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John, Master A.S.E Automotive technician
Category: Chevy
Satisfied Customers: 9176
Experience:  A.S.E MasterTechnician A1-A8 w/L1,38 years experience General Motors Master Technician
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Trailblazer: Chev...The differential goes through the oil pan

Resolved Question:

How is the 4.2 engine in a 2002 Chev. Trailblazer removed. The differential goes through the oil pan. Any help appreciated.
Submitted: 6 years ago.
Category: Chevy
Expert:  John replied 6 years ago.

HelloCustomer

Yea,the engineers must have been in the ozone when they thought up this one.See if this helps.

xTooltipElement Service Information Home Publications Number Search New Bulletins Bulletin Search Feedback Help
2002 Chevrolet TrailBlazer - 4WD | Bravada, Envoy, TrailBlazer (VIN S/T) Service Manual | Driveline/Axle | Front Drive Axle | Repair Instructions | Document ID:(NNN) NNN-NNNN

Differential Carrier Assembly Replacement

Removal Procedure


    Object Number: 656803  Size: SH
    Click here for detailed picture of above imageidth=
  1. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
    Object Number: 687450  Size: SH
    Click here for detailed picture of above imageidth=
  2. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  3. Drain the engine of oil.
  4. Drain the front drive axle. Refer to Lubricant Change .
  5. Remove the front propeller shaft from the front axle.
  6. Wrap the bearing caps with tape in order to prevent the loss of the roller bearings.
    Object Number: 886518  Size: MH
    Click here for detailed picture of above imageidth=
  7. Remove the ABS wiring harness from the retainers.
    Object Number: 886462  Size: SH
    Click here for detailed picture of above imageidth=
  8. Remove the brake hose retaining bolts.
  9. Remove the front drive axle vent hose.
    Object Number: 731542  Size: SH
    Click here for detailed picture of above imageidth=
  10. Remove the left and right upper ball pinch bolt and nut.
    Object Number: 886764  Size: SH
    Click here for detailed picture of above imageidth=
  11. Remove the left and right upper shock module retaining nuts.
    Object Number: 731562  Size: SH
    Click here for detailed picture of above imageidth=
  12. Remove the front stabilizer bar links from the frame. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  13. Remove the shock module from the frame.
  14. Remove the steering knuckle from the upper control arm.
  15. Remove the left and right front wheel drive shafts from the front drive axle.
    Object Number: 887945  Size: SH
    Click here for detailed picture of above imageidth=
  16. Relocate and secure the left and right front wheel drive shafts to the frame.
    Object Number: 887942  Size: SH
    Click here for detailed picture of above imageidth=
  17. Using mechanics wire or hook, support the front shock modules and steering knuckle.
    Object Number: 687447  Size: SH
    Click here for detailed picture of above imageidth=
  18. Remove the power steering gear assembly. Refer to Steering Gear Replacement in Power Steering System.
    Object Number: 756293  Size: SH
    Click here for detailed picture of above imageidth=
  19. Remove the inner shaft from the front drive axle. Refer to Front Drive Axle Inner Shaft Replacement .
    Object Number: 893104  Size: SH
    Click here for detailed picture of above imageidth=
  20. Remove the front drive axle from the oil pan.
  21. Secure the front drive axle to the frame.
  22. Remove the oil pan. Refer to Oil Pan Replacement in 4.2L Engine Mechanical.
    Object Number: 893108  Size: SH
    Click here for detailed picture of above imageidth=
  23. Remove the front drive axle from the vehicle.

Installation Procedure


    Object Number: 893104  Size: SH
    Click here for detailed picture of above imageidth=
  1. Install the front drive axle to the frame.
  2. Secure the front drive axle to the frame.
  3. Install the oil pan. Refer to Oil Pan Replacement in 4.2L Engine Mechanical.
  4. Remove the front drive axle from the frame.
  5. Install the front drive axle to the oil pan.

    Notice: Refer to Fastener Notice in the Preface section.

  6. Install the front drive axle mounting bolts.

    Tighten
    Tighten the front drive axle mounting bolts to 85 N·m (63 lb ft).


    Object Number: 756293  Size: SH
    Click here for detailed picture of above imageidth=
  7. Install the inner axle to the front drive axle. Refer to Front Drive Axle Inner Shaft Replacement .
    Object Number: 687447  Size: SH
    Click here for detailed picture of above imageidth=
  8. Install the power steering gear. Refer to Steering Gear Replacement in Power Steering System.
  9. Remove the left and right front wheel drive shafts from the frame.
  10. Remove the left, right shock module and steering knuckles from their supports.
  11. Install the right and left front wheel drive shafts to the front drive axle.
  12. Install the vent hose to the front drive axle.
  13. Install the left and right shock modules to the frame.
  14. Install the upper shock module retaining nuts.

    Tighten
    Tighten the upper shock module mounting bolts to 100 N·m (74 lb ft).

  15. Install the steering knuckle to the upper control arm.
  16. Install the upper ball joint pinch bolt and nut.

    Tighten
    Tighten the upper shock module mounting bolts to 40 N·m (30 lb ft).


    Object Number: 731562  Size: SH
    Click here for detailed picture of above imageidth=
  17. Install the front stabilizer bar links to the frame. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    Object Number: 886462  Size: SH
    Click here for detailed picture of above imageidth=
  18. Install the brake hose retaining bolts.

    Tighten
    Tighten the brake hose retaining bolt to 25 N·m (18 lb ft).


    Object Number: 886518  Size: MH
    Click here for detailed picture of above imageidth=
  19. Install the right and left ABS wiring harness in the retainers.
  20. Fill the front drive axle with the proper fluid. Refer to Lubricant Change .
  21. Fill the engine with the proper amount motor oil. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.
    Object Number: 687450  Size: SH
    Click here for detailed picture of above imageidth=
  22. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
    Object Number: 656803  Size: SH
    Click here for detailed picture of above imageidth=
  23. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

© 2008 General Motors Corporation. All rights reserved.

xTooltipElement Service Information Home Publications Number Search New Bulletins Bulletin Search Feedback Help
2002 Chevrolet TrailBlazer - 4WD | Bravada, Envoy, TrailBlazer (VIN S/T) Service Manual | Engine | Engine Mechanical - 4.2L | Repair Instructions | Document ID: 751789

Engine Replacement

Tools Required

J 44220 Engine Lift Bracket

Removal Procedure

  1. Remove the hood. Refer to Hood Replacement in Body Front End.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Drain engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
    Object Number: 637677  Size: SH
    Click here for detailed picture of above imageidth=

    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 Replacement in Engine Controls - 4.2L.
  8. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L
  9. Remove the map sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 4.2L
  10. Remove the washer solvent container. Refer to Windshield Washer Solvent Container Replacement 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 in Exterior Trim.
  13. Remove the headlamp housing. Refer to Headlamp Housing Panel Replacement in Body Front End.
  14. Remove the radiator support brace. Refer to Radiator Support Diagonal Brace Replacement 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 in Engine Cooling.
  20. Remove the drive belt. Refer to Drive Belt Replacement .
  21. Remove the power steering pump bolts and lay the pump aside.
    Object Number: 771722  Size: SH
    Click here for detailed picture of above imageidth=
  22. Ensure the heater hoses at the heater core are disconnected.
    Object Number: 754346  Size: SH
    Click here for detailed picture of above imageidth=
  23. Disconnect the transmission filler tube bracket nut from the AIR adapter.
    Object Number: 750190  Size: SH
    Click here for detailed picture of above imageidth=
  24. Remove the AIR adapter.
    Object Number: 750188  Size: SH
    Click here for detailed picture of above imageidth=
  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.
    Object Number: 754348  Size: SH
    Click here for detailed picture of above imageidth=
  30. Unclip the transmission cooler lines from right side of the engine block.
  31. Disconnect the ignition coil harness connectors.
    Object Number: 750195  Size: SH
    Click here for detailed picture of above imageidth=
  32. Carefully disconnect harness retainer at clips (1) and remove.
  33. Remove power brake hose at booster.
    Object Number: 761548  Size: SH
    Click here for detailed picture of above imageidth=
  34. Remove the PCM. Refer to Powertrain Control Module Replacement in Engine Controls - 4.2L.
  35. Disconnect the fuel lines at the fuel pressure regulator and cap lines. Refer to Fuel Pressure Regulator Replacement in Engine Controls - 4.2L.
  36. Remove all harnesses from the engine harness bracket.
  37. Disconnect the front differential vent hose from the engine harness bracket.
    Object Number: 761550  Size: SH
    Click here for detailed picture of above imageidth=
  38. Remove the engine harness bracket bolt and remove bracket.
    Object Number: 754358  Size: SH
    Click here for detailed picture of above imageidth=
  39. Disconnect starter electrical connections (1).
  40. Disconnect the A/C pressure sensor and clutch electrical connector.
    Object Number: 754357  Size: SH
    Click here for detailed picture of above imageidth=
  41. Disconnect generator electrical connector and battery lead (1).
  42. Disconnect the knock sensor electrical connector.
  43. Disconnect the crankshaft sensor electrical connector.
  44. Disconnect the camshaft sensor electrical connector.
    Object Number: 756989  Size: SH
    Click here for detailed picture of above imageidth=
  45. Remove 4 grounds on the left side of the block (1).
  46. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  47. Remove the wheel drive shafts, left and right. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  48. Remove the propeller shaft from the front axle pinion yoke. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  49. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Body Front End.
    Object Number: 750208  Size: SH
    Click here for detailed picture of above imageidth=
  50. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
  51. Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement in Frame and Underbody.
  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 Replacement in Frame and Underbody.
  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.
    Object Number: 754319  Size: SH
    Click here for detailed picture of above imageidth=
  65. Remove the left upper engine mount nut.
    Object Number: 754322  Size: SH
    Click here for detailed picture of above imageidth=
  66. Remove the right upper engine mount nut (1).
  67. Install the engine hoist.
  68. Raise the engine out of the compartment slowly keeping the transmission supported.
  69. Remove both engine mounts for clearance.
  70. Continue raising the engine out of the vehicle.
  71. Install the engine to the engine stand.

Installation Procedure

  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.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  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 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 Replacement in Frame and Underbody.
  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. Refer to Fuel Tank Shield Replacement in Frame and Underbody.
  17. Install the engine protection shield. Refer to Engine Protection Shield Replacement .
  18. Install the propeller shaft to the front axle pinion yoke. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
    Object Number: 750208  Size: SH
    Click here for detailed picture of above imageidth=
  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.
    Object Number: 637677  Size: SH
    Click here for detailed picture of above imageidth=
  22. Install the oil pan drain plug.

    Tighten
    Tighten the plug to 26 N·m (19 lb ft).


    Object Number: 750179  Size: SH
    Click here for detailed picture of above imageidth=
  23. Install the lower radiator hose (1).
  24. Install the left and right wheel drive shafts. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  25. Lower the vehicle.
    Object Number: 756989  Size: SH
    Click here for detailed picture of above imageidth=
  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.
    Object Number: 754357  Size: SH
    Click here for detailed picture of above imageidth=
  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.
    Object Number: 754358  Size: SH
    Click here for detailed picture of above imageidth=
  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 Replacement in Engine Controls - 4.2L.
    Object Number: 761550  Size: SH
    Click here for detailed picture of above imageidth=
  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 Replacement in Engine Controls - 4.2L.
  38. Install the power brake hose at booster
    Object Number: 750195  Size: SH
    Click here for detailed picture of above imageidth=
  39. Install the harness retainer (1) to the original location.
  40. Install the ignition coil harness electrical connectors.
    Object Number: 754348  Size: SH
    Click here for detailed picture of above imageidth=
  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.
    Object Number: 750188  Size: SH
    Click here for detailed picture of above imageidth=
  46. Remove the lift hook J 44220 .
    Object Number: 750190  Size: SH
    Click here for detailed picture of above imageidth=
  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).


    Object Number: 754346  Size: SH
    Click here for detailed picture of above imageidth=
  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 Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation, and Air Conditioning.
  50. Install the power steering pump.
    Object Number: 687444  Size: SH
    Click here for detailed picture of above imageidth=
  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 .
  53. Install cooling fan and shroud, tilting the radiator forward for clearance.
  54. Finish installing the radiator. Refer to Radiator Replacement in Engine Cooling.
  55. Install transmission cooler lines together.
  56. Install map Sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 4.2L.
  57. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 4.2L.
  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 in Body Front End.
  60. Install the grill. Refer to Grille Replacement 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 Windshield Washer Solvent Container Replacement in Wipers/Washer Systems.
  63. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.2L.
  64. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection 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 Cooling System Draining and Filling 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 Crankshaft Position System Variation Learn in Engine Controls - 4.2L.

    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.

© 2008 General Motors Corporation. All rights reserved.

John, Master A.S.E Automotive technician
Category: Chevy
Satisfied Customers: 9176
Experience: A.S.E MasterTechnician A1-A8 w/L1,38 years experience General Motors Master Technician
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