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Engine Replacement Chevrolet TrailBlazer I

Engine Mechanical - 4.2L: Removal & Installation 43 illustrations ~2201 words

Engine Replacement

Tools Required

J 44220 Engine Lift Bracket

Scheme 991

Scheme 991: Removal Procedure
Scheme 991: Removal Procedure

Scheme 992

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Scheme 1005
Scheme 1005
  1. Remove the hood. Refer to HOOD REPLACEMENT in Body Front End.
  2. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  3. Drain engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6) or DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3) in Engine Cooling.
  4. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning. IMPORTANT: Keep drain plug removed during engine removal and installation.
  5. Remove the oil pan drain plug and drain the oil.
  6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the procedure.
  7. Remove the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY»(ref-159085-S37652319732003111400000) .
  8. Remove the throttle body. Refer to «THROTTLE BODY»(ref-159085-S22330361012003111100000) .
  9. Remove the map sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE SENSOR»(ref-159085-S17062346442003111100000) .
  10. Remove the washer solvent container. Refer to «WASHER SOLVENT CONTAINER REPLACEMENT»(ref-188870-S21358678172005090500000) in Wipers/Washer Systems.
  11. Remove the air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Body Front End.
  12. Remove the grill. Refer to GRILLE REPLACEMENT (GMC) or GRILLE REPLACEMENT (OLDSMOBILE) or GRILLE REPLACEMENT (CHEVROLET) in Body Exterior.
  13. Remove the headlamp housing. Refer to HEADLAMP HOUSING PANEL REPLACEMENT (OLDSMOBILE) or HEADLAMP HOUSING PANEL REPLACEMENT (CHEVROLET, GMC) in Body Front End.
  14. Remove the radiator support brace. Refer to BRACE REPLACEMENT - RADIATOR SUPPORT DIAGONAL in Body Front End.
  15. Remove the hood latch. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
  16. Disconnect A/C lines at the condenser.
  17. Disconnect the transmission cooler lines at the engine, not the radiator.
  18. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud rearward for clearance. Refer to COOLING FAN AND SHROUD REPLACEMENT in Engine Cooling.
  19. Remove the radiator with condenser and transmission cooler lines. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
  20. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
  21. Remove the power steering pump bolts and lay the pump aside.
  22. Ensure the heater hoses at the heater core are disconnected.
  23. Disconnect the transmission filler tube bracket nut from the AIR adapter.
  24. Remove the AIR adapter.
  25. Install the lift hook J 44220 to the AIR adapter.
  26. Disconnect the oxygen sensor electrical connector.
  27. Disconnect the A/C line at the accumulator.
  28. Disconnect the front axle actuator electrical connector.
  29. Disconnect the camshaft phaser actuator valve electrical connector.
  30. Unclip the transmission cooler lines from right side of the engine block.
  31. Disconnect the ignition coil harness connectors.
  32. Carefully disconnect harness retainer at clips (1) and remove.
  33. Remove power brake hose at booster.
  34. Remove the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
  35. Disconnect the fuel lines at the fuel pressure regulator and cap lines. Refer to «FUEL PRESSURE REGULATOR»(ref-159085-S36539169562003111100000) .
  36. Remove all harnesses from the engine harness bracket.
  37. Disconnect the front differential vent hose from the engine harness bracket.
  38. Remove the engine harness bracket bolt and remove bracket.
  39. Disconnect starter electrical connections (1).
  40. Disconnect the A/C pressure sensor and clutch electrical connector.
  41. Disconnect generator electrical connector and battery lead.
  42. Disconnect the knock sensor electrical connector.
  43. Disconnect the crankshaft sensor electrical connector.
  44. Disconnect the camshaft sensor electrical connector.
  45. Remove 4 grounds on the left side of the block (1).
  46. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
  47. Remove the wheel drive shafts, left and right. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
  48. Remove the propeller shaft from the front axle pinion yoke. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
  49. Remove the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000)
  50. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
  51. Remove the fuel tank shield, if equipped.
  52. Remove the torque converter bolt access cover.
  53. Remove the torque converter bolts.
  54. Place a jack on the transmission oil pan for support.
  55. Remove the transmission support. Refer to «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000) .
  56. Lower the transmission enough to reach the top bell housing bolts.
  57. 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.
  58. Raise the transmission.
  59. Reinstall the transmission support using only 2 through bolts.
  60. Remove the remaining bell housing bolts, for a total of 11 bolts.
  61. Remove the left and right engine lower mount nuts.
  62. Disconnect the oil lever sensor electrical connector.
  63. Disconnect the oil pressure switch electrical connector.
  64. Lower the vehicle.
  65. Remove the left upper engine mount nut.
  66. Remove the right upper engine mount nut.
  67. Install the engine hoist.
  68. Raise the engine out of the compartment slowly keeping the transmission supported.
  69. Remove both engine mount for clearance.
  70. Continue raising the engine out of the vehicle.
  71. Install the engine to the engine stand.

Scheme 1006

Scheme 1006: Installation Procedure
Scheme 1006: Installation Procedure

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Scheme 1018
Scheme 1018
  1. Remove the engine from the engine stand.
  2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
  3. 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. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  4. Lower the engine onto the mounts and install the upper engine mount nuts. Tighten Tighten the nuts to 70 N.m (51 lb ft).
  5. Remove the engine hoist.
  6. Lay the radiator into the radiator support, but do not install the radiator completely.
  7. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
  8. Install all of the lower bell housing bolts, excluding the top four.
  9. Remove the two through bolts securing the transmission support.
  10. Lower the transmission.
  11. Install the top four bell housing bolts. Tighten Tighten all eleven bell housing bolts to 50 N.m (37 lb ft).
  12. Raise the transmission.
  13. Install the transmission support. Refer to «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000) .
  14. Install the 3 torque converter bolts. Tighten Tighten the torque converter bolts to 60 N.m (44 lb ft).
  15. Install the torque converter bolt cover.
  16. Install the fuel tank shield, if removed.
  17. Install the engine protection shield. Refer to «ENGINE PROTECTION SHIELD REPLACEMENT»(ref-213485-S39117197742005122800000) .
  18. Install the propeller shaft to the front axle pinion yoke. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
  19. Connect the exhaust pipe to the manifold and secure the pipe with the bolts. Tighten Tighten the exhaust pipe bolts to 50 N.m (37 lb ft).
  20. Connect the oil level switch electrical connector.
  21. Connect the oil pressure sensor electrical connector.
  22. Install the oil pan drain plug. Tighten Tighten the plug to 26 N.m (19 lb ft).
  23. Install the lower radiator hose (1).
  24. Install the left and right wheel drive shafts. Refer to «AXLE SHAFTS»(ref-167337-S25682428292004101200000) .
  25. Lower the vehicle.
  26. Install the 4 grounds on the left side of the block (1).
  27. Install the camshaft sensor electrical connectors.
  28. Install the crankshaft sensor electrical connector.
  29. Install the knock sensor electrical connector.
  30. Install the generator electrical connector and battery lead (1). Tighten Tighten the generator battery lead nut to 9 N.m (80 lb in).
  31. Install the A/C pressure sensor and clutch electrical connector.
  32. Install starter electrical connectors and battery lead (1). Tighten Tighten the starter battery lead to 9 N.m (80 lb in).
  33. Install the fuel lines at the fuel pressure regulator. Refer to «FUEL PRESSURE REGULATOR»(ref-159085-S36539169562003111100000) .
  34. Install the engine harness bracket and bolt. Tighten Tighten the engine harness bracket bolt to 50 N.m (37 lb ft).
  35. Install the front differential vent hose, to the engine harness bracket.
  36. Install all the harnesses to the engine harness bracket.
  37. Install the PCM. Refer to «POWERTRAIN CONTROL MODULE»(ref-159085-S36870747962003111100000) .
  38. Install the power brake hose at booster
  39. Install the harness retainer to the original location.
  40. Install the ignition coil harness electrical connectors.
  41. Clip the transmission cooler lines to the right side of the engine block.
  42. Connect the camshaft phaser actuator valve electrical connector.
  43. Connect the front axle actuator electrical connector.
  44. Connect the A/C line at the accumulator.
  45. Install the oxygen sensor electrical connector.
  46. Remove the lift hook J 44220 .
  47. Install the AIR adapter and secure the adapter with the studs. Tighten Tighten the AIR adapter studs to 25 N.m (18 lb ft).
  48. Install the transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut. Tighten Tighten the nut to 10 N.m (89 lb in).
  49. Install the heater hoses to the heater core. Refer to HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 3) or HEATER HOSE REPLACEMENT - INLET (BODY TYPE VIN 6) and HEATER HOSE REPLACEMENT - OUTLET (LL8) in Heating, Ventilation, and Air Conditioning.
  50. Install the power steering pump.
  51. Install the power steering pump bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
  52. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-188499-S12793626322005090700000) .
  53. Install cooling fan and shroud, tilting the radiator forward for clearance.
  54. Finish installing the radiator. Refer to RADIATOR REPLACEMENT (BODY VIN CODE 6) or RADIATOR REPLACEMENT (BODY VIN TYPE 3) in Engine Cooling.
  55. Install transmission cooler lines together.
  56. Install map Sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE SENSOR»(ref-159085-S17062346442003111100000) .
  57. Install the throttle body. Refer to «THROTTLE BODY»(ref-159085-S22330361012003111100000) .
  58. Install the hood latch. Refer to HOOD LATCH SUPPORT REPLACEMENT in Body Front End.
  59. Install the head lamp housing. Refer to HEADLAMP HOUSING PANEL REPLACEMENT (OLDSMOBILE) or HEADLAMP HOUSING PANEL REPLACEMENT (CHEVROLET, GMC) in Body Front End.
  60. Install the grill. Refer to GRILLE REPLACEMENT (GMC) or GRILLE REPLACEMENT (OLDSMOBILE) or GRILLE REPLACEMENT (CHEVROLET) in Exterior Trim.
  61. Install the air intake baffle. Refer to AIR INTAKE BAFFLE REPLACEMENT - RADIATOR in Engine Controls - 4.2L.
  62. Install the washer solvent container. Refer to «WASHER SOLVENT CONTAINER REPLACEMENT»(ref-188870-S21358678172005090500000) in Wipers/Washer Systems.
  63. Install the air cleaner assembly. Refer to «AIR CLEANER ASSEMBLY»(ref-159085-S37652319732003111400000) .
  64. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  65. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.
  66. Service the engine oil.
  67. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 6) or DRAINING AND FILLING COOLING SYSTEM (BODY VIN CODE 3) in Engine Cooling.
  68. Recharge the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
  69. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(ref-159085-S15986821592003111100000) . IMPORTANT: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle. Disable the ignition system. Crank the engine several times. Listen for unusual noises or evidence that parts are binding. Enable the ignition system. Start the engine and listen for unusual noises. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature. Listen for a sticking lifter and other unusual noises. Inspect for fuel, oil and/or coolant leaks while the engine is running. Perform a final inspection for the proper engine oil and coolant levels.
  70. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.

Scheme 1019

Scheme 1019: Removal Procedure
Scheme 1019: Removal Procedure
  1. Remove the oil fill cap.
  2. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188480-S19457848752005090300000) in General Information.
  3. Remove the oil pan drain plug and drain the oil into a suitable container. IMPORTANT: Check the old oil filter to ensure the filter seal is not left on the engine block.
  4. Remove the oil filter using a suitable wrench.
  5. Wipe the excess oil from the oil filter housing.

Scheme 1020

Scheme 1020: Installation Procedure
Scheme 1020: Installation Procedure
  1. Lubricate the oil filter seal with clean engine oil. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) in Cautions and Notices.
  2. Install the new oil filter. Tighten Tighten the oil filter to 17 N.m (22 lb ft) plus 150 degrees.
  3. Install the oil pan drain plug. Tighten Tighten the oil pan drain plug to 26 N.m (19 lb ft).
  4. Lower the vehicle.
  5. Fill the crankcase with the proper quantity of engine oil.
  6. Remove the oil level indicator.
  7. Wipe the indicator with a clean cloth.
  8. Install the oil level indicator.
  9. Remove the oil level indicator and check the oil level.
  10. Add oil if necessary.
  11. Check for any oil leaks.

Scheme 1021

Scheme 1021: Engine Flywheel Removal
Scheme 1021: Engine Flywheel Removal
  1. Remove the flywheel bolts.
  2. Remove the flywheel.

Scheme 1022

Scheme 1022: Draining Fluids and Oil Filter Removal
Scheme 1022: Draining Fluids and Oil Filter Removal

Scheme 1023

Scheme 1023
Scheme 1023
  1. Remove the oil pan drain plug.
  2. Drain the engine oil.
  3. Remove the oil filter.

Scheme 1024

Scheme 1024: Drive Belt Tensioner Removal
Scheme 1024: Drive Belt Tensioner Removal
  1. Remove the drive belt tensioner bolt.
  2. Remove the drive belt tensioner.

Scheme 1025

Scheme 1025: Power Steering Pump Bracket Removal
Scheme 1025: Power Steering Pump Bracket Removal
  1. Remove the power steering pump bracket bolts.
  2. Remove the power steering pump bracket.

Scheme 1026

Scheme 1026: Drive Belt Idler Pulley Removal
Scheme 1026: Drive Belt Idler Pulley Removal
  1. Remove the drive belt idler pulley bolts.
  2. Remove the drive belt idler pulley.

Scheme 1027

Scheme 1027: Oil Level Indicator and Tube Removal
Scheme 1027: Oil Level Indicator and Tube Removal
  1. Remove the oil level indicator.
  2. Remove the oil level indicator tube stud.
  3. Remove the oil level indicator tube.

Scheme 1028

Scheme 1028: Exhaust Manifold Removal
Scheme 1028: Exhaust Manifold Removal

Scheme 1029

Scheme 1029
Scheme 1029

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Scheme 1030
Scheme 1030

Scheme 1031

Scheme 1031
Scheme 1031
  1. Remove the exhaust manifold heat shield nuts.
  2. Remove the exhaust manifold heat shield.
  3. Remove the exhaust manifold studs. (if needed)
  4. Remove the exhaust manifold bolts.
  5. Remove the exhaust manifold.
  6. Remove the exhaust manifold gasket.

Scheme 1032

Scheme 1032: Oil Filter Adapter Removal
Scheme 1032: Oil Filter Adapter Removal

Scheme 1033

Scheme 1033
Scheme 1033
  1. Remove the oil filter adapter.
  2. Remove the oil filter bypass valve.