Hole in motor? Engine upgrades?

[GrizzlyDippah]

Hey guys I am pretty new to the forum. I live in Maine and I am picking up my 2004 Chevrolet Trailblazer with the 4.2L I6 next week for $500.00. This TB has 160,000 miles and Needs a windshield and the motor has a hole 3in. x 3in. On the lower drivers side. Haven't really gotten a real close look but it seems to be on the lower end just above the oil pan.

Here is a pic of where it is:

So I am picking up a motor at my local scrapyard that was in an accident. Motor will cost me about $300.00(He's a good friend of the family). And it's from an 02 so I know I have to switch over the intake and plan on throwing my oil pan on too just in case the accident damaged the one on that motor.

I was wondering if anyone else had problems like mine. This happened while he was accelerating to get on the interstate and he said he heard a loud thump and pulled over to check it out. Of course the oil spewed out of it but he said it still ran great! I started it to see and besides oil spraying onto the ground she runs amazing. What I am wondering is if maybe a rock or road hazard would be able to hit the motor and do this kind of damage and if anyone else had related problems.

So since I am putting a new motor in I figured why not do some upgrades while I have this one out... I am replacing the motor for a senior project at school and have completed ASE training and I have replaced motors, transmission and rear ends before but never on a TB. Should I run into any issues? Are there ways that would make the process easier to complete? and what would be some upgrades to improve gas mileage and over all performance? I have acess to a garage and a lift and all the necessary tools.

I will post pictures of my new TB when I can make it over to take some. I have plans of putting the MarkMC 3 inch lift and spacers with 32 inch tires. Also plan on putting a custom bumper with grill gaurd on it along with some of the LED mods shown in the appearance thread. I got 3 months til I get my license back so I got some time and money to get this TB looking great. Also going to remove the moldings and badges and put something a little more appealing on it. Any suggestions would be greatly appreciated! The TB is taken care of and the body is flawless! No door dings, dents, scratches, or other blemishes.

But for the time being here is a pic from google same as the one I am picking up:

 

[Mark20]

Welcome to the Nation.

I am definitely no expert but since you intend to the motor as a unit it should be pretty straight forward.

That location is pretty high up on the engine but somewhat open. Road debris is a possibility.

 

[GrizzlyDippah]

Welcome to the Nation.

I am definitely no expert but since you intend to the motor as a unit it should be pretty straight forward.

That location is pretty high up on the engine but somewhat open. Road debris is a possibility.

Ya I am getting into diesel mechanics

Gas jobs are so much easier! If only I had the tools and garage myself

But nope I gotta use a friends :/ Looking to build a garage this summer is I can get financed for it then pick up some snap on tools!

But it looks like its going to be straight forward replacing the motor! Gonna pull the grille and radiator for easier assembly and while Im there going to put in a transmission cooler since I am putting the bigger tires on it. Future upgrades will be a shift kit and a posi rear end. I got the perfect place to test her out after I get my upgrades finished . Thanks for the input Ill make sure I update this thread on my progress and pics of the old motor once I pull it! Hopefully start tearing down by next Monday!

 

[AbsoluteZero]

If you have access to GM's TSB's suggest looking thru them for any engine updates for the 02 engine since it was first yr.. I recall there was one related to the oil pump or oil pickup or maybe both. Perhaps the 04 engine's part could be swapped for any update(s).
Also re-torque the intake manifold bolts... much easier with the engine out.
Take your time... this forum has the collective knowledge equal in magnitude to Alvarado's number.

 

[Hatchet]

This is what you want it to look like...

Anything you can remove, remove to make it easier. Myself and 3 other members knocked it out in a weekend.

my thread on the motor swap.
http://gmtnation.com/forums/topic/8260-is-this-the-end/
not alot of info, as we were busy the whole time. But it was easier than I thought it was gunna be.

 

[GrizzlyDippah]

Well I am planning to invite like 5 of my friends over to help(2 have swapped motors before(including me lol)). But we got a lift and some tools to work with But I'm gonna have to go track down a motor lift. We are going to start the job at 6am and work til we get the motor out. Then put the new one in the following day, and we hope to have it done in about the same time you guys finished yours! Then I'll be taking my new ride for a trip with the guys! BTW What about a PCM relearn? I have swapped motors on trucks without all that happy horses***. Any ideas on a price for a pcm relearn?

 

[jimmyjam]

BTW What about a PCM relearn? I have swapped motors on trucks without all that happy horses***. Any ideas on a price for a pcm relearn?

you should do a CASE relearn. you can either go to a dealer, or if you've got access to HPTuners or a dashhawk or something like that.

 

[gmcman]

Does your TB have 4WD? This will make a difference as far as time is concerned, make sure you have all the necessary hardware for the front driveshafts.

If I had to pull a motor I would probably replace the rod bearings, front cover with oil pump and pick up screen. It's alot of work but not bad if on a stand....and would be peace of mind. Just a tip but not necessary.

 

[GrizzlyDippah]

Ya it's 4wd and the best I have to use is the snap on MODIS scan tool...

 

[Mounce]

Have you started the swap yet?

 

[GrizzlyDippah]

Project is put on hold... my Buddy went to Florida and gets back tomorrow. Got the trailblazer all paid for and should have it home tonight. Take pictures in the am(it's raining) and will update.

 

[Mounce]

Sounds good man. Good luck!

 

[GrizzlyDippah]

Got it all picked up and ready to put into the garage. Will be posting updates on my progress as I go.

 

[Mounce]

It looks great man, you got a good deal!

 

[ChrisinVictoria]

I just put a used engine in my 02 TB (4wd) last week. It took me 4 days in my driveway with 2 hours help from a neighbour. Hardest part was the upper bell housing bolt(only had 1 other was MIA). Wouldn't run after the swap so I put my older fuel rail and injectors and it flashed right up. I guess the injectors seize if they sit for years. I paid $40 for a CASE relearn at a local independant with a good scanner. Get your a/c evacuated if you can before you start,(nice to mother Nature). It will nedd recharge when you are done. I didn't have any major problems and it runs great now. Good Luck !!!

 

[GrizzlyDippah]

4 days by yourself? Wow. I am only waiting to pick up an engine hoist. Going to do some mods while I have it here anyway Any suggestions?

 

[ChrisinVictoria]

I got lucky with the hoist. Bought it used on a site similar to craigslist for $100. Figure I can sell it if I want for as much or more than I paid. I couldn't see paying for a rental. Great excuse to buy more shop equipment. Wife couldn't argue with my logic. Best advice I can give you is do each step right and don't get in a rush. You will be glad you did. As other forums have said do basic maintenance, plugs, clean T/B, new air filter, fluids. I found the installing the rear ward hook point at the AIR gives you much better balance than at the back of the head.

 

[GrizzlyDippah]

Nice! Now before I start pulling the motor...

What should I replace while I have the motor out and everything's apart? For example: Gaskets, Pumps, Filters, Universals, or Lines.
Looking to get a good list coming together so I can get an estimate on how much I am going to have to pay out and maybe even shop around for some deals.

Update on the motor: I am going to have to switch the Intake and Fuel Rails over to the new engine from my old one, And will switch the oil pans over while I have it apart.

So far here are my plans:

Pull the old motor.
Transfer Oil Pan, Intake, and Fuel Rail over to my new motor.
Replace spark plugs.
Check lines(Tranny lines, Brake Lines, Coolant and A/C Lines) for damage and replace if needed. Seems brake lines would be easier to route with the motor out
Get the new motor in and hook it up.
Replace ALL fluids(Front/Rear end, Transfer Case, Transmission, And 5w-30 Synthetic for the motor).
Test it.
And lastly the PCM Relearn. Anyone know if you can do this manually? Or do you have to have the shop do it?

Thanks for the help guys! Anyone who has completed a motor swap and has any more suggestions, I am always open to criticism and new ideas. I want to get this done right!

 

[ChrisinVictoria]

While out you should pick the best of parts from each for your new ride.Check the bearings on the idler, tensioner and water pump. Pull the CPAS and use the best one-clean it up real nice if needed. Clean your throttle body, you'll have it off anyway. You will probabily be swapping the front diff. and the 4wd disconnect. Thay are bolted to the oil pan. You may want to consider new seals. The used engine I got came with a diff. but it was the wrong ratio, get a VIN with the used engine and call a dealer for the ratio.If you are doing it in your driveway you will need jack stands, a good jack and an engine crane, also a lot of extensions to get the upper bell housing bolts. I think mine would have been easier if I had a leveller for the crane, but I got by. I went to a shop for the CASE relearn, there are threads here that will tell you what scanner you might need. Make your life a lot easier and have a service manual.
Best of luck

 

[GrizzlyDippah]

If I can't get an engine hoist I'm gonna pull this off redneck style
I got a tractor and a chain

Hopefully I am going to pick up my motor soon! And I will get to work.

 

[Hatchet]

When I did my engine swap, here is a list of the things I can remember replacing.

Fuel injector o-rings (the ones that go into the engine not the fuel rail)
spark plugs
thermostat
upper radiator hose
not sure if I replaced the water pump or not.
the engine
checked pullies

 

[GrizzlyDippah]

Thanks Hatchet! I got my deadline extended for school and I have until May, 28th to do it and write a full how to guide Maybe I will post it on the forum with pictures

But I got a few more questions...

1.) Can you pull and oil pan without removing the front differential from the oil pan?

And 2.) Is it true that there is no oil pan gasket and I have to special order the Engine sealant from GM?

 

[Sparky]

I would think you could use black RTV

 

[Hatchet]

Thanks Hatchet! I got my deadline extended for school and I have until May, 28th to do it and write a full how to guide Maybe I will post it on the forum with pictures

But I got a few more questions...

1.) Can you pull and oil pan without removing the front differential from the oil pan?

And 2.) Is it true that there is no oil pan gasket and I have to special order the Engine sealant from GM?

1. We removed the front diff to get the engine out I think. Not sure if the dif would be blocking any bolts to remove the oil pan.

2. I don't remember.

 

[GrizzlyDippah]

Going to go check out the new motor tomorrow and see if I think it's worth the $350.00. If it is hopefully work out a deal with my mechanic to get it for $280.00

Depending on whether I'm getting it me and my friend are going to pick up the motor and get it to the garage along with the trailblazer
And all I have to do is hope the motor will make it the 2 miles down the road

I will be taking pictures and updating this thread on my progress. After I'm done might even post a How to for dummies.

 

[Mypetropig]

While you have the motor on the stand I would also install a new t-stat and coolant temp sensor.

 

[Texan]

Rock Auto shows black RTV for oil pan gasket.

 

[Mounce]

X2 on the thermostat and coolant temp sensor. They're not easy to get to with the motor in the car.

 

[ChrisinVictoria]

From what I understand the only difference in the 2 oil pans is the oil level sensor. If you are putting an 02 engine(with sensor) in to an 04(no sensor), you should be able to just leave the sensor in the pan and not swap pans. I left the front diff. attatched when I pulled my engine. The diff. is easy to take off when out of the vehicle(4 bolts). If the engine isn't all you want, it makes sense to pay a little more to get a good one. Consider the time and effort versus saving a couple hundred bucks. It is a step back to put an 02 engine into an 04 but sometimes it's all we can afford.

 

[GrizzlyDippah]

If I were to say put a 350 in it how would I attach the front diff?

 

[GrizzlyDippah]

Started pulling the motor!

Removed the grille, Headlights, Housing, Radiator, Washer Reservoir, Air intake, Throttle Body, and Intake Manifold, got the PCM out the wiring put aside, Drained all fluids, Removed the crappy plastic skid plates, Have the AIR solenoid out, pulled the power steering pump, Have all the hoses and lines off(Transmission, Fuel, and Cooling/Heating Lines), Still need to work on the wiring on the drivers side to get the grounds and starter off. Probably more but I can't list it right now.

Have the tires off and the TB on jack stands to pull the front drive shaft, CV Shafts, Exhaust and to start on the bell housing and Torque Converter bolts.

Got a partial pic of the hole. And some more pictures on progress below. Will have this motor out soon(Before May, 28th).

So far all is well, Done all of the work myself. Will be calling up the friends when I pull it to help set up the tripod with chain fall to pull it.

 

[GrizzlyDippah]

I will have to get some more pictures of the hole... And up close to the motor. For some reason they didn't save on my phone.

Let me know what you think! Hoping to get the motor out tomorrow if the weather seems fit for it.