S&T Series Blazer, Bravada, Envoy, Jimmy, Rainier, Trailblazer, Xtreme

Engine

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Removal & Installation



4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine cooling system
    NOTE
    Keep the oil drain plug removed during the engine removal and installation.

  4.  
  5. Drain the engine oil. Install a suitable plug into the oil pan to prevent oil leakage during the remainder of the procedure.
  6.  
  7. Using the proper equipment, discharge and recover the refrigerant from the A/C system, if equipped.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Fuel system pressure
     
    Air cleaner assembly
     
    Throttle body
     
    Manifold Absolute Pressure (MAP) sensor
     
    Windshield washer solvent container
     
    Air intake baffle
     
    Grille
     
    Headlight housing
     
    Radiator support brace
     
    Hood
     
    A/C lines from the condenser
     
    Transmission cooler lines from the engine, not the radiator
     

  10.  
  11. Remove the cooling fan and shroud, tilting the radiator forward, and the cooling fan and shroud rearward for clearance.

    Accessory belt
     
    Power steering pump bolts; position the pump aside
     
    Heater hoses from the heater core
     
    Transmission filler tube bracket nut from the Air Injector Reactor (AIR) adapter
     
    AIR adapter
     

  12.  
  13. Install a suitable lift hook to the AIR adapter
  14.  
  15. Remove or disconnect the following:

    Oxygen (O 2 ) sensor connector
     
    A/C line from the accumulator
     
    Front axle actuator electrical connector
     
    Camshaft phaser actuator valve electrical connector
     
    Transmission cooler lines from the clips on the right side of the engine block
     
    Ignition coil harness connectors
     
    Harness retainer from the clips
     
    Power brake hose from the booster
     
    Powertrain Control Module (PCM)
     
    Fuel lines from the fuel pressure regulator. Cap the lines to avoid excessive fuel leakage.
     
    All harnesses from the engine harness bracket
     
    Engine harness bracket bolt and bracket
     
    Starter electrical connections
     
    A/C pressure sensor and clutch electrical connector
     
    Alternator electrical connector and battery lead
     
    Knock Sensor (KS), Crankshaft Position (CKP) and Camshaft Position (CMP) sensor electrical connectors
     
    4 ground on the left side of the block
     

  16.  
  17. Raise and safely support the vehicle.

    Left and right side driveshafts
     
    Propeller shaft from the front axle pinion yoke
     
    Engine protection shield
     
    Exhaust pipe from the exhaust manifold. Slide the exhaust pipe backward slightly.
     
    Fuel tank shield, if equipped
     
    Torque converter access cover and bolts
     

  18.  
  19. Place a jack on the transmission fluid pan for support.
  20.  
  21. Remove the transmission support.
  22.  
  23. Lower the transmission enough to reach the top bell housing bolts.
  24.  
  25. Remove the top 4 bell housing bolts, there may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts.
  26.  
  27. Raise the transmission.
  28.  
  29. Reinstall the transmission support using only 2 through bolts.
  30.  
  31. Remove or disconnect the following:

    Remaining bell housing bolts (11 total)
     
    Left and right engine lower mount nuts
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     

  32.  
  33. Carefully lower the vehicle.
  34.  
  35. Remove the left, then the right upper engine mount nut.
  36.  
  37. Install a suitable engine hoist.
  38.  
  39. Raise the engine out of the compartment slowly, keeping the transmission supported.
  40.  
  41. Remove both engine mounts for clearance.
  42.  
  43. Continue raising the engine out of the vehicle.
  44.  
  45. Place the engine on a suitable engine stand.
  46.  

To install:

  1. Remove the engine from the engine stand.
  2.  
  3. Slowly install the engine into the engine compartment, aligning the engine mounts with the brackets.
  4.  
  5. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.
  6.  
  7. Lower the engine onto the mounts and install the upper engine mounting nuts. Tighten the nuts to 51 ft. lbs. (71 Nm).
  8.  
  9. Remove the engine hoist.
  10.  
  11. Lay the radiator into the radiator support, but do not install the radiator completely.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Install the lower bell housing bolts, except the top four.
  16.  
  17. Remove the 2 through bolts secure the transmission support, then lower the transmission.
  18.  
  19. Install the top 4 bell housing bolts and tighten all 11 bolts to 37 ft. lbs. (50 Nm).
  20.  
  21. Raise the transmission.
  22.  
  23. Install or connect the following:

    Transmission support
     
    3 torque converter bolts and tighten to 44 ft. lbs. (60 Nm)
     
    Torque converter bolt cover
     
    Fuel tank shield, if equipped
     
    Engine protection shield
     
    Propeller shaft to the front axle pinion yoke
     
    Exhaust pipe to the manifold and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Oil level switch and oil pressure sender electrical connectors
     
    Oil pan drain plug and tighten to 19 ft. lbs. (26 Nm)
     
    Lower radiator hose
     
    Left and right wheel driveshafts
     

  24.  
  25. Lower the vehicle.

    4 grounds on the left side of the block
     
    CMP, CKP and knock sensor electrical connectors
     
    Alternator and starter electrical connectors and battery leads. Torque the nuts to 80 inch lbs. (9 Nm).
     
    Fuel lines at the fuel pressure regulator
     
    Engine harness bracket and bolt. Torque the bolt to 37 ft. lbs. (50 Nm).
     
    Front differential vent hose, to the engine harness bracket
     
    PCM
     
    Power brake hose to the booster
     
    Harness retainer to its original location
     
    Ignition coil harness connectors
     
    Transmission cooler lines to clips on right side of engine block
     
    Camshaft phaser actuator valve electrical connector
     
    Front axle actuator electrical connector
     
    A/C line at the accumulator
     

  26.  
  27. Remove the lift hook.
  28.  
  29. Install or connect the following:

    AIR adapter and secure with the studs. Tighten to 18 ft. lbs. (25 Nm).
     
    Transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut. Torque the nut to 89 inch lbs. (10 Nm).
     
    Heater hoses to the heater core
     
    Power steering pump and tighten the bolts to 18 ft. lbs. (25 Nm).
     

  30.  
  31. The remainder of installation is the reverse of removal, but please note the following important steps:
  32.  
  33. Connect the negative battery cable
  34.  
  35. Check all powertrain fluid levels and add, as necessary.
  36.  
  37. Refill the engine crankcase.
  38.  
  39. Refill the engine cooling system.
  40.  
  41. Perform the CKP System Variation Learn Procedure, as follows:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 4.2L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Slowly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  42.  
  43. Start and run the engine, then check for leaks.
  44.  

4.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine cooling system
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel system pressure
     
    Vacuum reservoir and/or the underhood light from the hood, as equipped
     
    Outer cowl vent grilles
     
    Hood
     
    Oxygen Sensor (O 2 S) and/or wiring
     
    Exhaust pipes at the manifolds and loosen the hanger at the catalytic converter. This is necessary to remove the rear catalytic converter cushion mounts for removal of the exhaust assembly.
     
    Skid plate, if equipped
     
    Engine-to-transmission pencil braces
     
    Slave cylinder and position aside, if equipped
     
    Line clamp at the bell housing
     
    Wiring from the starter
     
    Starter
     
    Transfer case on 2000-01 models, if equipped
     
    Oil filter
     
    Engine mount through bolts
     
    Rear engine mount crossbar, nut and washer
     
    Bell housing bolts, except the upper left.
     
    Battery ground (negative) cable from the engine
     
    Front drive axle bolts and roll the axle downward, on 4WD vehicles
     
    Air cleaner assembly
     
    Upper radiator shroud
     
    Fan assembly
     
    Drive belt assembly
     
    Water pump pulley
     
    Upper radiator hose
     
    Air conditioning compressor, if equipped, and position aside with the lines intact
     
    Lower radiator hose
     
    Oil cooler and overflow lines from the radiator, plug the openings to prevent system contamination or excessive fluid loss
     
    Radiator and lower radiator shroud
     
    Power steering hoses from the steering gear, then cap the openings to prevent system contamination or excessive fluid loss
     
    Heater hoses from the intake manifold and the water pump
     
    Wiring harness and vacuum lines from the engine
     
    Throttle cables
     
    Distributor cap
     
    Remaining bell housing bolt
     
    Fuel lines and the bracket
     
    Ground strap(s) from the rear of the cylinder head
     
    Front body mount bolts, on 4WD vehicles
     

  8.  
  9. Support the transmission.
  10.  
  11. Install a lifting device and lift the engine.
  12.  

To install:

  1. Install or connect the following:

    Engine into the vehicle
     
    Front body mount bolts, on 4WD vehicles
     
    Ground strap(s) to the rear of the cylinder head
     
    Fuel lines and the bracket
     
    Upper left bell-housing bolt
     
    Distributor, cap and wires
     
    Throttle cables
     
    Vacuum lines and wiring harness connectors
     
    Heater hoses
     
    Power steering hoses
     
    Lower shroud and radiator
     
    Oil cooler lines to the radiator and overflow hose
     
    Lower radiator hose
     
    Air conditioning compressor to the engine, if equipped
     
    Upper radiator hose
     
    Water pump pulley
     
    Drive belt assembly
     
    Fan assembly
     
    Upper radiator shroud
     
    Air cleaner assembly
     
    Front drive axle, for 4WD vehicles
     
    Battery ground strap to the engine block
     
    Remaining bell housing bolts
     
    Engine mount through-bolts. Torque them to 49 ft. lbs. (66 Nm).
     
    Rear engine mount crossbar nut and washer. Tighten the nut to 33 ft. lbs. (45 Nm).
     
    Oil filter
     
    Starter motor
     
    Transfer case on 2000-01 models, if equipped
     
    Flywheel cover
     
    Clutch slave cylinder, if equipped
     
    Pencil brace and the skid plate, as equipped
     
    Catalytic converter Y-pipe assembly and hangers
     
    Hood
     
    Outer cowl vent grilles
     
    Vacuum reservoir and/or the underhood light to the hood, as equipped
     
    Negative battery cable
     

  2.  
  3. Check all powertrain fluid levels and add, as necessary.
  4.  
  5. Refill the engine crankcase.
  6.  
  7. Refill the engine cooling system.
  8.  
  9. Start and run the engine, then check for leaks.
  10.  

5.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine cooling system
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove and recover the refrigerant, if equipped with A/C.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Radiator
     
    Radiator support brace
     
    Front axle, if 4WD
     
    Drive shafts
     
    Intake manifold
     
    Oil pressure sensor connector
     
    Oxygen (O 2 ) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    A/C compressor hose
     
    Rear auxiliary A/C compressor pipe fitting
     
    Rear auxiliary A/C compressor pipe nut and bolt. Tie the pipe out of the way.
     
    Engine Coolant Temperature (ECT) sensor
     
    Ground terminal bolt
     
    Retaining clips from the brackets
     
    A/C pressure switch electrical connector
     
    Retaining clip from the cylinder head
     
    Ground terminal bolts
     
    Starter
     
    Battery cable channel bolt
     
    Battery cable channel from the oil pan
     
    A/C compressor electrical connector
     

  10.  
  11. Collect all branches of the engine wiring harness, then position the harness out of the way.

    Alternator cable from the alternator
     
    Alternator bracket bolts, then position the bracket and alternator assembly aside
     
    Inlet and outlet hoses from the water outlet, using J 38185 to move the hose clamps
     
    Auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes
     
    Auxiliary heater inlet and outlet hoses/pipes from the water pump, using Hose Clamp Pliers J 38185
     
    Remove ignition coils, if necessary, to install Engine Lifting Brackets J 41798 to the cylinder heads

    Click image to see an enlarged view

    Fig. If necessary, remove ignition coil(s) to install the engine lifting brackets-5.3L engine

     

  12.  
  13. Install Engine Lifting Brackets J 41798 to the cylinder heads. Tighten the M8 bolts to 18 ft. lbs. (25 Nm) and the M10 bolts to 37 ft. lbs. (50 Nm).

    Catalytic converter
     
    3 frame engine mount bracket bolts from the right and left sides
     
    Torque converter bolts
     
    Transmission oil level dipstick tube nut and tube
     
    Transmission bolt and stud on the right side
     
    Lower transmission bolt/studs
     
    3 upper transmission bolts/studs
     

  14.  
  15. Install a suitable engine hoist to the engine lifting brackets.
  16.  
  17. Place a floor jack under the transmission for support.
  18.  
  19. Separate the engine from the transmission.
  20.  
  21. Remove the engine from the vehicle and place on a suitable engine stand.
  22.  
  23. Install Converter Holding Strap J 21366 to the transmission to hold the torque converter.
  24.  

To install:

  1. Remove Converter Holding Strap J 21366 from the transmission.
  2.  
  3. Attach the engine to a hoist and remove it from the engine stand
  4.  
  5. Install or connect the following:

    Engine into the vehicle. Match the transmission up to the engine, then remove the floor jack.
     
    3 upper transmission bolts/studs and tighten to 37 ft. lbs. (50 Nm)
     
    Lower transmission bolts/studs and tighten to 37 ft. lbs. (50 Nm)
     
    Transmission bolt and stud on the right side and tighten to 37 ft. lbs. (50 Nm)
     
    Transmission oil level dipstick tube and nut. Torque to 89 inch lbs. (10 Nm).
     
    Torque converter bolts and tighten to 44 ft. lbs. (60 Nm)
     
    3 frame engine mount bracket bolts to both the right and left sides. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Catalytic converter
     

  6.  
  7. Remove the engine lifting brackets from the cylinder heads

    Ignition coils, if removed, and tighten the bolts to 71 inch lbs. (8 Nm)
     
    Auxiliary heater inlet and outlet hoses
     
    Auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes
     
    Outlet and inlet hoses to the water outlet
     
    Bracket and alternator assembly. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Cable to the alternator
     
    Position the engine wiring harness back over the engine
     
    A/C compressor electrical connector
     
    Battery cable channel to the oil pan and secure with the bolt. Torque to 106 inch lbs. (12 Nm).
     
    Starter
     
    Ground terminal bolts and tighten to 18 ft. lbs. (25 Nm)
     
    Retaining clip to the cylinder head
     
    A/C pressure switch electrical connector
     
    Retaining clips to the brackets
     
    Ground terminal bolt and tighten to 18 ft. lbs. (25 Nm)
     
    ECT sensor connector
     
    Rear auxiliary A/C compressor pipe nut and bolt. Torque to 15 ft. lbs. (20 Nm).
     
    A/C compressor hose
     
    Oil pressure sensor connector
     
    O 2 sensor connector
     
    CMP sensor connector
     
    Intake manifold
     
    Drive shafts
     
    Front axle, if removed
     
    Radiator support brace
     
    Radiator
     

  8.  
  9. Recharge the A/C system

    Negative battery cable
     
    Hood
     

  10.  
  11. Check all powertrain fluid levels and add, as necessary.
  12.  
  13. Refill the engine crankcase.
  14.  
  15. Refill the engine cooling system.
  16.  
  17. Start and run the engine, then check for leaks.
  18.  

 
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