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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1224 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Engine Front Cover Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  4. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  5. Lower the vehicle.
  6. Loosen the water pump pulley bolts.
  7. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) .
  8. Remove the water pump pulley.
  9. Remove the radiator outlet hose. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.1 L) or RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) .
  10. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
    IMPORTANT: Be careful not to damage the crankshaft.
  11. Pry out the crankshaft front oil seal with a flat bladed tool such as a large screwdriver. Use care to avoid damaging the crankshaft front oil seal bore or the crankshaft front oil seal contact surfaces.
    Fig 1: Crankshaft Position Sensor Shield
    G01703265Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the electrical connectors from the following:
    • Camshaft position (CMP) sensor
    • Crankshaft position (CKP) sensor
    • Oil pressor sensor
  13. Remove the crankshaft position sensor shield.
  14. Lower the vehicle.
  15. Install the engine support fixture. Refer to Engine Support Fixture .
  16. Raise the vehicle.
    IMPORTANT: The oil pan can be dropped slightly for engine front cover clearance if all pan bolts are loosened and the oil level sensor is removed.
  17. Remove the engine mount bracket for oil pan access. Refer to Engine Mount and Bracket Replacement .
  18. Remove the oil filter.
  19. Disconnect the oil level sensor electrical connector.
  20. Remove the oil level sensor.
  21. Remove the oil pan-to-engine front cover bolts.
  22. Lower the oil pan and remove the oil pan-to-engine front cover bolts.
  23. Loosen the remaining oil pan bolts to gain access for the engine front cover removal. DO NOT remove the remaining oil pan bolts.
  24. Remove the crankshaft position sensor stops.
    Fig 2: Oil Filter
    G01703266Courtesy of GENERAL MOTORS CORP.
  25. Remove the crankshaft position sensor.
    Fig 3: Crankshaft Position Sensor
    G01703267Courtesy of GENERAL MOTORS CORP.
  26. Remove the engine front cover bolts.
  27. Remove the engine front cover with the oil filter adapter as one assembly.
    Fig 4: Engine Front Cover
    G01703268Courtesy of GENERAL MOTORS CORP.
  28. Remove the engine front cover gasket.
    Fig 5: Engine Front Cover Gasket
    G01703269Courtesy of GENERAL MOTORS CORP.
  29. If replacing the engine front cover, remove the oil filter adapter and pressure relief valve from the engine front cover.
    Fig 6: Oil Filter Adapter
    G01703270Courtesy of GENERAL MOTORS CORP.
  30. If replacing the engine front cover, remove the water pump from the engine front cover.
    Fig 7: Water Pump & Bolts
    G01703271Courtesy of GENERAL MOTORS CORP.
  31. If replacing the engine front cover, remove the oil pump cover and gear set from the engine front cover. Refer to Oil Pump Cover and Gear Set Replacement .
  32. Inspect the oil pump cover and gear set. Refer to OIL PUMP CLEANING AND INSPECTION .
    Fig 8: Oil Pump Cover & Gear Set
    G01703272Courtesy of GENERAL MOTORS CORP.
  33. If replacing the engine front cover, remove the camshaft position sensor from the engine front cover.
  34. Inspect the timing chain for overall in and out movement. Maximum movement is 25.4 mm (1 in). Refer to TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION (L36) or TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION (L67) .
  35. Inspect the sprockets for wear.
  36. Inspect the oil pan gasket. Replace the oil pan gasket if necessary.
  37. Clean the engine front cover mating surfaces.
    Fig 9: Camshaft Position Sensor
    G01703273Courtesy of GENERAL MOTORS CORP.
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