PRECAUTIONS ENGINE REPAIR

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1 3234_U01.qxd 9/23/03 3:44 PM Page 13 BLAZER XTREME TRAILBLAZER BRAVADA ENVOY JIMMY 1-13 PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If Distributor REMOVAL Spark plug wires and the coil leads from the distributor Electrical connector from the distributor Distributor cap fasteners and the cap 3. Using a marker, matchmark the rotorto-housing and housing-to-intake manifold positions so that they can be matched during installation. eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. Clean, high quality brake fluid from a ENGINE REPAIR Distributor hold-down bolt Distributor from the engine 4. As the distributor is being removed from the engine the rotor will move in a counterclockwise direction about 42. This will appear as slightly more than one clock position. 5. Place a second mark on the distributor to mark the position of the rotor segment. This will help to ensure the correct rotor alignment when installing the distributor. INSTALLATION Engine Not Disturbed 1. If installing a new distributor, place two marks on the new distributor housing in the same position as the marks on the old distributor housing. sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage.refer to the maintenance interval charts in the front of this section for the recommended replacement interval for the timing belt, and to the timing belt procedure in this section for belt replacement and inspection. Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. 2. Align the rotor with the second mark made on the distributor. 3. Install the distributor in the engine making sure that the mounting hole in the distributor hold-down base is aligned over the mounting hole in the intake manifold. 4. As you are installing the distributor, watch the rotor move in a clockwise direction about Once the distributor is fully seated, the rotor should be aligned with the first mark made on the distributor housing. If the rotor is not aligned with the first mark made on the housing, the distributor and camshaft teeth have meshed one or more teeth out of alignment. If this is the case, remove the distributor and reinstall it so that all the marks are aligned. 6. Install or connect the following:

2 3234_U01.qxd 9/23/03 3:44 PM Page BLAZER XTREME TRAILBLAZER BRAVADA ENVOY JIMMY Hold-down bolt and tighten the bolt to 18 ft. lbs. (25 Nm) Distributor cap and engage the electrical connector to the distributor Spark plug wires and coil leads Engine Disturbed 1. Remove the No. 1 cylinder spark plug. Turn the engine using a socket wrench on the large bolt on the front of the crankshaft pulley. Place a finger near the No. 1 spark plug hole and turn the crankshaft until the piston reaches Top Dead Center (TDC). As the engine approaches TDC, you will feel air being expelled by the No. 1 cylinder. If the position is not being met, turn the engine another full turn (360 degree). Once the engine position is correct, install the spark plug. 2. Align the cast arrow in the distributor housing, the driven gear roll pin and the pre-drilled indent hole in the distributor driven gear. If the driven gear is installed correctly, the dimple will be approximately 180 opposite the rotor segment when it is installed in the distributor. Installing the distributor 180 out of alignment, or locating the rotor in the wrong holes, may cause a no start condition or can cause premature engine damage and wear. 3. Make sure the rotor is pointing to the cap hold-down mount nearest the flat side of the housing. 4. Using a long screwdriver, align the oil pump driveshaft in the engine in the mating drive tab in the distributor. 5. Install the distributor in the engine. Make sure the spark plug towers are perpendicular to the centerline of the engine. 6. When the distributor is fully seated, the rotor segment should be aligned with the pointer cast in the distributor base. The pointer will have a 6 cast into it indicating a 6 cylinder engine. If the rotor segment is not within a few degrees of the pointer, the distributor gear may be off a tooth or more. If this is the case repeat the process until the rotor aligns with the pointer. 7. Install the cap and fasten the mounting screws. 8. Tighten the distributor mounting bolt to 18 ft. lbs. (25 9. Engage the electrical connections and the spark plug wires. Alternator REMOVAL 4.2L Engine Positive battery cable nut from the generator A/C line mounting bracket bolt at the engine lift hook Right engine lift hook bolts Engine lift hook Mounting bolts Alternator 4.3L Engine Air inlet duct, if necessary Heater hose brace Wires Mounting bolts Alternator 5.3L Engine Electrical connector Terminal stud nut, after sliding boot down Alternator cable Mounting bolts Alternator INSTALLATION 4.2L Engine 1. Install or connect the following: Alternator and loosely install the mounting blots Tighten the alternator mounting bolts to 37 ft. lbs. (50 Nm) Positive battery cable and secure with the nut; tighten the nut to 80 inch lbs. (9 Nm) Engine lift hook and bolts; tighten the bolts to 37 ft. lbs. (50 Nm) A/C line bracket to the lift hook, then tighten the retaining bolt to 89 inch lbs. (10 Nm) 4.3L Engine 1. Install or connect the following: Alternator and loosely install the mounting bolts Tighten the rear bolt to 37 ft. lbs. (50 Nm) and the front bolt to 18 ft. lbs. (25 Nm) Tighten the brace-to-alternator and brace-to-intake retainers to 18 ft. lbs. (25 Tighten the brace-toengine stud nut to 37 ft. lbs. (50 Wires and the battery feed wire nut Heater hose bracket 5.3L Engine 1. Install or connect the following: Alternator and loosely install the mounting bolts Tighten the bolts to 37 ft. lbs. (50 Nm) Alternator cable Terminal stud nut and tighten to 80 inch lbs. (9 Nm) Boot back over terminal stud Electrical connector Ignition Timing ADJUSTMENT The ignition timing is preset and cannot be adjusted. Engine Assembly REMOVAL & INSTALLATION 4.2L Engine 2. Drain the engine cooling system Keep the oil drain plug removed during the engine removal and installation.

3 3234_U01.qxd 9/23/03 3:44 PM Page 15 BLAZER XTREME TRAILBLAZER BRAVADA ENVOY JIMMY Drain the engine oil. Install a suitable plug into the oil pan to prevent oil leakage during the remainder of the procedure. 4. Using the proper equipment, discharge and recover the refrigerant from the A/C system, if equipped. 5. Remove or disconnect the following: 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 A/C lines from the condenser Transmission cooler lines from the engine, not the radiator 6. Remove the cooling fan and shroud, tilting the radiator forward, and the cooling fan and shroud rearward for clearance. 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 7. Install a suitable lift hook to the AIR adapter 8. 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 9. 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 10. Place a jack on the transmission fluid pan for support. 11. Remove the transmission support. 12. Lower the transmission enough to reach the top bell housing bolts. 13. 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. 14. Raise the transmission. 15. Reinstall the transmission support using only 2 through bolts. 16. 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 17. Carefully lower the vehicle. 18. Remove the left, then the right upper engine mount nut. 19. Install a suitable engine hoist. 20. Raise the engine out of the compartment slowly, keeping the transmission supported. 21. Remove both engine mounts for clearance. 22. Continue raising the engine out of the vehicle. 23. Place the engine on a suitable engine stand. To install: 24. Remove the engine from the engine stand. 25. Slowly install the engine into the engine compartment, aligning the engine mounts with the brackets. 26. 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. 27. Lower the engine onto the mounts and install the upper engine mounting nuts. Tighten the nuts to 51 ft. lbs. ( Remove the engine hoist. 29. Lay the radiator into the radiator support, but do not install the radiator completely. 30. Raise and safely support the vehicle. 31. Install the lower bell housing bolts, except the top four. 32. Remove the 2 through bolts secure the transmission support, then lower the transmission. 33. Install the top 4 bell housing bolts and tighten all 11 bolts to 37 ft. lbs. ( Raise the transmission. 35. 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 36. 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 Fuel lines at the fuel pressure regulator Engine harness bracket and bolt. Torque the bolt to 37 ft. lbs. (50 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 37. Remove the lift hook.

4 3234_U01.qxd 9/23/03 3:44 PM Page BLAZER XTREME TRAILBLAZER BRAVADA ENVOY JIMMY 38. Install or connect the following: AIR adapter and secure with the studs. Tighten to 18 ft. lbs. (25 Transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut. Torque the nut to 89 inch lbs. (10 Heater hoses to the heater core Power steering pump and tighten the bolts to 18 ft. lbs. ( The remainder of installation is the reverse of removal, but please note the following important steps: 40. Connect the negative battery cable 41. Check all powertrain fluid levels and add, as necessary. 42. Refill the engine crankcase. 43. Refill the engine cooling system. 44. Perform the CKP System Variation Learn Procedure, as follows: a. 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. b. With the scan tool, select the crankshaft position variation learn procedure. c. Observe the fuel cut-off for the 4.2L engine. d. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly. e. Enable the crankshaft position system variation learn procedure. 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. f. Slowly increase the engine speed to the RPM that you observed. g. Immediately release the throttle when fuel cut-out is reached. h. 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. i. Turn the ignition OFFfor 30 seconds after the learn procedure has been completed successfully. 45. Start and run the engine, then check for leaks. 4.3L Engine the precautions in the beginning of this section. 2. Drain the engine cooling system 3. Drain the engine oil. 4. Remove or disconnect the following: Fuel system pressure Vacuum reservoir and/or the underhood light from the hood, as equipped Outer cowl vent grilles Oxygen Sensor (O 2S) 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 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 5. Support the transmission. 6. Install a lifting device and lift the engine. To install: 7. 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 Rear engine mount crossbar nut and washer. Tighten the nut to 33 ft. lbs. (45 Oil filter Starter motor Flywheel cover Clutch slave cylinder, if equipped Pencil brace and the skid plate, as equipped Catalytic converter Y-pipe assembly and hangers

5 3234_U01.qxd 9/23/03 3:44 PM Page 17 BLAZER XTREME TRAILBLAZER BRAVADA ENVOY JIMMY 1-17 Outer cowl vent grilles Vacuum reservoir and/or the underhood light to the hood, as equipped 8. Check all powertrain fluid levels and add, as necessary. 9. Refill the engine crankcase. 10. Refill the engine cooling system. 11. Start and run the engine, then check for leaks. 5.3L Engine 2. Drain the engine cooling system 3. Drain the engine oil. 4. Remove and recover the refrigerant, if equipped with A/C. 5. Remove or disconnect the following: 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 6. 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 to move the hose clamps If necessary, remove ignition coil(s) to install the engine lifting brackets 5.3L engine 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 Remove ignition coils, if necessary, to install Engine Lifting Brackets J to the cylinder heads 7. Install Engine Lifting Brackets J to the cylinder heads. Tighten the M8 bolts to 18 ft. lbs. (25 Nm) and the M10 bolts to 37 ft. lbs. (50 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 8. Install a suitable engine hoist to the engine lifting brackets. 9. Place a floor jack under the transmission for support. 10. Separate the engine from the transmission BLAZ-G Remove the engine from the vehicle and place on a suitable engine stand. 12. Install Converter Holding Strap J to the transmission to hold the torque converter. To install: 13. Remove Converter Holding Strap J from the transmission. 14. Attach the engine to a hoist and remove it from the engine stand 15. 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 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

6 3234_U01.qxd 9/23/03 3:44 PM Page BLAZER XTREME TRAILBLAZER BRAVADA ENVOY JIMMY Catalytic converter 16. 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 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 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 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 17. Recharge the A/C system 18. Check all powertrain fluid levels and add, as necessary. 19. Refill the engine crankcase. 20. Refill the engine cooling system. 21. Start and run the engine, then check for leaks. 2. Disconnect the negative battery cable. 3. Drain the engine cooling system. 4. For 5.3L engines, loosen the air cleaner outlet duct clamps at the throttle body and Mass Airflow/Intake Air Temperature (MAP/IAT) sensor. Remove the bolt and air cleaner outlet duct. 5. Relieve the belt tension and remove the accessory drive belts or the serpentine drive belt, as applicable. 6. Remove or disconnect the following: Upper fan shroud Fan or fan and clutch assembly, as applicable Exploded view of the water pump assembly mounting 4.2L engine Water pump pulley; use a suitable tool to hold the pulley while removing the bolts Coolant hose(s) from the water pump For the hoses on some engines, removal may be easier if the hose is left attached until the pump is free from the block. Once the pump is removed from the engine, the pump may be pulled (giving a better grip and greater leverage) from the tight hose connection. 9355MG01 Water Pump REMOVAL & INSTALLATION the precautions in the beginning of this section. Exploded view of the water pump assembly mounting 4.3L engine 7924JG06

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