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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 419 (Engine Mechanical - 3.5L (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 to FASTENER NOTICE in Cautions and Notices.

    Important:  The bolt installed in position (5) is two millimeters shorter than the other engine-to-transaxle bolts and requires the use of thread sealant.

  3. Install the bolts attaching the engine to the transaxle.

    Tighten 

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

    Fig 1: Installing Transaxle To Engine Bolts
    G01817000Courtesy of GENERAL MOTORS CORP.
  4. Install the nut (1) securing the front engine mount to the front engine mount bracket.

    Tighten 

    Tighten the front engine mount to bracket nut to 55 N.m (41 lb ft).

    5. Fig 2: Installing Front Engine Mount Nut
    G01817001Courtesy of GENERAL MOTORS CORP.
  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.
  7. Install the bolts securing the transaxle brace to the engine and transaxle.

    Tighten 

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

    Fig 3: Installing Transaxle Brace Bolts
    G01817002Courtesy of GENERAL MOTORS CORP.
  8. Position the right engine mount bracket to the engine.
  9. Install the 3 bolts securing the right engine mount bracket to the engine.

    Tighten 

    Tighten the right engine mount bracket bolts to 60 N.m (44 lb ft).

    Fig 4: Installing Right Engine Mount Bracket
    G01817003Courtesy of GENERAL MOTORS CORP.
  10. Install the power steering pressure hose (1) to the power steering pump.

    Tighten 

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

  11. Install the bolt (2) securing the power steering pressure hose to the secondary AIR valve bracket.

    Tighten 

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

    Fig 5: Installing Power steering Pressure Hose Securing Bolt
    G01817004Courtesy of GENERAL MOTORS CORP.
  12. Connect the power steering return hose to the power steering pump reservoir.
  13. Install the power steering return hose retaining bolt to the cylinder head.

    Tighten 

    Tighten the power steering return hose retaining bolt to 17 N.m (13 lb ft).

  14. Install the secondary air injection crossover pipe/hose.
    15. Fig 6: Removing Secondary Air Injector Crossover Pipe/Hose
    G01816516Courtesy of GENERAL MOTORS CORP.
  15. Connect the engine wiring harness to the engine. Refer to COMPONENT LOCATIONS in Engine Controls-3.5 L.
    Fig 7: Installing Power Steering Return Hose Retaining Bolt
    G01817005Courtesy of GENERAL MOTORS CORP.
  16. 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
    Fig 8: Installing Frame To Body Mounting Bolts
    G01817006Courtesy of GENERAL MOTORS CORP.
  17. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
  18. 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 lb ft).

  19. Install the nut securing the right engine mount to the engine mount bracket.
    Fig 9: Installing Nut Securing Right Engine Mount To Engine Mount Bracket
    G01817007Courtesy of GENERAL MOTORS CORP.

    Tighten 

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

  20. Remove the block of wood between the front of the engine oil pan and the engine frame.
  21. 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 lb ft).

  22. Raise and support the vehicle.
    Fig 10: Removing Nut Securing Left Engine Mount To Engine Mount Bracket
    G01817008Courtesy of GENERAL MOTORS CORP.
  23. Remove the J 39580  powertrain support dolly from under the engine frame.

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

    24. Fig 11: Identifying J 39580
    G01817009Courtesy of GENERAL MOTORS CORP.
  24. Install the bolts securing the flywheel to the torque converter.

    Tighten 

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

  25. Install the torque converter cover. Refer to TRANSAXLE (4T65-E) in Automatic Transaxle-4T65-E.
  26. Connect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS HEAT SHIELD REPLACEMENT in Engine Exhaust.
    CAUTION: 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.
  27. Connect the intermediate shaft to the steering gear.
  28. Install the pinch bolt.

    Tighten 

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

    Fig 12: Connecting Intermediate Shaft To Steering Gear
    G01817010Courtesy of GENERAL MOTORS CORP.
  29. Connect the A/C suction hose to the compressor.

    Tighten 

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

    Fig 13: Connecting A/C Suction Hose From Compressor
    G01817011Courtesy of GENERAL MOTORS CORP.
  30. Connect the A/C discharge hose (3) to the compressor.

    Tighten 

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

  31. Connect the A/C pressure sensor (1).
    Fig 14: Connecting A/C Pressure Sensor & Discharge Hose
    G01817012Courtesy of GENERAL MOTORS CORP.
  32. Connect the 2 rear brake pipes at the rear of the engine frame.

    Tighten 

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

    Fig 15: Locating Rear Brake Pipes At Rear Of Engine Frame
    G01817013Courtesy of GENERAL MOTORS CORP.
  33. Connect the front brake pipes to the retainers at the body frame rails.
  34. 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 lb ft).

    Fig 16: Locating Front Brake Pipe Frame Bracket Nuts
    G01817014Courtesy of GENERAL MOTORS CORP.
  35. Connect the secondary AIR inlet hose to the secondary AIR pump.
  36. Install the front fascia extensions. Refer to FASCIA EXTENSION REPLACEMENT -- FRONT in Bumpers.
  37. Install the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT -- FRONT in Body Front End.
    Fig 17: Connecting Secondary AIR Inlet Hose
    G01817015Courtesy of GENERAL MOTORS CORP.
  38. Attach the front wheel speed sensor electrical leads (2) to the body frame rail.
  39. Install the exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT (LX5) in Engine Exhaust.
  40. Install the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
    Fig 18: Connecting Front Wheel Speed Sensor Electrical Leads
    G01817016Courtesy of GENERAL MOTORS CORP.
  41. Install the transaxle oil cooler pipe bracket bolt to the lower tie bar.

    Tighten 

    Tighten the transaxle oil cooler pipe bracket to lower tie bar bolt to 9 N.m (80 lb in).

    Fig 19: Installing Transaxle Oil Cooler Pipe Bracket Bolt To Lower Tie Bar
    G01817017Courtesy of GENERAL MOTORS CORP.
  42. Lower the vehicle ONLY enough to allow the threaded holes in the strut to align with the holes in the strut towers.
  43. Install the right and left side strut tower bolts.

    Tighten 

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

  44. Lower the vehicle.
    Fig 20: Installing Strut Tower Bolts
    G01817018Courtesy of GENERAL MOTORS CORP.
  45. Remove the J 42640  from the steering column.
    Fig 21: Unlocking steering Column
    G01817019Courtesy of GENERAL MOTORS CORP.
  46. Push the upper (1) and lower (2) transaxle oil cooler pipes into the radiator quick connect fitting, until a click is heard.
  47. Tug gently on the cooler pipe to ensure proper retention.
    Fig 22: Connecting Upper & Lower Transaxle Oil Cooler Pipes From Radiator
    G01817020Courtesy of GENERAL MOTORS CORP.
  48. Slide the plastic caps (1) over the quick connect joints.
    Fig 23: Sliding Plastic Caps Over Quick Connect Joints
    G01817021Courtesy of GENERAL MOTORS CORP.
  49. Align the transaxle oil cooler pipes with the routing features (1, 2) on the fan shroud.
    Fig 24: Aligning Transaxle Oil Cooler Pipes With Routing Features On The Shroud
    G01817022Courtesy of GENERAL MOTORS CORP.
  50. Install the transaxle oil cooler pipe bracket bolt to the fan shroud.

    Tighten 

    Tighten the transaxle oil cooler pipe bracket to fan shroud bolt to 6 N.m (53 lb in).

    Fig 25: Installing Transaxle Oil Cooler Pipe Bracket Bolt From Fan Shroud
    G01817023Courtesy of GENERAL MOTORS CORP.
  51. 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 lb ft).

    Fig 26: Installing Master Cylinder Brake Pipes
    G01817024Courtesy of GENERAL MOTORS CORP.
  52. Position the J 38185  to the clamp in order to connect the heater inlet hose to the water crossover.
    Fig 27: Installing Heater Inlet Hose
    G01817025Courtesy of GENERAL MOTORS CORP.
  53. Position the J 38185  to the clamp in order to connect the heater outlet hose to the thermostat housing.
    Fig 28: Unclamping Heater Outlet Hose
    G01817026Courtesy of GENERAL MOTORS CORP.
  54. Connect the surge tank inlet hose (2) to the surge tank (1).
    Fig 29: Connecting Surge Tank Inlet Hose From Surge Tank
    G01817027Courtesy of GENERAL MOTORS CORP.
  55. Position the J 38185  to the clamp in order to connect the radiator outlet hose (1) to the thermostat housing.
  56. Position the J 38185  to the clamp in order to connect the radiator inlet hose (2) to the engine.
    Fig 30: Connecting Radiator Outlet & Inlet Hoses
    G01817028Courtesy of GENERAL MOTORS CORP.
  57. Insert the transaxle range selector cable into the bracket.
  58. Connect the transaxle range selector cable terminal to the transaxle manual shift lever pin.
    Fig 31: Connecting Transaxle Range Selector Cable Terminal
    G01817029Courtesy of GENERAL MOTORS CORP.
  59. Install the retainer to the transaxle range selector cable mechanism.
  60. Adjust the transaxle range selector cable. Refer to SHIFT CABLE in Automatic Transaxle - 4T65-E.
    Fig 32: Installing Transaxle Range Selector Cable Mechanism Retainer
    G01817030Courtesy 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 and do not kink the cable. You must replace a damaged cable.
  61. Install a NEW accelerator control cable to the throttle body. Refer to THROTTLE BODY in Engine Controls-3.5 L.
  62. Slide the cruise control cable (2) fully into the throttle body bracket until it snaps into place.
  63. Install the cruise control cable (1) to the throttle body lever.
    Fig 33: Installing Cruise Control Cable
    G01817031Courtesy of GENERAL MOTORS CORP.
  64. 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 36 N.m (27 lb ft).

    Fig 34: Installing Engine Ground Cable Bolt
    G01817032Courtesy of GENERAL MOTORS CORP.
  65. Connect the wiring harness electrical connectors to the following components:
    Fig 35: Identifying C101 Wiring Harness Electrical Connector
    G01817033Courtesy of GENERAL MOTORS CORP.
  66. 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 lb in).

    Fig 36: Install Nut Securing Battery Positive Cable To Remote Positive Terminal
    G01817034Courtesy of GENERAL MOTORS CORP.
  67. Attach the secondary AIR relay (1) to the relay bracket.
  68. Install the air cleaner assembly.
    Fig 37: Connecting Secondary AIR Relay
    G01817035Courtesy of GENERAL MOTORS CORP.
  69. Connect the hose (4) to the evaporative emission canister purge valve (3).
  70. Connect the fuel inlet and return quick-connect fittings at the fuel rail.
    Fig 38: Connecting Evaporative Emission Canister Purge Valve Hose
    G01817036Courtesy of GENERAL MOTORS CORP.
  71. Connect the vacuum brake booster hose to the vacuum brake booster.
    Fig 39: Connecting Vacuum Brake Booster Hose
    G01817037Courtesy of GENERAL MOTORS CORP.
  72. Insert the tab of the fuel injector sight shield under the engine bracket.
  73. Lower the fuel injector sight shield, aligning the holes with the studs.
  74. Install the 2 fuel injector sight shield nuts onto the studs.

    Tighten 

    Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

    75. Fig 40: Installing Fuel Injector Sight Shield
    G01817038Courtesy of GENERAL MOTORS CORP.
  75. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PRO in Engine Electrical.
  76. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  77. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  78. Bleed the hydraulic brake system. Refer to MANUAL BLEEDING or PRESSURE BRAKE BLEEDING in Hydraulic Brakes.
  79. Recharge the A/C refrigerant system. Refer to GENERAL MOTORS in Heating, Ventilation and Air Conditioning.
  80. Bleed the power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM in Power Steering System.
  81. Measure the wheel alignment. Refer to MEASURING WHEEL ALIGNMENT in Wheel Alignment.
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