. Connect the lower transaxle oil cooler pipe fitting to the radiator.

    Tighten 

    Tighten the transaxle oil cooler pipe fitting to 35 N.m (26 ft lbs).

    Fig 26: Connecting Lower Transaxle Oil Cooler Pipe Fitting To Radiator
    G01819627Courtesy of GENERAL MOTORS CORP.
  56. Install the upper transaxle oil cooler pipe retaining bolt to the fan shroud.

    Tighten 

    Tighten the transaxle oil cooler pipe retaining bolt to 6 N.m (53 in lbs).

    Fig 27: Connecting Upper Transaxle Oil Cooler Pipe From Radiator
    G01819628Courtesy of GENERAL MOTORS CORP.
  57. Push the upper transaxle oil cooler pipe into the radiator quick connect fitting, until a click is heard.
  58. Tug gently on the cooler pipe to ensure proper retention.
  59. Slide the plastic cap (1) over the quick connect fitting.
    Fig 28: Sliding Plastic Cap Over Quick Connect Fitting
    G01819629Courtesy of GENERAL MOTORS CORP.
  60. Install the 2 master cylinder brake pipes (1) to the BPMV (2) using the location recorded during the removal procedure.

    Tighten 

    Tighten the brake pipes to 15 N.m (11 ft lbs).

    Fig 29: Installing Master Cylinder Brake Pipes From BPMV
    G01819630Courtesy of GENERAL MOTORS CORP.
  61. Connect the heater hoses (1, 2) to the heater pipes.
    Fig 30: Connecting Heater Hoses From Heater Pipes
    G01819631Courtesy of GENERAL MOTORS CORP.
  62. Connect the surge tank inlet hose (2) to the surge tank (1).
    Fig 31: Connecting Surge Tank Inlet Hose To Surge Tank
    G01819632Courtesy of GENERAL MOTORS CORP.
  63. Position the J 38185  to the clamp in order to connect the radiator outlet hose (2) to the thermostat housing.
  64. Position the J 37097-A  to the clamp in order to connect the radiator inlet hose (1) to the engine.
    Fig 32: Connecting Radiator Inlet & Outlet Hoses
    G01819633Courtesy of GENERAL MOTORS CORP.
  65. Install the shift cable (1) to the manual shift lever (2) and the bracket.
    Fig 33: Installing Shift Cable To Manual Shift Lever & Bracket
    G01819634Courtesy of GENERAL MOTORS CORP.
    WARNING: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
    In order to avoid cruise control cable damage, position the cable out of the way while you remove or Install the engine. Do not pry or lean against the cruise control cable. You must replace a damaged cable.
  66. Install a NEW accelerator control cable to the throttle body. Refer to THROTTLE BODY .
  67. Install the cruise control cable (2) to the throttle body lever (1).
  68. Slide the cruise control fully into the throttle body bracket until it snaps into place.
    Fig 34: Installing Cruise Control Cable From Throttle Body Bracket & Lever
    G01819635Courtesy of GENERAL MOTORS CORP.
  69. Install the bolt (1) securing the engine ground cable (2) to the right side body frame rail.

    Tighten 

    Tighten the engine ground cable bolt to 50 N.m (37 ft lbs).

    Fig 35: Installing Engine Ground Cable Bolt
    G01819636Courtesy of GENERAL MOTORS CORP.
  70. Connect the wiring harness electrical connectors to the following components:
    Fig 36: Connecting C 101 Wiring Harness Electrical Connector
    G01819637Courtesy of GENERAL MOTORS CORP.
  71. Install the nut (1) securing the battery positive cable to the remote positive terminal.

    Tighten 

    Tighten the battery positive cable to remote positive terminal nut to 12 N.m (106 in lbs).

    Fig 37: Installing Battery Positive Cable Nut
    G01819638Courtesy of GENERAL MOTORS CORP.
  72. Attach the secondary AIR relay (1) to the relay bracket.
  73. Install the air cleaner assembly. .
    Fig 38: Connecting Secondary AIR Relay
    G01819639Courtesy of GENERAL MOTORS CORP.
  74. Connect the hose (4) to the evaporative emission canister purge valve (3).
  75. Connect the fuel inlet and return quick-connect fittings at the fuel rail.
    Fig 39: Connecting Evaporative Emission Canister Purge Valve Hose
    G01819640Courtesy of GENERAL MOTORS CORP.
  76. Connect the vacuum brake booster hose to the vacuum connection.
    Fig 40: Installing Brake Booster Hose
    G01819641Courtesy of GENERAL MOTORS CORP.
  77. Position the intake manifold sight shield (1) to the engine.
  78. Install the 2 intake manifold sight shield nuts (2).

    Tighten 

    Tighten the intake manifold sight shield nuts to 3 N.m (27 in lbs).

  79. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PRO .
  80. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  81. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  82. Bleed the hydraulic brake system. Refer to MANUAL BLEEDING or PRESSURE BRAKE BLEEDING .
  83. Recharge the A/C refrigerant system. Refer to GENERAL MOTORS .
  84. Bleed the power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM .
  85. Measure the wheel alignment. Refer to MEASURING WHEEL ALIGNMENT .
    Fig 41: Installing Intake Manifold Sight Shield
    G01819642Courtesy of GENERAL MOTORS CORP.
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