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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 598 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the right exhaust manifold, the left exhaust manifold, and the exhaust crossover. Refer to or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) and EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8L) in EXHAUST SYSTEM .
  2. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement 
  3. Install the engine lift brackets.
  4. Install the bolts and nuts to the left and the right engine lift bracket.

    Tighten: 

    Tighten the bolts and nuts to 30 N.m (22 lb ft) 

  5. Install the generator brace bracket to the right cylinder head.
  6. Install the generator brace bracket bolts.

    Tighten: 

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

  7. Install the upper intake manifold or the supercharger. Refer to Intake Manifold Replacement - Upper  or to Supercharger Replacement 
  8. Install the EGR valve adapter to the right cylinder head.
  9. Install the bracket to the fuel injector sight shield.
  10. Install the bracket nuts to the fuel injector sight shield.

    Tighten: 

    Tighten the nuts to 30 N.m (22 lb ft) 

    Fig 1: Fuel Injector Sight Shield.
    G01764338Courtesy of GENERAL MOTORS CORP.
  11. Install the A/C compressor bracket and bolts.

    Tighten: 

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

    Fig 2: A/C Compressor Bracket And Bolts
    G01764339Courtesy of GENERAL MOTORS CORP.
  12. Install the engine mount brackets to the left and to the right side. Refer to Engine Mount Strut Bracket Replacement - Left  and to Engine Mount Strut Bracket Replacement - Right Upper (L36) 
  13. Install the ignition control module bracket and the ignition control module. Refer to IGNITION CONTROL MODULE
  14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) 
  15. Install the engine mount bracket. Install the bracket bolts to the right side engine mount.
    16. Fig 3: Bracket Bolts To The Right Side Engine Mount
    G01764340Courtesy of GENERAL MOTORS CORP.
  16. Install the bracket bolts to the left side engine mount.

    Tighten: 

    Tighten the bracket bolts to 102 N.m (75 lb ft) 

    Fig 4: Bracket Bolts To The Left Side Engine Mount.
    G01764341Courtesy of GENERAL MOTORS CORP.
  17. Install the oil indicator tube to the engine. Ensure that the O-ring is in place. Ensure that the oil level indicator tube is fully seated in the engine.

    Tighten: 

    Tighten the nut on the oil level indicator tube to 19 N.m (14 lb ft) 

    Fig 5: Oil Indicator Tube To The Engine
    G01764342Courtesy of GENERAL MOTORS CORP.
  18. Remove the engine from the engine stand.
  19. Install the flywheel. Refer to Engine Flywheel Replacement 
  20. With the aid of an assistant, install the engine to the vehicle.
  21. Install the bolts (2,3,4,5) which secure the upper transaxle to the engine.

    Tighten: 

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

    Fig 6: Upper Transaxle To The Engine Bolts
    G01764343Courtesy of GENERAL MOTORS CORP.
  22. Remove the engine lifting device.
  23. Install the A/C compressor and the A/C compressor nuts to the A/C compressor bracket.

    Tighten: 

    Tighten the nuts to 30 N.m (22 lb ft) 

    Fig 7: A/C Compressor
    G01764344Courtesy of GENERAL MOTORS CORP.
  24. Install the heater hoses to the drive belt tensioner.
  25. Install the radiator outlet hose to the engine. Refer to or RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in ENGINE COOLING .
  26. Install the radiator inlet hose to the engine. Refer to or RADIATOR HOSE REPLACEMENT - INLET (3.8L) in ENGINE COOLING .
  27. Reposition the engine wiring to the engine.
  28. Connect the upper engine electrical connectors to the following components:
    • Manifold absolute pressure (MAP) sensor
    • Exhaust gas recirculation (EGR) valve
    • EVAP purge solenoid
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • Fuel injectors
  29. Install the upper engine wiring harness to the retaining clips.
  30. Install the power steering pump to the engine.

    Tighten: 

    Tighten the power steering bolts to 34 N.m (25 lb ft) 

    Fig 8: Power Steering Pump
    G01764345Courtesy of GENERAL MOTORS CORP.
  31. Connect the A/C vacuum hose to the engine.
  32. Install the vacuum booster hose to the engine. Refer to VACUUM BRAKE BOOSTER CHECK VALVE AND/OR HOSE
  33. Install the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC in ENGINE COOLING .
  34. Connect the positive battery cable.

    Tighten: 

    Tighten the cable terminal nut to 15 N.m (11 lb ft) 

  35. Install the engine mount brackets to the radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support 
  36. Install the engine mount struts to the engine mount strut brackets. Refer to Engine Mount Strut Replacement - Right  or Engine Mount Strut Replacement - Left 
  37. Install the water pump pulley.
  38. Install the water pump pulley bolts.

    Tighten: 

    Tighten the pulley bolts to 13 N.m (116 lb in) 

    Fig 9: Water Pump Pulley And Bolts
    G01764346Courtesy of GENERAL MOTORS CORP.
  39. Install the drive belt.
  40. Install the throttle cable, the cruise control cable, and the bracket to the throttle body.
  41. Connect the fuel vapor line.
  42. Connect the fuel lines (1,2) to the fuel rail.
    43. Fig 10: Fuel Lines
    G01764347Courtesy of GENERAL MOTORS CORP.
  43. Install the throttle body air inlet duct and the air cleaner assembly.
  44. Raise the vehicle and remove the transaxle support.
  45. Install the bolt (6) and the stud (1) which secure the lower transaxle to the engine.

    Tighten: 

    Tighten the bolt and the stud to 75 N.m (55 lb ft) 

  46. Install the engine ground to the transaxle stud.

    Tighten: 

    Tighten the engine ground nut to 35 N.m (26 lb ft) 

    Fig 11: Lower Transaxle To The Engine Bolts
    G01764348Courtesy of GENERAL MOTORS CORP.
  47. Install the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement 
  48. Reposition and connect the electrical connectors to the following components:
    • Heated oxygen (HO2) sensor
    • Knock sensors
    • Oil level sensor
    • Oil pressure sensor
    • Vehicle speed sensor (VSS)
  49. Install the oil level sensor harness retainer to the engine.

    Tighten: 

    Tighten the retainer bolt to 10 N.m (89 lb in) 

  50. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L) in ENGINE EXHAUST .
  51. Install the engine mount lower nuts.

    Tighten: 

    Tighten the nuts to 78 N.m (58 lb ft) 

    Fig 12: Engine Mount Lower Nuts
    G01764349Courtesy of GENERAL MOTORS CORP.
  52. Install the transaxle brace. Refer to AUTOMATIC TRANSMISSION BRACE REPLACEMENT in AUTOMATIC TRANSAXLE-4T65-E
  53. Install the engine flywheel-to-torque converter bolts. Refer to FLYWHEEL TO TORQUE CONVERTER BOLT REPLACEMENT in AUTOMATIC TRANSAXLE-4T65-E
  54. Install the starter motor. Refer to STARTER
  55. Install the torque converter cover. Refer to TORQUE CONVERTER COVER REPLACEMENT in AUTOMATIC TRANSAXLE-4T65-E
  56. Lower the vehicle.
  57. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) 
  58. Install the hood. Refer to HOOD REPLACEMENT in BODY FRONT END
  59. Connect the negative battery cable.
  60. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement 
  61. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  62. Inspect for leaks.
  63. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR SYSTEM VARIATION LEARN PROCEDURE
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