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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 902 (ENGINE MECHANICAL - 2.2L (LN2))REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSENGINE REPLACEMENTINSTALLATION PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Installation Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 GMC Sonoma and 2003 Chevrolet S10 Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the engine to the vehicle.
  2. Install the right side engine mount through-bolt. Refer to ENGINE MOUNT REPLACEMENT - RIGHT  .
  3. Install the left side engine mount through-bolt. Refer to ENGINE MOUNT REPLACEMENT - LEFT  .
  4. Remove the engine lifting device from the engine lift brackets.
  5. Connect the fuel hoses.
    Fig 1: Removing Engine Lifting Device From Engine Lift Brackets
    G01977068Courtesy of GENERAL MOTORS CORP.
  6. Position the engine wiring harness.
  7. Install the engine wiring harness to the bracket.
  8. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
  9. Connect the fuel injector harness electrical connector.
    Fig 2: Installing Engine Wiring Harness To Bracket
    G01977069Courtesy of GENERAL MOTORS CORP.
  10. Connect the following electrical connectors to the top of the engine:
    • Engine coolant temperature (ECT) sensor (3)
    • Idle air control (IAC) motor (1)
    • Manifold absolute pressure (MAP) sensor (4)
    • Throttle position (TP) sensor (2)
  11. Connect the engine coolant heater, if equipped. Refer to COOLANT HEATER REPLACEMENT (2.2L) in Engine Cooling.
  12. Connect the generator electrical connectors. Refer to GENERATOR in Generators & Regulators.
    Fig 3: Connecting Electrical Connectors To Top Of Engine
    G01977070Courtesy of GENERAL MOTORS CORP.
  13. Attach the battery positive cable with bolt to the underhood fuse block.

    Tighten 

    Tighten the battery positive cable to the underhood fuse block bolt to 10 N.m (89 lb in).

    Fig 4: Attaching Battery Positive Cable With Bolt To Underhood Fuse Block
    G01977071Courtesy of GENERAL MOTORS CORP.
  14. Install the battery positive cable cover.
    CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
  15. Install a NEW accelerator control cable.
  16. Connect the cruise control cable to the throttle body, if equipped. Refer to CRUISE CONTROL CABLE REPLACEMENT (2.2L) in Cruise Control.
    Fig 5: Installing Battery Positive Cable Cover
    G01977072Courtesy of GENERAL MOTORS CORP.
  17. Install both heater hoses to the heater core. Refer to HEATER HOSE REPLACEMENT - INLET (2.2L) and HEATER HOSE REPLACEMENT - OUTLET (2.2L) in Heating Ventilation and Air Conditioning.
  18. Install the power steering pump. Refer to POWER STEERING PUMP REPLACEMENT (2.2L) in Power Steering Systems.
  19. Install the air conditioning compressor, if equipped. Refer to COMPRESSOR REPLACEMENT (2.2L) in Heating Ventilation and Air Conditioning.
  20. Install the drive belt. Refer to DRIVE BELT REPLACEMENT  .
  21. Install the radiator. Refer to RADIATOR REPLACEMENT (2.2L) in Engine Cooling.
  22. Install the air intake duct.
  23. Connect the heating and air conditioning control vacuum source hose.
  24. Connect the EVAP emission purge tube from the throttle body.
    Fig 6: Connecting EVAP Emission Purge Tube To Throttle Body
    G01977073Courtesy of GENERAL MOTORS CORP.
  25. Install the bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

  26. Install the nut holding the engine wiring harness clip and the battery negative cable clip to the intake manifold.

    Tighten 

    Tighten the engine wiring harness clip nut to 10 N.m (89 lb ft).

  27. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.

    Tighten 

    Tighten the engine wiring harness clip nut to 30 N.m (22 lb ft).

  28. Raise the vehicle to a height in order to work through the wheelhouse opening.
    Fig 7: Installing Nut Holding Engine Wiring Harness Clip To Intake Manifold
    G01977074Courtesy of GENERAL MOTORS CORP.
  29. Connect the following electrical connectors to the right side of the engine:
    • Engine oil pressure sensor (6)
    • Camshaft position (CMP) sensor (5)
    • Crankshaft position (CKP) sensor (3)
    • Knock (KS) sensor (4)
  30. Install the bolt and the ground wires (1) to the engine.

    Tighten 

    Tighten the ground wire bolt to 35 N.m (26 lb ft).

  31. Install the bolt and the battery negative cable (2) to the engine.

    Tighten 

    Tighten the battery negative cable bolt to 35 N.m (26 lb ft).

    Fig 8: Connecting Electrical Connectors To Right Side Of Engine
    G01977075Courtesy of GENERAL MOTORS CORP.
  32. Connect both ignition control module (ICM) electrical connectors (2).
  33. Connect the EVAP purge canister solenoid valve electrical connector (1).
    Fig 9: Connecting Both Ignition Control Module (ICM) Electrical Connectors
    G01977076Courtesy of GENERAL MOTORS CORP.
  34. Install the generator brace using the following procedure.
    1. 34.1. Install the brace to the engine.
    2. 34.2. Install the two nuts holding the brace to the engine.
    3. 34.3. Install the bolt to the rear of the generator.

      Tighten 

      Tighten the generator rear brace nuts and bolt to 25 N.m (18 lb ft).

  35. Install the right fender wheelhouse extension. Refer to WHEELHOUSE EXTENSION REPLACEMENT in Body Front End.
  36. Connect the oxygen sensor electrical connector. Refer to HEATED OXYGEN SENSOR in System & Component Testing - 2.2L in Engine Performance.
  37. Install the transmission.
    • Refer to TRANSMISSION REPLACEMENT in Manual Transmission - NV 1500.
    • Refer to TRANSMISSION in Automatic Transmission - 4L60-E.
      Fig 10: Installing Generator Brace
      G01977077Courtesy of GENERAL MOTORS CORP.
  38. Install the starter motor. Refer to STARTER MOTOR in Starter.
  39. Install the oil filter drain deflector on the transmission brace rod, if equipped.
  40. Connect the exhaust pipe to the exhaust manifold. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT in Engine Exhaust.
  41. Lower the vehicle.
  42. Install the manual transmission shift tower, if removed. Refer to SHIFT TOWER REPLACEMENT in Manual Transmission - NV 1500.
  43. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.
  44. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  45. Fill the crankcase with engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  46. Fill the cooling system with coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
    Fig 11: Installing Oil Filter Drain Deflector On Transmission Brace Rod
    G01977078Courtesy of GENERAL MOTORS CORP.
  47. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any of the parts are binding.
  48. Start the engine and listen for unusual noises.
  49. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.

    If necessary, install an oil pressure gauge and measure the engine oil pressure.

  50. Operate the engine at about 1,000 RPM until the engine has reached normal operating temperature.
  51. Listen for improperly adjusted or sticking valves, sticking valve lifters, or other unusual noises.
  52. Inspect for oil and/or coolant leaks while the engine is operating.
  53. Verify that the distributor is properly positioned.
  54. Perform a final inspection for the proper engine oil and coolant levels.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.