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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 855 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

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NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. Install the J 41798  to the engine.

    Tighten 

    • Tighten the M8 engine lift bracket bolts to 25 N.m (18 lb ft).
    • Tighten the M10 engine lift bracket bolts to 50 N.m (37 lb ft).
  2. Install an engine hoist to the J 41798  .
  3. Remove the engine from the engine stand.
  4. Install the engine to the vehicle.
  5. Align the engine and transmission.
    Fig 1: Installing J 41798 To Engine
    G02116565Courtesy of GENERAL MOTORS CORP.
  6. Install the left and right engine mount-to-engine mount bracket bolts.

    Tighten 

    Tighten the engine mount-to-engine mount bracket bolts to 65 N.m (48 lb ft).

  7. Install the upper transmission bolts until snug.
  8. Remove the floor jack from under the transmission.
  9. Remove the engine hoist.
    Fig 2: Installing Left & Right Engine Mount-To-Engine Mount Bracket Bolts
    G02116566Courtesy of GENERAL MOTORS CORP.
  10. Remove the J 41798  from the engine.
    Fig 3: Removing J 41798 From Engine
    G02116567Courtesy of GENERAL MOTORS CORP.
  11. Install the ignition coils and the spark plug wires. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
  12. Raise the vehicle.
    Fig 4: Installing Ignition Coils & Spark Plug Wires
    G02116568Courtesy of GENERAL MOTORS CORP.
  13. Remove the J 21366  from the transmission.
  14. Install the automatic transmission bolt/studs.
    Fig 5: Installing Automatic Transmission Bolt/Studs
    G02116569Courtesy of GENERAL MOTORS CORP.
  15. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.
    Fig 6: Installing Transmission Converter Cover Bolts
    G02116570Courtesy of GENERAL MOTORS CORP.
  16. If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side.

    Tighten 

    Tighten the automatic transmission bolts/studs to 50 N.m (37 lb ft).

    Fig 7: Installing Transmission Bolt & Stud On Right Side
    G02116571Courtesy of GENERAL MOTORS CORP.
  17. Install the automatic transmission oil level indicator tube.
    Fig 8: Installing Automatic Transmission Oil Level Indicator Tube
    G02116572Courtesy of GENERAL MOTORS CORP.
  18. Install the automatic transmission oil level indicator tube nut.

    Tighten 

    Tighten the nut to 18 N.m (13 lb ft).

    Fig 9: Installing Automatic Transmission Oil Level Indicator Tube Nut
    G02116573Courtesy of GENERAL MOTORS CORP.
  19. Install the flywheel to torque converter bolts.

    Tighten 

    • If equipped with a 4L60E transmission, tighten the bolts to 63 N.m (47 lb ft).
    • If equipped with a 4L80E transmission, tighten the bolts to 60 N.m (44 lb ft).
    Fig 10: Installing Flywheel To Torque Converter Bolts
    G02116574Courtesy of GENERAL MOTORS CORP.
  20. Install the positive battery cable clip and bolt.

    Tighten 

    Tighten the bolt to 9 N.m (80 lb in).

  21. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (4.8L AND 5.3L ENGINES) or CATALYTIC CONVERTER REPLACEMENT (6.0L AND 8.1L ENGINES) in Engine Exhaust.
  22. Install the starter motor. Refer to STARTER MOTOR in Engine Electrical.
    Fig 11: Installing Positive Battery Cable Clip & Bolt
    G02116575Courtesy of GENERAL MOTORS CORP.
  23. Install the oil pan skid plate and bolts, if equipped.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

    Fig 12: Installing Oil Pan Skid Plate & Bolts
    G02116576Courtesy of GENERAL MOTORS CORP.
  24. Install the engine shield and bolts.

    Tighten 

    Tighten the bolts to 20 N.m (15 lb ft).

  25. Lower the vehicle.
    Fig 13: Installing Engine Shield & Bolts
    G02116577Courtesy of GENERAL MOTORS CORP.
  26. Install the vacuum brake booster hose.
    Fig 14: Installing Vacuum Brake Booster Hose
    G02116578Courtesy of GENERAL MOTORS CORP.
  27. Position the generator bracket to the front of the engine.
  28. Install the generator bracket bolts until snug.
  29. Install the rear power steering pump-to-engine block bolt until snug.

    Tighten 

    • Tighten the rear power steering pump bolt to 50 N.m (37 lb ft).
    • Tighten the generator bracket bolts to 50 N.m (37 lb ft).
  30. Route the engine wiring harness to the lower engine area.
  31. Raise the vehicle.
    Fig 15: Installing Generator Bracket & Bolts
    G02116579Courtesy of GENERAL MOTORS CORP.
  32. Slide the channel pin into the oil pan tab.
  33. Install the battery cable channel bolt.

    Tighten 

    Tighten the bolt to 12 N.m (106 lb in).

    Fig 16: Installing Battery Cable Channel Bolt
    G02116580Courtesy of GENERAL MOTORS CORP.
  34. Connect the following electrical connectors:
    • The CKP sensor (1)
    • The engine oil level sensor (6)
    • The coolant heater, if equipped
  35. Lower the vehicle.
  36. Connect the fuel pipes.
    Fig 17: Connecting CKP Sensor, Coolant Heater & Engine Oil Level Sensor
    G02116581Courtesy of GENERAL MOTORS CORP.
  37. Install the EVAP purge solenoid vent tube to the solenoid (1).
  38. Install the EVAP tube end (3) to the vapor pipe.
    Fig 18: Installing EVAP Tube End To Solenoid & Vapor Pipe
    G02116582Courtesy of GENERAL MOTORS CORP.
  39. Install the battery cable junction block to the junction block bracket.
  40. Clip all of the engine wiring harness clips to their correct location.
    Fig 19: Installing Battery Cable Junction Block To Junction Block Bracket
    G02116583Courtesy of GENERAL MOTORS CORP.
  41. Connect the following electrical connectors:
    • The oil pressure sensor (1)
    • The CMP sensor (2)
  42. Position the harness ground and the engine ground strap to the block.
  43. Install the harness ground bolt at the left rear of the engine block.
  44. Position the harness ground, and auxiliary negative battery cable, if equipped to the block.
  45. Install the harness ground bolt at the right rear of the engine block.

    Tighten 

    Tighten the bolts to 16 N.m (12 lb ft).

    Fig 20: Connecting CMP Sensor & Oil Pressure Sensor
    G02116584Courtesy of GENERAL MOTORS CORP.
  46. Connect the following electrical connectors:
    • The coolant temperature sensor (1)
    • The electronic variable orifice switch (2)
  47. Position the harness ground and negative battery cable to the block.
  48. Install the harness ground bolt.

    Tighten 

    Tighten the bolt to 25 N.m (18 lb ft).

    Fig 21: Connecting Coolant Temperature Sensor & Electronic Variable Orifice Switch
    G02116585Courtesy of GENERAL MOTORS CORP.
  49. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.
    Fig 22: Connecting MAP Sensor & Knock Sensor Electrical Connectors
    G02116586Courtesy of GENERAL MOTORS CORP.
  50. Connect the following electrical connectors:
    • The main coil harness (1)
    • The fuel injectors (3)
    Fig 23: Connecting Main Coil Harness & Fuel Injectors
    G02116587Courtesy of GENERAL MOTORS CORP.
  51. Connect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.
    Fig 24: Connecting Main Coil Harness & Fuel Injector Electrical Connectors On Left Side
    G02116588Courtesy of GENERAL MOTORS CORP.
  52. Install the generator cable to the generator, perform the following:
    1. 52.1. Install the generator cable.
    2. 52.2. Install the generator cable nut to the terminal stud.

      Tighten 

      Tighten the nut to 9 N.m (80 lb in).

    3. 52.3. Slide the boot over the terminal stud.
    Fig 25: Installing Generator Cable To Generator
    G02116589Courtesy of GENERAL MOTORS CORP.
  53. Install the radiator vent inlet hose to the throttle body.
  54. Position the vent inlet hose clamp at the throttle body.
    Fig 26: Installing Radiator Vent Inlet Hose To Throttle Body
    G02116590Courtesy of GENERAL MOTORS CORP.
  55. Install the engine wiring harness bracket and nut (2).

    Tighten 

    Tighten the nut to 5 N.m (44 lb in).

  56. Connect the following electrical connectors:
    • The EVAP canister purge solenoid (1)
    • The Generator (3)
    • The ETC
    Fig 27: Connecting EVAP Canister Purge Solenoid, Generator & ETC
    G02116591Courtesy of GENERAL MOTORS CORP.
  57. If equipped with the 6.0L with RPO LQ9, perform the following:
    1. 57.1. Install the right fuel rail cover.
    2. 57.2. Tighten the right fuel rail cover bolts.

      Tighten 

      Tighten the bolts to 9 N.m (80 lb in).

    3. 57.3. Install the left fuel rail cover.
    4. 57.4. Tighten the left fuel rail cover bolts.

      Tighten 

      Tighten the bolts to 9 N.m (80 lb in).

    5. 57.5. Install the sight shield to the retainer.
    6. 57.6. Tighten the intake manifold sight shield bolt.

      Tighten 

      Tighten the bolt to 9 N.m (80 lb in).

    Fig 28: Installing Sight Shield To The Retainer - 6.0L With RPO LQ9
    G02116592Courtesy of GENERAL MOTORS CORP.
  58. If equipped with the 4.8L, 5.3L, or 6.0L with RPO LQ4, install the engine sight shield to the retainer.
  59. Tighten the engine sight shield bolt.

    Tighten 

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

  60. Install the heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET (UTILITY LR4, LM7, LQ4) or HEATER HOSE REPLACEMENT - INLET (AVALANCHE/XIT LR4, LM7, LQ4) or HEATER HOSE REPLACEMENT - OUTLET (UTILITY LR4, LM7, LQ4) or HEATER HOSE REPLACEMENT - OUTLET (AVALANCHE/XIT LR4, LM7, LQ4) in HEATING, VENTILATION AND AIR CONDITIONING .
    Fig 29: Installing Sight Shield To The Retainer - 4.8L, 5.3L, or 6.0L with RPO LQ4
    G02116593Courtesy of GENERAL MOTORS CORP.
  61. Install the radiator outlet hose to the water pump.
  62. Position the radiator outlet hose clamp at the water pump.
    Fig 30: Installing Radiator Outlet Hose To Water Pump
    G02116594Courtesy of GENERAL MOTORS CORP.
  63. Install the radiator inlet hose to the water pump.
  64. Position the radiator inlet hose clamp at the water pump.
  65. Install the radiator supports. Refer to RADIATOR SUPPORT REPLACEMENT in Body Front End.
  66. Install the A/C compressor. Refer to COMPRESSOR REPLACEMENT (LR4, LM7, AND LQ4) in HVAC System - Manual.
    Fig 31: Installing Radiator Inlet Hose To Water Pump
    G02116595Courtesy of GENERAL MOTORS CORP.
  67. Remove the hood hinge bolts from the service position (2).
  68. Lower the hood to the normal position.
  69. Install the hood hinge bolts.

    Tighten 

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

  70. Remove the fender covers.
  71. Perform the engine prelubing procedure. Refer to ENGINE PRELUBING  .
  72. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE in Engine Controls - 4.8L, 5.3L, and 6.0L.
    Fig 32: Installing Hood Hinge & Bolts
    G02116596Courtesy of GENERAL MOTORS CORP.

    Important:  After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

    1. 72.1. Disable the ignition system.
    2. 72.2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
    3. 72.3. Enable the ignition system.
    4. 72.4. Start the engine and listen for unusual noises.
    5. 72.5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    6. 72.6. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
    7. 72.7. Listen for sticking lifter and other unusual noises.
    8. 72.8. Inspect for fuel, oil and/or coolant leaks while the engine is running.
    9. 72.9. Perform a final inspection for the proper engine oil and coolant levels.
  73. Close the hood.
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