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 419 (Engine Mechanical - 3.5L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Removal Procedure

Removal 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. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PRO in Engine Electrical.
  2. Recover the A/C refrigerant system. Refer to GENERAL MOTORS in Heating, Ventilation and Air Conditioning.
  3. Disconnect the vacuum brake booster hose from the vacuum brake booster and secure to the top of the engine.
  4. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille.
    Fig 1: Disconnecting Vacuum Brake Booster Hose
    G01816962Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the hose (4) from the evaporative emission canister purge valve (3) and secure to the air inlet grille.
    6. Fig 2: Disconnecting Evaporative Emission Canister Purge Valve Hose
    G01816963Courtesy of GENERAL MOTORS CORP.
  6. Remove the air cleaner assembly.
  7. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
  8. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.
    Fig 3: Removing Fuel Injector Sight Shield
    G01816964Courtesy of GENERAL MOTORS CORP.
  9. Remove the nut (1) securing the battery positive cable to the remote positive terminal and secure to the top of the engine.
    Fig 4: Removing Battery Positive Cable To Remote Positive Terminal Nut
    G01816965Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the secondary AIR relay (1) from the relay bracket and secure to the top of the engine.
    Fig 5: Disconnecting Secondary AIR Relay
    G01816966Courtesy of GENERAL MOTORS CORP.
  11. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:
    Fig 6: Identifying C101 Wiring Harness Electrical Connector
    G01816967Courtesy of GENERAL MOTORS CORP.
  12. Remove the bolt (1) securing the engine ground cable (2) from the right side body frame rail.
    Fig 7: Removing Engine Ground Cable Bolt
    G01816968Courtesy 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.
  13. Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever.
  14. Remove the accelerator control cable from the throttle body. Refer to THROTTLE BODY in Engine Controls-3.5 L.
    Fig 8: Removing Cruise Control Cable
    G01816969Courtesy of GENERAL MOTORS CORP.
  15. Set the park brake and chock the wheels.
  16. Fully lift the retainer from the transaxle range selector cable mechanism.
    Fig 9: Lifting Transaxle Range Selector Cable Mechanism Retainer
    G01816970Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the transaxle range selector cable terminal from the transaxle manual shift lever pin.
    18. Fig 10: Disconnecting Transaxle Range Selector Cable Terminal
    G01816971Courtesy of GENERAL MOTORS CORP.
  18. Press the locking tabs inward in order to release the transaxle range selector cable from the bracket.
  19. Remove the transaxle range selector cable and position aside.
  20. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  21. Position the J 38185  to the clamp in order to remove the radiator inlet hose (2) from the water housing crossover and position aside.
  22. Position the J 38185  to the clamp in order to remove the radiator outlet hose (1) from the thermostat housing and position aside.
    Fig 11: Clamping Radiator Outlet & Inlet Hoses
    G01816972Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the surge tank inlet hose (2) from the surge tank (1).
    Fig 12: Disconnecting Surge Tank Inlet Hose From Surge Tank
    G01816973Courtesy of GENERAL MOTORS CORP.
  24. Position the J 38185  to the clamp in order to remove the heater outlet hose from the thermostat housing.
    Fig 13: Clamping Heater Outlet Hose
    G01816974Courtesy of GENERAL MOTORS CORP.
  25. Position the J 38185  to the clamp in order to remove the heater inlet hose from the water crossover.
    Fig 14: Removing Heater Inlet Hose
    G01816975Courtesy of GENERAL MOTORS CORP.
    WARNING: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
    • Eye contact-rinse thoroughly with water.
    • Skin contact-wash with soap and water.
    • If ingested-consult a physician immediately.

    Important:  Record the location of the brake pipes to the brake pressure modulator valve (BPMV) for use as an aid during installation.

  26. Remove the two master cylinder brake pipes (1) from the BPMV (2).

    Plug the open outlet ports to prevent fluid loss and contamination.

    Fig 15: Removing Master Cylinder Brake Pipes
    G01816976Courtesy of GENERAL MOTORS CORP.
  27. Remove the transaxle oil cooler pipe bracket bolt from the fan shroud.
    Fig 16: Removing Transaxle Oil Cooler Pipe Bracket Bolt From Fan Shroud
    G01816977Courtesy of GENERAL MOTORS CORP.
  28. Slide the plastic cap off the transaxle oil cooler pipe quick connect fittings.
  29. Disconnect the upper (1) and lower (2) transaxle oil cooler pipes from the radiator using the J 41623-B. 
    Fig 17: Disconnecting Upper & Lower Transaxle Oil Cooler Pipes From Radiator
    G01816978Courtesy of GENERAL MOTORS CORP.
    CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
  30. Lock the steering column by installing the J 42640  into the underside of the steering column.
    Fig 18: Locking steering Column
    G01816979Courtesy of GENERAL MOTORS CORP.
  31. Remove the right and left side strut tower bolts.
  32. Raise and support the vehicle.
    Fig 19: Removing Strut Tower Bolts
    G01816980Courtesy of GENERAL MOTORS CORP.
  33. Remove the transaxle oil cooler pipe bracket bolt from the lower tie bar.
    34. Fig 20: Removing Transaxle Oil Cooler Pipe Bracket Bolt From Lower Tie Bar
    G01816981Courtesy of GENERAL MOTORS CORP.
  34. Remove the exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT (LX5) in Engine Exhaust.
  35. Remove the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  36. Disconnect the front wheel speed sensor electrical leads (2) from the body frame rail.
    37. Fig 21: Disconnecting Front Wheel Speed Sensor Electrical Leads
    G01816982Courtesy of GENERAL MOTORS CORP.
  37. Remove the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT -- FRONT in Body Front End.
  38. Remove the front fascia extensions. Refer to FASCIA EXTENSION REPLACEMENT -- FRONT in Bumpers.
  39. Disconnect the secondary AIR inlet hose from the secondary AIR pump.
    Fig 22: Disconnecting Secondary AIR Inlet Hose
    G01816983Courtesy of GENERAL MOTORS CORP.
  40. Loosen the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.
  41. Disconnect the front brake pipes from the retainers at the body frame rails.
  42. Carefully pull the front brake pipes away from the body frame rails.
    Fig 23: Locating Front Brake Pipe Frame Bracket Nuts
    G01816984Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the 2 rear brake pipes at the rear of the engine frame.

    Plug the open outlet ports to prevent fluid loss and contamination.

    Fig 24: Locating Rear Brake Pipes At Rear Of Engine Frame
    G01816985Courtesy of GENERAL MOTORS CORP.
  44. Disconnect the A/C pressure sensor (1).
  45. Disconnect the A/C discharge hose (3) from the compressor and secure to the cooling fan assembly.
    Fig 25: Disconnecting A/C Pressure Sensor & Discharge Hose
    G01816986Courtesy of GENERAL MOTORS CORP.
  46. Disconnect the A/C suction hose from the compressor and secure to the cooling fan assembly.
    Fig 26: Disconnecting A/C Suction Hose From Compressor
    G01816987Courtesy of GENERAL MOTORS CORP.
    WARNING: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.
  47. Remove the intermediate shaft pinch bolt.
  48. Remove the steering gear from the intermediate shaft.
    49. Fig 27: Removing Steering Gear From Intermediate Shaft
    G01816988Courtesy of GENERAL MOTORS CORP.
  49. Disconnect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS HEAT SHIELD REPLACEMENT in Engine Exhaust.
  50. Remove the torque converter cover. Refer to TRANSAXLE (4T65-E) in Automatic Transaxle-4T65-E.

    Important:  Mark the flywheel to torque converter relationship prior to removal of the bolts.

  51. Remove the torque converter to the flywheel bolts.
  52. Position the J 39580  powertrain support dolly under the engine frame.
  53. Lower the vehicle on to the J 39580. 
    Fig 28: Identifying J 39580
    G01816989Courtesy of GENERAL MOTORS CORP.
  54. If the powertrain support dolly is unavailable. Support the powertrain with 4 suitable jackstands.
    Fig 29: Supporting Powertrain Using Jackstands
    G01816990Courtesy of GENERAL MOTORS CORP.
  55. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.
  56. Remove the nut securing the right engine mount to the engine mount bracket.
    Fig 30: Removing Nut Securing Right Engine Mount To Engine Mount Bracket
    G01816991Courtesy of GENERAL MOTORS CORP.
  57. Remove the nut (1) securing the left transaxle mount to the transaxle mount bracket.
    WARNING: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
    58. Fig 31: Removing Nut Securing Left Engine Mount To Engine Mount Bracket
    G01816992Courtesy of GENERAL MOTORS CORP.
  58. Secure the front hoist pads to the vehicle.
  59. Remove the 6 frame to body mounting bolts (3).

    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
    60. Fig 32: Removing Frame To Body Mounting Bolts
    G01816993Courtesy of GENERAL MOTORS CORP.
  60. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
  61. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  62. Remove the secondary air injection crossover pipe/hose.
    63. Fig 33: Removing Secondary Air Injector Crossover Pipe/Hose
    G01816516Courtesy of GENERAL MOTORS CORP.
  63. Disconnect the engine wiring harness from the engine. Refer to COMPONENT LOCATIONS in Engine Controls-3.5 L.
  64. Disconnect the power steering return hose from the power steering pump reservoir.
  65. Remove the power steering return hose retaining bolt from the cylinder head.
    Fig 34: Removing Power Steering Return Hose Retaining Bolt
    G01816994Courtesy of GENERAL MOTORS CORP.
  66. Remove the power steering pressure hose (1) from the power steering pump.
  67. Remove the bolt (2) securing the power steering pressure hose to the secondary AIR valve bracket.
    Fig 35: Removing Power steering Pressure Hose Securing Bolt
    G01816995Courtesy of GENERAL MOTORS CORP.
  68. Remove the 3 bolts securing the right engine mount bracket to the engine.
  69. Remove the right engine mount bracket.
    Fig 36: Removing Right Engine Mount Bracket
    G01816996Courtesy of GENERAL MOTORS CORP.
  70. Remove the bolts securing the transaxle brace to the engine and transaxle.
  71. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.
    Fig 37: Removing Transaxle Brace Bolts
    G01816997Courtesy of GENERAL MOTORS CORP.
  72. Remove the nut (1) securing the front engine mount to the front engine mount bracket.
    Fig 38: Removing Front Engine Mount Nut
    G01816998Courtesy of GENERAL MOTORS CORP.
  73. Remove the bolts attaching the engine to the transaxle.
    74. Fig 39: Removing Transaxle To Engine Bolts
    G01816999Courtesy of GENERAL MOTORS CORP.
  74. Raise the engine from the supported frame and transaxle assembly.
  75. Remove the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front .
scientia non olet · About LEMON Manuals