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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 721 (Engine Mechanical - 8.1L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of J 36857 At Right Cylinder Head
    GM66457Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. Attach J 36857  to the rear of the right cylinder head and to the front of the left cylinder head.
  2. Install the attaching bolt and washer. Use GM P/N 9428217 with GM P/N 15650963.

    Tighten:  Tighten the lift bracket bolts to 40 N.m (30 lb ft).

    3. Fig 2: A/C Compressor/Power Steering Pump Bracket
    GM746257Courtesy of GENERAL MOTORS CORP.
  3. Install the air compressor/power steering mounting bracket to the engine block.

    Tighten:  Tighten the power steering pump bracket bolts and nut to 50 N.m (37 lb ft).

  4. Install the generator bracket. Refer to GENERATOR (8.1L ENGINE) .
  5. Remove the engine using a suitable lifting devise.
  6. Install the engine into the vehicle.
    7. Fig 3: View Of Engine Mount-To-Engine Mount Bracket
    GM750192Courtesy of GENERAL MOTORS CORP.
  7. Install the engine mount to engine mount bracket bolts.
    8. Fig 4: View Of Engine Mount Heat Shield
    GM750194Courtesy of GENERAL MOTORS CORP.
  8. Install the engine mount heat shield and bolts.
  9. Remove the engine lift hooks from the cylinder heads.
  10. Raise the vehicle and support with safety stands.
  11. Install the engine oil cooler lines to the engine block. Refer to ENGINE OIL COOLER HOSE/PIPE REPLACEMENT (6.0L AND 8.1L ENGINES) in Engine Cooling.
    12. Fig 5: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  12. Install the bolts from the transmission to the engine. For 4L80-E, refer to TRANSMISSION .
  13. Install the torque converter bolts.
  14. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (6.0L AND 8.1L ENGINES) in Engine Exhaust.
  15. Install the exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT (6.0L, AND 8.1L ENGINES) in Engine Exhaust.
  16. Install the hoses to the power steering pump. Refer to POWER STEERING COOLER PIPE/HOSE REPLACEMENT (WITHOUT HYDROBOOST) or POWER STEERING COOLER PIPE/HOSE REPLACEMENT (WITH HYDROBOOST) in Power Steering System.
  17. Install the starter motor. Refer to STARTER in Engine Electrical.
  18. Lower the vehicle.
  19. Route the engine electrical harness.
  20. Install the generator. Refer to GENERATOR (8.1L ENGINE) .
    21. Fig 6: View Of Ground Cable Bolt At Engine Block
    GM663475Courtesy of GENERAL MOTORS CORP.
  21. Install the ground cable bolt at the engine block.

    Tighten:  Tighten the engine wiring harness bolt to 16 N.m (12 lb ft).

  22. Install the EGR valve adapter. Refer to EGR VALVE .
  23. Install the vacuum lines to the engine.
    24. Fig 7: TAC Module Electrical Connector
    GM751290Courtesy of GENERAL MOTORS CORP.
  24. Connect the TAC module electrical connector (1).
  25. Install the radiator. Refer to RADIATOR REPLACEMENT in Engine Cooling.
  26. Install the A/C compressor. Refer to COMPRESSOR .
    27. Fig 8: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
  28. Install the ignition coils. Refer to IGNITION COILS .
    29. Fig 9: View Of Battery Cables
    GM662092Courtesy of GENERAL MOTORS CORP.
  29. Connect the positive battery cable.
  30. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) or BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY) .
    31. Fig 10: View Of Air Cleaner Outlet Duct
    GM700979Courtesy of GENERAL MOTORS CORP.
  31. Install the air cleaner outlet duct.
  32. Tighten the clamps at the throttle body and air cleaner.
  33. Remove fender covers from both fenders.
    34. Fig 11: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  34. Remove the hood hinge bolts from the service position (2).
  35. Lower the hood to the normal position.
  36. Install the hood hinge bolts.

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

  37. Before starting a new engine or one that has been repaired, complete the following procedure.
    1. Fill the engine with the proper quantity and grade of oil.
    2. Add engine oil supplement GM U.S. P/N 1052367, Canada P/N 992869, or equivalent to the engine oil.
    3. Remove the fuel pump fuse and disconnect the coil harness connectors, then crank the engine until oil pressure is present.
    4. Crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
    5. Install the fuel pump fuse and connect the coil harness connectors and start the engine and listen for unusual noises.
    6. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure. If necessary install an oil pressure gauge and measure the oil pressure.
    7. Run the engine at about 1000 RPM's until the engine has reached normal operating temperature.
    8. Inspect for oil and or coolant leaks while the engine is running.
    9. Stop the engine and perform a final inspection for the proper engine oil and coolant levels.
    10. The final step is to perform the crankshaft position (CKP) sensor variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR SYSTEM VARIATION LEARN PROCEDURE .
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