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Home >> Chevrolet >> 2001 >> Camaro Base, 2D Convertible, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 63 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  2. Disconnect the positive battery cable.
    Fig 1: Disconnecting Positive Battery Cable
    G01728889Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the intake air temperature (IAT) sensor electrical connector.
    Fig 2: Disconnecting Intake Air Temperature (IAT) Sensor Electrical Connector
    G01728890Courtesy of GENERAL MOTORS CORP.
  4. Remove the air intake duct.
    Fig 3: Removing Air Intake Duct
    G01728891Courtesy of GENERAL MOTORS CORP.
  5. Recover the refrigerant. Refer to COOLANT RECOVERY RESERVOIR REPLACEMENT .
  6. Raise and support the vehicle. LIFTING AND JACKING THE VEHICLE
  7. Remove the starter motor. Refer to STARTER MOTOR (3.8L) .
  8. If equipped, remove the torque converter to flywheel bolts.
  9. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  10. Remove the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels .
  11. Drain the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM .
  12. Remove the 3-way catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L ENGINE) .
  13. Remove the propeller shaft.
  14. Remove the torque arm. Refer to TORQUE ARM REPLACEMENT .
  15. If equipped with an automatic transmission, remove the transmission range selector lever cable from the range selector lever.
    Fig 4: Removing Transmission Range Selector Lever Cable From Range Selector Lever
    G01728892Courtesy of GENERAL MOTORS CORP.
  16. Remove the retainer from the range selector lever cable.
    Fig 5: Removing Retainer From Range Selector Lever Cable
    G01728893Courtesy of GENERAL MOTORS CORP.
  17. Remove the range selector lever cable from the cable bracket.
    Fig 6: Removing Range Selector Lever Cable From Cable Bracket
    G01728894Courtesy of GENERAL MOTORS CORP.
  18. If equipped with a manual transmission, disconnect the clutch actuator cylinder line from the actuator cylinder using the J 36221.
    19. Fig 7: Disconnecting Clutch Actuator Cylinder Line From The Actuator Cylinder
    G01728895Courtesy of GENERAL MOTORS CORP.
  19. Remove the left side front air deflector.
  20. Remove the stabilizer bar brackets. Refer to STABILIZER SHAFT INSULATOR REPLACEMENT .
  21. Remove the intermediate steering shaft bolt and shaft from the rack. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column .
    Fig 8: Removing Intermediate Steering Shaft Bolt And Shaft From Rack
    G01728896Courtesy of GENERAL MOTORS CORP.
  22. Remove the wiring harness ground bolt and RF (Radio Frequency) ground strap and cruise control ground lead from the front rail.
    23. Fig 9: Removing Wiring Harness Ground Bolt, RF (Radio Frequency) Ground Strap And Cruise Control Ground Lead From Front Rail
    G01728897Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the knock sensor electrical connectors.
  24. Disconnect the wheel speed sensors electrical connectors.
    Fig 10: Disconnecting Wheel Speed Sensors Electrical Connectors
    G01728898Courtesy of GENERAL MOTORS CORP.
  25. Remove the A/C compressor and condenser hose bolt from the compressor.
    26. Fig 11: Removing A/C Compressor And Condenser Hose Bolt From The Compressor
    G01728899Courtesy of GENERAL MOTORS CORP.
  26. Discard the O-ring.
  27. Remove the A/C compressor and condenser hose nut from the condenser.
  28. Discard the O-ring.
    Fig 12: Removing A/C Compressor And Condenser Hose Nut From The Condenser
    G01728900Courtesy of GENERAL MOTORS CORP.
  29. Remove the front fuel pipe heat shield nuts (1).
  30. Remove the front fuel pipe heat shield (2).
  31. Remove the brake lines from the brake pipe clip.
  32. Lower the vehicle.
    Fig 13: Removing Front Fuel Pipe Heat Shield Nuts
    G01728901Courtesy of GENERAL MOTORS CORP.
  33. Remove the engine wiring harness ground bolt (1).
    Fig 14: Removing Engine Wiring Harness Ground Bolt
    G01728902Courtesy of GENERAL MOTORS CORP.
  34. Remove the engine ground.
  35. Remove the A/C compressor and condenser hose bolt from the accumulator.
    Fig 15: Removing A/C Compressor And Condenser Hose Bolt From Accumulator
    G01728903Courtesy of GENERAL MOTORS CORP.
  36. Discard the O-ring.
  37. Remove the heater hoses from the drive belt tensioner.
  38. Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  39. Disconnect the fuel lines from the fuel rail. Refer to REMOVAL (QUICK-CONNECT FITTING - WITH METAL) .
  40. Disconnect the fuel vapor line from the EVAP canister purge valve. Refer to REMOVAL (QUICK-CONNECT FITTING - WITH PLASTIC) .
    Fig 16: Disconnecting Fuel Vapor Line From EVAP Canister Purge Valve
    G01728904Courtesy of GENERAL MOTORS CORP.
  41. Disconnect the electronic throttle control (ETC) electrical connector (1).
    Fig 17: Disconnecting Electronic Throttle Control (ETC) Electrical Connector
    G01728905Courtesy of GENERAL MOTORS CORP.
  42. Remove the forward lamp harness branch from the wire harness clip.
  43. Remove the inlet hose from the water outlet.
    Fig 18: Removing Inlet Hose From The Water Outlet
    G01728906Courtesy of GENERAL MOTORS CORP.
  44. Remove the outlet hose from the coolant pump.
    Fig 19: Removing Outlet Hose From The Coolant Pump
    G01728907Courtesy of GENERAL MOTORS CORP.
  45. Remove the brake booster vacuum hose (2) from the intake manifold fitting (1).
    Fig 20: Remove Brake Booster Vacuum Hose From Intake Manifold Fitting
    G01728908Courtesy of GENERAL MOTORS CORP.
  46. Remove the front 2 brake pipes from the brake modulator.
  47. Disconnect the forward lamp harness from the engine harness.
  48. Disconnect the engine harness vacuum tube from the bottom of the vacuum check valve.
    49. Fig 21: Disconnecting Engine Harness Vacuum Tube
    G01728909Courtesy of GENERAL MOTORS CORP.
  49. Remove the PCM from the vehicle. Refer to POWERTRAIN CONTROL MODULE .
  50. Remove the right side insulator panel.
  51. Remove the hinge pillar trim panel.
  52. Disconnect the engine wiring harness from the instrument panel wiring harness.
    Fig 22: Disconnecting Engine Wiring Harness From Instrument Panel Wiring Harness
    G01728910Courtesy of GENERAL MOTORS CORP.
  53. Remove the engine wire harness through the front of the cowl. Place the harness on top of the engine.
  54. If equipped with the manual transmission remove the transmission shift control.
    Fig 23: Remove Transmission Shift Control
    G01728911Courtesy of GENERAL MOTORS CORP.
  55. Raise the vehicle.
  56. Remove the right and left side shock absorber lower mounting bolts.
    Fig 24: Removing Right And Left Side Shock Absorber Lower Mounting Bolts
    G01728912Courtesy of GENERAL MOTORS CORP.
  57. Remove the cotter pins and nuts from the left and right upper ball joints.
  58. Remove the left and right upper ball joints from the steering knuckles using the J 39549.
  59. Support the left and right steering knuckles.
  60. Position the J 39580 under the vehicle.
  61. Lower the vehicle on the J 39580.
  62. Remove the crossmember bolts.
    Fig 25: Removing Crossmember Bolts
    G01728913Courtesy of GENERAL MOTORS CORP.
  63. Remove the transmission support bolts.
  64. Raise the vehicle and remove the engine and transmission from the vehicle.
  65. Secure the crossmember to the J 39580.
  66. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  67. Remove the A/C compressor and the A/C compressor mounting bracket. Refer to COMPRESSOR .
    Fig 26: Removing A/C Compressor And A/C Compressor Mounting Bracket
    G01728914Courtesy of GENERAL MOTORS CORP.
  68. Remove the power steering pump nuts (3).
    Fig 27: Removing Power Steering Pump Nuts
    G01728915Courtesy of GENERAL MOTORS CORP.
  69. Reposition the power steering pump to crossmember.
  70. Disconnect the generator electrical connector.
    Fig 28: Disconnecting Generator Electrical Connector
    G01728916Courtesy of GENERAL MOTORS CORP.
  71. Remove the positive cable nut from the generator terminal.
    Fig 29: Removing Positive Cable Nut From Generator Terminal
    G01728917Courtesy of GENERAL MOTORS CORP.
  72. Remove the generator from the engine.
  73. Install a lifting device to the engine.
  74. Remove the right engine mount bracket bolts (1, 2) and the right engine mount bracket (3).
    Fig 30: Removing Right Engine Mount Bracket Bolts And Right Engine Mount Bracket
    G01728918Courtesy of GENERAL MOTORS CORP.
  75. Remove the left engine mount bracket bolts (3).
  76. Remove the left engine mount bracket stud (2) and the left engine mount bracket (1).
  77. With the aide of an assistant, raise the engine and transmission from the crossmember.
    Fig 31: Removing Left Engine Mount Bracket Bolts
    G01728919Courtesy of GENERAL MOTORS CORP.
  78. If equipped with the automatic transmission remove the following from the right side:
    • The transmission support brace bolts (1, 2, 3)
    • The transmission support nut (6)
    • The transmission support (4)
    Fig 32: Removing Transmission Support Brace Bolts
    G01728920Courtesy of GENERAL MOTORS CORP.
  79. If equipped with the automatic transmission remove the following from the left side:
    • The transmission support brace bolts (3, 5)
    • The transmission support nut (1)
    • The transmission support (4)
    Fig 33: Removing Transmission Support Brace Bolts
    G01728921Courtesy of GENERAL MOTORS CORP.
  80. If equipped with the manual transmission remove the following from the right side:
    • The transmission support bolts (3, 4)
    • The transmission support (1)
    Fig 34: Removing Transmission Support Bolts
    G01728922Courtesy of GENERAL MOTORS CORP.
  81. If equipped with the manual transmission remove the following from the left side:
    • The transmission support bolts (2, 3)
    • The transmission support (1)
    Fig 35: Removing Transmission Support Bolts
    G01728923Courtesy of GENERAL MOTORS CORP.
  82. Disconnect the electrical connectors from the transmission.
  83. Place the transmission on a suitable table.
  84. For the automatic transmission, remove the transmission to engine bolts and nut.
  85. Separate the engine from the transmission.
  86. Attach the J 21366 to the transmission to secure the torque converter.
    Fig 36: Removing Transmission To Engine Bolts And Nut (A/T)
    G01728924Courtesy of GENERAL MOTORS CORP.
  87. For the manual transmission, remove the transmission to engine bolts (1, 2) and nuts (3).
    Fig 37: Removing The Transmission To Engine Bolts And Nuts
    G01728925Courtesy of GENERAL MOTORS CORP.
  88. Separate the engine from the transmission.
  89. Remove the engine flywheel. Refer to Engine Flywheel Replacement .
  90. Install the engine to an engine stand.
  91. Remove the lifting device from the engine.
  92. Disconnect and remove the engine wiring harness from the engine.
  93. Remove the left and right exhaust manifolds. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8 L) and EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) .
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