CHEVROLET AND GMC BLAZER • JIMMY • S10 • SONOMA

1 BVC 58-26770 GMC CARS JCK/MJS/KJE 8/22/057-8 CHEVROLET AND GMCBLAZER JIMMY S10 8/30/05 3:01 PM Page 8 CHEVROLET AND GMCBLAZER JIMMY S10 SONOMA BVC 58-26770 GMC CARS JCK/MJS/KJE 8/22 8/30/05 3:01 PM Page 9 BVC 58-26770 GMC CARS JCK/MJS/KJE 8/22/057-10 CHEVROLET AND GMCBLAZER JIMMY S10 8/30/05 3:01 PM Page 10 CHEVROLET AND GMCBLAZER JIMMY S10 SONOMA BVC 58-26770 GMC CARS JCK/MJS/KJE 8/22 8/30/05 3:01 PM Page 11 BVC 58-26770 GMC CARS JCK/MJS/KJE 8/22/057-12 CHEVROLET AND GMCBLAZER JIMMY S10 8/30/05 3:01 PM Page 12 CHEVROLET AND GMCBLAZER JIMMY S10 SONOMA BVC 58-26770 GMC CARS JCK/MJS/KJE 8/22/057-13 ENGINE REPAIRD istributorREMOVALThe engine is equipped with a dis-tributorless Engine1. Remove or disconnect the following: Negative battery cable Air cleaner assembly Spark plug and coil wires Electrical connector Distributor cap2.

2 Use a grease pencil in order to notethe position of the rotor in relation to thedistributor Mark the distributor housing and theintake manifold location with a grease Remove the mounting clamp holddown bolt and the distributor. As the distributor is being removedfrom the engine, watch the rotor movein a counter-clockwise direction about42 degrees. This will appear as slightlymore than the 1 o clock position. Notethe position of the rotor segment. Placea second mark on the base of the dis-tributor. This will aid in achievingproper rotor alignment during the dis-tributor install:5. If installing a new distributor assem-bly, place 2 marks on the new distributorhousing in the same location as the 2 markson the original Align the rotor with the second Guide the distributor into the Align the hole in the distributorhold-down base over the mounting hole inthe intake As the distributor is being installed,observe the rotor moving in a clockwisedirection about 42 Once the distributor is completelyseated, the rotor segment should be alignedwith the mark on the distributor If the rotor segment is not alignedwith the number 1 mark, the driven gearteeth and the camshaft have meshed one ormore teeth out of alignment.

3 In order to cor-rect this condition, remove and reinstall Install the distributor mountingclamp bolt and tighten to 18 ft. lbs. (25Nm).13. Install or connect the following: Distributor cap Electrical connector Spark plug and coil wires Air cleaner assembly Negative battery Engine1. Remove or disconnect the following: Passenger side wheel assembly Alternator brace-to-block bolt , thebrace-to-intake nut and the brace-to-engine stud Alternator wiring Accessory belt Mounting bolts Engine1. Remove or disconnect the following: Negative battery cable Air inlet duct, if necessary Accessory belt Heater hose brace Wires Mounting bolts EngineInstall or connect the following: Alternator Mounting bolts. torque the left boltto 22 ft. lbs. (30 Nm) and the rightbolt to 32 ft. lbs. (43 Nm). Wires. torque the battery feed wirenut to 71 inch lbs. (8 Nm). Alternator brace. torque the nutsand bolts to 22 ft. lbs. (30 Nm). Accessory belt Negative battery EngineInstall or connect the following: Alternator and loosely install themounting bolts Tighten the rear bolt to 37 ft.

4 Lbs.(50 Nm) and the front bolt to 18 (25 Nm) Tighten the brace-to-alternator andbrace-to-intake retainers to 18 ft. lbs.(25 Nm). Tighten the brace-to-enginestud nut to 37 ft. lbs. (50 Nm). Wires and the battery feed wire nut Heater hose bracket Accessory belt Negative battery cableIgnition TimingADJUSTMENTThe ignition timing is preset and cannotbe AssemblyREMOVAL & Engine In certain cases on some models theA/C system will have to be evacuatedbecause the compressor may need tobe removed from the vehicle to allowclearance for engine removal. On othermodels you maybe able to set the com-pressor and lines to one side and stillhave enough clearance to remove theengine. In this case the system doesnot have to be evacuated because thelines do not have to be disconnectedfrom the compressor. To check if yoursystem has to be evacuated, unplug theelectrical connectors from the com-pressor, then unbolt the compressorassembly. Unfasten any brackets hold-ing the refrigerant lines and try to setthe components aside so that you willhave enough clearance for engineremoval.

5 If there is not enough clear-ance for engine removal you mustrecover the refrigerant from the A/Csystem with an approved recovery sta-tion before attempting to remove theengine from your vehicle. DO NOTattempt this without the proper equip-ment. R-134a should NOT be mixedwith R-12 refrigerant and, dependingon your local laws, attempting to ser-vice this system could be Disconnect the negative battery cableand properly relieve the fuel system Drain the engine cooling system andthe engine oil into separate drain Remove or disconnect the following: Hood Oxygen Sensor (O2S) electricalconnection Exhaust pipe from the 8/30/05 3:01 PM Page 13 On some models it may also be nec-essary to disconnect the catalytic con-verter from the exhaust pipe. Braces from the engine and thetransmission, if equipped Starter motor Transmission and separate it fromthe engine or, if necessary, removeit from the vehicle Alternator rear brace by unfasteningthe bolt and nuts Ground straps from the engineblock Drive belt A/C compressor and bracket.

6 Ifpossible, set the compressor andbracket to one side without discon-necting the lines. Hoses and transmission coolantlines engaged to the radiator Radiator Power steering pump and cap thepower steering lines to avoid con-tamination Heater hoses from the heater core 12 volt supply from the mega fuse,if necessary All electrical connections andwiring harnesses All vacuum lines Throttle cable, and if equipped thecruise control cable Exhaust Gas Recirculation (EGR)pipe and the EGR valve Fuel lines4. Install a suitable lifting device to Remove the engine mount bolts andcarefully lift the engine from the several times while lifting the engineto make sure no wires or hoses havebecome install:6. Carefully lower the engine into thevehicle and install the engine mount the engine lifting Install or connect the following: Fuel lines 12 volt supply to the mega fuse, ifremoved All vacuum lines, electrical connec-tions and wiring harnesses EGR valve and pipe, if removed Throttle and if equipped, the cruisecontrol cable Heater hoses to the heater core Power steering pump and attachthe lines A/C compressor Radiator, all hoses and fluid coolerlines Water pump, if removed Drive belt Ground strap to the engine Alternator rear brace and tightenthe bolt and nuts, if removed Transmission to the engine Starter motor, if removed Braces to the engine and the trans-mission, if equipped Exhaust pipe to the manifold Catalytic converter to the exhaustpipe, if removed O2S electrical connection Battery Hood8.

7 Check all powertrain fluid levels andadd, as necessary. Be sure to properly fillthe engine crankcase with clean engine Connect the battery cables and prop-erly fill the engine cooling Start and run the engine, then checkfor Engine1. Drain the engine cooling system2. Drain the engine Remove or disconnect the following: Negative battery cable Fuel system pressure Vacuum reservoir and/or the under-hood light from the hood, asequipped Outer cowl vent grilles Hood Oxygen Sensor (O2S) and/or wiring Exhaust pipes at the manifolds andloosen the hanger at the catalyticconverter. This is necessary toremove the rear catalytic convertercushion mounts for removal of theexhaust assembly. Skid plate, if equipped Engine-to-transmission pencilbraces Slave cylinder and position aside, ifequipped Line clamp at the bell housing Wiring from the starter Starter Transfer case Oil filter Engine mount through bolts Rear engine mount crossbar, nutand washer Bell housing bolts, except theupper left.

8 Battery ground (negative) cablefrom the engine Front drive axle bolts and roll theaxle downward, on 4WD vehicles Air cleaner assembly Upper radiator shroud Fan assembly Drive belt assembly Water pump pulley Upper radiator hose Air conditioning compressor, ifequipped, and position aside withthe lines intact Lower radiator hose Oil cooler and overflow lines fromthe radiator, plug the openings toprevent system contamination orexcessive fluid loss Radiator and lower radiator shroud Power steering hoses from thesteering gear, then cap the open-ings to prevent system contami-nation or excessive fluid loss Heater hoses from the intake mani-fold and the water pump Wiring harness and vacuum linesfrom the engine Throttle cables Remaining bell housing bolt Fuel lines and the bracket Ground strap(s) from the rear of thecylinder head Front body mount bolts, on 4 WDvehicles4. Support the Install a lifting device and lift install:6. Install or connect the following: Engine into the vehicle Front body mount bolts, on 4 WDvehicles Ground strap(s) to the rear of thecylinder head Fuel lines and the bracket Upper left bell-housing bolt Throttle cables Vacuum lines and wiring harnessconnectors Heater hoses Power steering hoses Lower shroud and radiator Oil cooler lines to the radiator andoverflow hose Lower radiator hose Air conditioning compressor to theengine, 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 engineblock Remaining bell housing boltsBVC 58-26770 GMC CARS JCK/MJS/KJE 8/22/057-14 CHEVROLET AND GMCBLAZER JIMMY S10 8/30/05 3:01 PM Page 14 Engine mount them to 49 ft.

9 Lbs. (66 Nm). Rear engine mount crossbar nutand washer. Tighten the nut to 33ft. lbs. (45 Nm). Oil filter Starter motor Flywheel cover Clutch slave cylinder, if equipped Pencil brace and the skid plate, asequipped Catalytic converter Y-pipe assemblyand hangers Hood Outer cowl vent grilles Vacuum reservoir and/or the under-hood light to the hood, as equipped Negative battery cable7. Check all powertrain fluid levels andadd, as Refill the engine Refill the engine cooling Start and run the engine, then checkfor PumpREMOVAL & INSTALLATION1. Disconnect the negative battery Drain the engine cooling Relieve the belt tension and removethe accessory drive belts or the serpentinedrive belt, as Remove or disconnect the follow-ing: Upper fan shroud Fan or fan and clutch assembly, asapplicable Water pump pulley Coolant hose(s) from the waterpump For the hoses on some engines,removal may be easier if the hose isleft attached until the pump is freefrom the block.

10 Once the pump isremoved from the engine, the pumpmay be pulled (giving a better grip andgreater leverage) from the tight hoseconnection. Water pump retainers Water pump from the engine WARNINGNote the positions of all retainers assome engines will utilize differentlength fasteners in different locationsand/or bolts and studs in install:5. Clean the gasket mounting sur-faces. The water pumps on some of the ear-lier engines covered may have beeninstalled using sealer only, no gasket,at the factory. If a gasket is suppliedwith the replacement part, it should beused. Otherwise, a in. (3mm) beadof RTV sealer should be used aroundthe sealing surface of the Apply sealant to the water pumpretainer Install or connect the following: Water pump using a new the water pump retainers to18 ft. lbs. (25 Nm) for engineor to 30 ft. lbs. (41 Nm) for Coolant hose(s) Water pump pulley Fan or fan and clutch assembly Serpentine drive belt (if equipped)by positioning the belt over thepulleys and carefully allow the ten-sioner back into contact with thebelt V-belts (if equipped) and adjust thetension Upper fan shroud Negative battery cable8.