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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 418 (Engine Mechanical - 4.2L 6-Cylinder (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Bravada, 2002 GMC Envoy XL, 2002 GMC Envoy, and 2002 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine from the engine stand.
  2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
  3. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.
  4. Lower the engine onto the mounts and install the upper engine mount nuts.
    NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Tighten 

    Tighten the nuts to 70 N.m (51 lb ft).

  5. Remove the engine hoist.
  6. Lay the radiator into the radiator support, but do not install the radiator completely.
  7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Install all of the lower bell housing bolts, excluding the top four.
  9. Remove the two through bolts securing the transmission support.
  10. Lower the transmission.
  11. Install the top four bell housing bolts.

    Tighten 

    Tighten all eleven bell housing bolts to 50 N.m (37 lb ft).

  12. Raise the transmission.
  13. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
  14. Install the 3 torque converter bolts.

    Tighten 

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

  15. Install the torque converter bolt cover.
  16. Install the fuel tank shield, if removed. Refer to Fuel Tank Shield Replacement in Frame and Underbody.
  17. Install the engine protection shield. Refer to Engine Protection Shield Replacement .
  18. Install the propeller shaft to the front axle pinion yoke. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
  19. Connect the exhaust pipe to the manifold and secure the pipe with the bolts.

    Tighten 

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

    20. Fig 1: Connecting Exhaust Pipe To Manifold
    G01706376Courtesy of GENERAL MOTORS CORP.
  20. Connect the oil level switch electrical connector.
  21. Connect the oil pressure sensor electrical connector.
  22. Install the oil pan drain plug.

    Tighten 

    Tighten the plug to 26 N.m (19 lb ft).

    23. Fig 2: Installing Oil Pan Drain Plug
    G01706377Courtesy of GENERAL MOTORS CORP.
  23. Install the lower radiator hose (1).
    24. Fig 3: Installing Lower Radiator Hose
    G01706378Courtesy of GENERAL MOTORS CORP.
  24. Install the left and right wheel drive shafts. Refer to FRONT DRIVE AXLE - 4WD article.
  25. Lower the vehicle.
  26. Install the 4 grounds on the left side of the block (1).
    27. Fig 4: Installing 4 Grounds On Left Side Of Block
    G01706379Courtesy of GENERAL MOTORS CORP.
  27. Install the camshaft sensor electrical connectors.
  28. Install the crankshaft sensor electrical connector.
  29. Install the knock sensor electrical connector.
  30. Install the generator electrical connector and battery lead (1).

    Tighten 

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

    31. Fig 5: Installing Generator Electrical Connector And Battery Lead
    G01706380Courtesy of GENERAL MOTORS CORP.
  31. Install the A/C pressure sensor and clutch electrical connector.
  32. Install starter electrical connectors and battery lead (1).

    Tighten 

    Tighten the starter battery lead to 9 N.m (80 lb in).

    33. Fig 6: Installing Starter Electrical Connectors And Battery Lead
    G01706381Courtesy of GENERAL MOTORS CORP.
  33. Install the fuel lines at the fuel pressure regulator. Refer to FUEL PRESSURE REGULATOR in Engine Controls - 4.2L.
  34. Install the engine harness bracket and bolt.

    Tighten 

    Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).

    35. Fig 7: Installing Engine Harness Bracket
    G01706382Courtesy of GENERAL MOTORS CORP.
  35. Install the front differential vent hose, to the engine harness bracket.
  36. Install all the harnesses to the engine harness bracket.
  37. Install the PCM. Refer to POWERTRAIN CONTROL MODULE in Engine Controls - 4.2 L.
  38. Install the power brake hose at booster
  39. Install the harness retainer to the original location.
  40. Install the ignition coil harness electrical connectors.
    41. Fig 8: Installing Ignition Coil Harness Electrical Connectors
    G01706383Courtesy of GENERAL MOTORS CORP.
  41. Clip the transmission cooler lines to the right side of the engine block.
    42. Fig 9: Clipping Transmission Cooler Lines To Right Side Of Engine Block
    G01706384Courtesy of GENERAL MOTORS CORP.
  42. Connect the camshaft phaser actuator valve electrical connector.
  43. Connect the front axle actuator electrical connector.
  44. Connect the A/C line at the accumulator.
  45. Install the oxygen sensor electrical connector.
  46. Remove the lift hook J 44220.
    47. Fig 10: Removing Lift Hook
    G01706385Courtesy of GENERAL MOTORS CORP.
  47. Install the AIR adapter and secure the adapter with the studs.

    Tighten 

    Tighten the AIR adapter studs to 25 N.m (18 lb ft).

    48. Fig 11: Installing AIR Adapter
    G01706386Courtesy of GENERAL MOTORS CORP.
  48. Install the transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut.

    Tighten 

    Torque nut to 10 N.m (89 lb in).

    49. Fig 12: Installing Transmission Filler Tube Bracket
    G01706387Courtesy of GENERAL MOTORS CORP.
  49. Install the heater hoses to the heater core.
  50. Install the power steering pump.
    51. Fig 13: Installing Power Steering Pump
    G01706388Courtesy of GENERAL MOTORS CORP.
  51. Install the power steering pump bolts.

    Tighten 

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

  52. Install the drive belt. Refer to Drive Belt Replacement .
  53. Install cooling fan and shroud, tilting the radiator forward for clearance.
  54. Finish installing the radiator. Refer to Radiator Replacement in Engine Cooling.
  55. Install transmission cooler lines together.
  56. Install map Sensor. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR in Engine Controls - 4.2L.
  57. Install the throttle body. Refer to THROTTLE BODY in Engine Controls -4.2 L.
  58. Install the hood latch. Refer to Hood Latch Support Replacement in Body Front End.
  59. Install the head lamp housing. Refer to Headlamp Housing Panel Replacement (Chevy, GMC) or Headlamp Housing Panel Replacement (Olds) in Body Front End.
  60. Install the grill. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) or Grille Replacement (Oldsmobile) in Exterior Trim.
  61. Install the air intake baffle. Refer to Air Intake Baffle Replacement - Radiator in Engine Controls - 4.2 L.
  62. Install the washer solvent container. Refer to Washer Solvent Container Replacement in Wipers/Washer Systems.
  63. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.2 L.
  64. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  65. Install the hood. Refer to Hood Replacement .
  66. Service the engine oil.
  67. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  68. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  69. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 4.2 L, 5.3 L, and 6.0 L.
    IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
    • Disable the ignition system.
    • Crank the engine several times. Listen for unusual noises or evidence that parts are binding.
    • Enable the ignition system.
    • Start the engine and listen for unusual noises.
    • Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    • Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
    • Listen for a sticking lifter and other unusual noises.
    • Inspect for fuel, oil and/or coolant leaks while the engine is running.
    • Perform a final inspection for the proper engine oil and coolant levels.
  70. Close the hood.
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