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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 429 (Engine Mechanical - 1.8L (LNK)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the engine and transaxle assembly.
  2. Temporarily install the 6 crossmember bolts.
    Fig 1: Installing Crossmember Bolts
    G01546443Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the 5 bolts and 2 nuts from the right side engine mount, then remove the engine lift.

    Tighten 

    Tighten the right side engine mount nuts and bolts to 52 N.m (38 Ib. ft).

    Fig 2: Installing Bolts & Nuts From Right Side Engine Mount
    G01546444Courtesy of GENERAL MOTORS CORP.
  4. Install the left side mounting insulator bolt and nut.

    Tighten 

    Tighten the left side mounting insulator nut and bolt 80 N.m (60 Ib. ft).

    Fig 3: Installing left Side Mounting Insulator Bolt & Nut
    G01546445Courtesy of GENERAL MOTORS CORP.
  5. Align the right side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).
    Fig 4: Installing Right Side Of Crossmember
    G01546446Courtesy of GENERAL MOTORS CORP.
  6. Align the left side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).

    Tighten 

    Tighten the right and left side bolts (1) to 157 N.m (116 Ib. ft).

    Tighten 

    Tighten the right and left side bolts (2) to 113 N.m (83 Ib. ft).

    Fig 5: Installing Left Side Of Crossmember
    G01546447Courtesy of GENERAL MOTORS CORP.
  7. Install the crossmember rear bolts and tighten.

    Tighten 

    Tighten the crossmember rear bolts to 39 N.m (29 Ib. ft).

    Fig 6: Installing Crossmember Rear Bolts
    G01546448Courtesy of GENERAL MOTORS CORP.
  8. Connect the lower control arm assembly.

    Tighten 

    Tighten the nuts and the bolt to 89 N.m (65.6 Ib. ft).

  9. Connect the front stabilizer link assembly.

    Tighten 

    Tighten the nut to 74 N.m (54.6 Ib. ft).

  10. Install the left side tie rod end.

    Tighten 

    Tighten the outer tie rod nut to 49 N.m (36.1 Ib. ft). Align the cotter pin slot by tightening the outer tie rod nut up to 1/6 additional turn, or 70 N.m (52 Ib. ft) maximum. Do not loosen the nut in order to insert the cotter pin.

  11. Install the drive shaft lock nut.

    Tighten 

    Tighten the nut to 216 N.m (159 Ib. ft).

  12. Install the front exhaust pipe. Refer to FRONT PIPE REPLACEMENT .
  13. Connect the power steering lines (1), then refill the power steering system. Refer to CHECKING AND ADDING POWER STEERING FLUID .
    Fig 7: Connecting Power Steering Lines
    G01546449Courtesy of GENERAL MOTORS CORP.
  14. If equipped with AWD, install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - TWO PIECE .
  15. Install the left side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - LEFT .
  16. Install the right side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - RIGHT .
  17. Lower the vehicle.
  18. Connect the 3 engine compartment relay box connectors.
    Fig 8: Connecting Engine Compartment Relay Box Connectors
    G01546450Courtesy of GENERAL MOTORS CORP.
  19. Install the engine relay box cover.
  20. Install 1 clutch slave cylinder line bracket retaining bolt.
  21. Install 1 clutch slave cylinder line retaining bolt.
  22. Install 2 clutch slave cylinder bolts.
  23. If equipped with automatic transaxle, install the shift cable to the transaxle.
    1. 23.1. Install the shift cable nut.
    2. 23.2. Clip the cable to the mounting bracket.
    Fig 9: Installing Shift Cable To Transaxle
    G01546451Courtesy of GENERAL MOTORS CORP.
  24. If equipped with manual transaxle, connect the transaxle control cables to the transaxle.
    1. 24.1. Connect the transaxle control cables (2) to the transaxle.
    2. 24.2. Clip the cable (1) to the mounting bracket.
    Fig 10: Connecting Transaxle Control Cables
    G01546452Courtesy of GENERAL MOTORS CORP.
  25. Connect the clutch actuator cylinder. Refer to CLUTCH ACTUATOR CYLINDER REPLACEMENT .
  26. Connect the ground cable to the engine.
  27. Connect the ground cables to the transaxle.
  28. Connect the 2 wire harness clamps.
    Fig 11: Connecting Ground Cables
    G01546453Courtesy of GENERAL MOTORS CORP.
  29. Install the radiator. Refer to RADIATOR REPLACEMENT .
  30. Install the generator. Refer to GENERATOR .
  31. Install the accessory drive belt. Refer to Drive Belt Replacement .
  32. Install the radiator inlet hose. Refer to RADIATOR HOSE REPLACEMENT - INLET .
  33. Install the radiator outlet hose. Refer to RADIATOR HOSE REPLACEMENT - OUTLET .
  34. Connect the brake booster vacuum hose to the brake booster.
  35. Connect the heater hose to the water hose union on the cylinder head.
  36. Connect the heater hose to the water by-pass pipe.
  37. Connect the fuel tube to the fuel pipe
  38. Install the fuel tube clamp.
  39. Install the air cleaner case.

    Tighten 

    Tighten the bolts to 7 N.m (62 Ib. in).

  40. Install the air filter.
  41. Install the air cleaner cover.
  42. Connect the accelerator cable.
  43. Refill the engine oil.
  44. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  45. If the vehicle is equipped with A/C, position the A/C compressor and install the A/C compressor bolts. Refer to Compressor Replacement on page 1-19  in Heating, Ventilation, and Air Conditioning.
  46. Install the accessory drive belt. Refer to Drive Belt Replacement .
  47. Install the steering shaft coupling. Refer to STEERING SHAFT COUPLING REPLACEMENT .
  48. Pull the engine harness wire through the passenger compartment.
  49. Connect the 3 cowl wire electrical connectors from the connector mounting bracket.
  50. Connect the 2 ECM connectors.
  51. Install the battery. Refer to BATTERY REPLACEMENT .
  52. Install the engine cover (1).
    Fig 12: Installing Engine Cover
    G01546454Courtesy of GENERAL MOTORS CORP.
  53. Start the engine and check for fluid leaks.
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