Chevrolet Blazer/Jimmy 1969-1982 Repair Guide

Engine

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REMOVAL & INSTALLATION



Gasoline Engines
1969-76 MODELS
  1. Disconnect the negative battery cable, then the positive battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Scribe matchmarks on the hood hinges for reassembly and remove the hood.
  8.  
  9. Remove the radiator and fan shroud as outlined later in this section.
  10.  
  11. Disconnect and label (to avoid confusion) the wires at the following locations:
  12.  
    1. starter solenoid
    2.  
    3. alternator
    4.  
    5. temperature sending switch
    6.  
    7. oil pressure sending switch
    8.  
    9. coil
    10.  
    11. vacuum advance solenoid and/or the CEC solenoid
    12.  
    13. TCS solenoid (V8, if so equipped)
    14.  

  13. Disconnect the:
  14.  
    1. accelerator linkage at the manifold
    2.  
    3. fuel line from the tank at the fuel pump
    4.  
    5. heater hoses at the engine block
    6.  
    7. oil pressure gauge and the vacuum lines at the engine
    8.  
    9. evaporative emission system lines at the carburetor (on 1978 and later models, the hose at the fuel vapor storage canister)
    10.  
    11. power steering pump at the mounting bracket (lay the pump aside without disconnecting any of the lines)
    12.  
    13. ground straps at the engine block
    14.  
    15. exhaust pipe at the manifold (hang the pipe from the frame with a wire)
    16.  
    17. TCS switch at the transmission (V8, if so equipped)
    18.  
    19. vacuum line to the power brake unit at the manifold
    20.  

  15. If equipped with air conditioning, unbolt the compressor at the bracket and lay it aside.
  16.  


CAUTION
Please refer to before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Unbolt the engine fan and remove the fan and pulley.
  2.  
  3. On manual transmission models:
  4.  
    1. Disconnect the clutch fork return spring at the fork.
    2.  
    3. Disconnect the clutch pedal pushrod at the cross shaft lever. Let the pushrod hang from the lower lever.
    4.  
    5. At the frame end of the cross shaft, remove the ball stud and retaining nut.
    6.  
    7. Slide the shaft toward the engine, lift it up to clear the bracket and remove the shaft from the engine ball stud.
    8.  

  5. On the six cylinder, remove the rocker arm cover as outlined later in this section.
  6.  
  7. Attach a chain or lifting device to the brackets on the engine. If your engine doesn't have lifting eyes, good locations are under the intake manifold bolts on V8s or under the cylinder head bolts at either end on the sixes. You may need to remove the carburetor for clearance. Lift the engine slightly, just enough to take the weight off the motor mounts.
  8.  
  9. On four wheel drive models, support the transmission using a floor jack and disconnect it from the engine. Remove the engine mount bolts.
  10.  
  11. On two wheel drive models:
  12.  
    1. Remove the driveshaft as outlined in .
    2.  
    3. Disconnect the TCS switch at the transmission.
    4.  
    5. Disconnect the speedometer cable at the transmission.
    6.  
    7. Disconnect the shift linkage.
    8.  
    9. On manual transmission models, disconnect the clutch linkage.
    10.  
    11. Remove the engine mount bolts.
    12.  
    13. Remove the transmission cooler lines, if so equipped.
    14.  
    15. Remove the rear mount crossmember.
    16.  
    17. Raise the engine and transmission slightly and check that everything is disconnected and ready for removal.
    18.  
    19. Pull the engine/transmission assembly forward and remove it from the vehicle.
    20.  

  13. On four wheel drive models:
  14.  
    1. Raise the engine slightly and pull it forward until it is disconnected from the transmission.
    2.  
    3. Raise the engine and remove it from the vehicle.
    4.  

  15. Reverse the removal procedure to install.
  16.  

1977-82 MODELS
  1. Refer to Steps 1-8 of the 1969-76 engine removal procedure.
  2.  
  3. Raise the vehicle on a hoist and drain the engine oil.
  4.  
  5. Disconnect the exhaust pipe at the manifold.
  6.  
  7. Remove the flywheel splash shield or the converter housing cover, as applicable.
  8.  
  9. Remove the starter motor as outlined earlier in this section.
  10.  
  11. On automatic transmission models remove the converter-to-flywheel attaching bolts.
  12.  
  13. Remove the engine mount through bolts.
  14.  
  15. On 1979 and later four wheel drive models, remove the strut rods at the engine mount.
  16.  
  17. Remove the engine-to-bellhousing attaching bolts.
  18.  
  19. Lower the vehicle from the hoist.
  20.  
  21. Using a floor jack, raise the transmission slightly.
  22.  
  23. Attach a lifting device to the engine and raise it slightly, taking the weight off the engine mounts.
  24.  
  25. Remove the engine mount-to-engine brackets.
  26.  
  27. Remove the engine.
  28.  
  29. Reverse the removal procedure to install.
  30.  

Diesel Engine
  1. Disconnect the batteries.
  2.  
  3. Raise vehicle.
  4.  
  5. Remove transmission dust cover.
  6.  
  7. Disconnect torque converter.
  8.  
  9. Disconnect exhaust.
  10.  
  11. Remove starter bolts.
  12.  
  13. Disconnect wires and remove starter.
  14.  
  15. Remove transmission bell housing bolts.
  16.  
  17. Remove left motor mount bolts.
  18.  
  19. Remove right motor mount bolts.
  20.  
  21. Disconnect block heaters.
  22.  
  23. Remove wire harness, trans cooler lines and front battery cable clamp at oil pan.
  24.  
  25. Disconnect fuel return lines at engine.
  26.  
  27. Disconnect oil cooler lines at engine.
  28.  
  29. Remove lower fan shroud bolts.
  30.  
  31. Lower vehicle.
  32.  
  33. Remove hood.
  34.  
  35. Drain cooling system.
  36.  
  37. Remove air cleaner with resonator.
  38.  
  39. Remove primary filter from cowl.
  40.  
  41. Disconnect ground cable at alternator bracket.
  42.  
  43. Disconnect alternator wires and clips.
  44.  
  45. Unplug the Throttle Position Sensor (TPS), Exhaust Gas Recirculation (EGR) and the Exhaust Pressure Regulator (EPR) electrical connections. Disengage the fuel cut-off at injection pump.
  46.  
  47. Remove harness from clips at rocker covers. Disconnect the glow plugs.
  48.  
  49. Disconnect EGR-EPR solenoids, glow plugs, controller, temperature sender and move harness aside.
  50.  
  51. Disconnect ground strap, left side.
  52.  
  53. Remove fan.
  54.  
  55. Remove upper radiator hoses at engine.
  56.  
  57. Remove fan shroud.
  58.  
  59. Remove power steering pump and belt.
  60.  
  61. Remove power steering reservoir-lay pump and reservoir aside.
  62.  
  63. Disconnect vacuum at cruise servo and accelerator cable at injection pump.
  64.  
  65. Disconnect heater hose at engine.
  66.  
  67. Disconnect lower radiator hose at engine.
  68.  
  69. Disconnect oil cooler lines at radiator.
  70.  
  71. Disconnect heater hose and overflow at radiator.
  72.  
  73. Disconnect auto trans cooler lines.
  74.  
  75. Remove upper radiator cover.
  76.  
  77. Remove radiator.
  78.  
  79. Remove the detent cable.
  80.  
  81. Remove engine and support transmission.
  82.  
  83. Installation is in the reverse order. If fuel filters were removed, they must be filled with clean diesel fuel to avoid long cranking.
  84.  

 
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