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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 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.
CAUTION: Refer to BATTERY DISCONNECT CAUTION .
NOTE: Refer to ENGINE EMISSION NOTICE .
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Remove the hood. Refer to HOOD REPLACEMENT .
  3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) .
  4. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  6. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  7. Remove the torque converter cover. Refer to
  8. Remove the starter motor. Refer to STARTER MOTOR .
  9. Remove the engine flywheel-to-torque converter bolts. Refer to
  10. Scribe the torque converter to the flywheel for installation.
  11. Remove the transaxle brace. Refer to TRANSAXLE BRACE .
  12. Remove the engine mount lower nuts.
  13. Remove the three-way catalytic converter pipe from the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.1L) or CATALYTIC CONVERTER REPLACEMENT (3.8L) .
  14. Remove the oil level sensor harness retainer bolt.
  15. Remove the oil level harness retainer from the engine.
  16. Disconnect and reposition the electrical connectors from the following components:
    • The vehicle speed sensor (VSS)
    • The oil pressure sensor
    • The oil level sensor
    • The knock sensors
    • The heated oxygen (H02) sensor
  17. Remove the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  18. Remove the engine ground nut and engine ground from the transaxle stud.
    Fig 1: Removing Engine Mount Lower Nuts
    G01703383Courtesy of GENERAL MOTORS CORP.
  19. Remove the bolt (6) and stud (1) which secure the lower transaxle to the engine.
  20. Lower the vehicle while supporting the transaxle.
  21. Remove the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY .
    Fig 2: Removing Lower Transaxle Bolt, Stud & Air Cleaner Assembly
    G01703384Courtesy of GENERAL MOTORS CORP.

    Important:  Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .

  22. Disconnect the fuel lines (1,2) from the fuel rail. Lay the fuel lines aside. Refer to
  23. Disconnect the fuel vapor line.
  24. Remove the throttle and cruise control cables and bracket from the throttle body. Refer to
    Fig 3: Fuel Lines
    G01703385Courtesy of GENERAL MOTORS CORP.
  25. Loosen the water pump pulley bolts.
  26. Remove the drive belt. Refer to Drive Belt Replacement (L36)  or Drive Belt Replacement (L67) .
  27. Remove the water pump pulley bolts and the water pump pulley.
  28. Remove the right and left engine mount struts. Refer to Engine Mount Strut Replacement - Right  and to Engine Mount Strut Replacement - Left .
  29. Remove the engine mount brackets from the radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
  30. Disconnect the positive battery cable.
  31. Remove the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC .
    Fig 4: Removing Water Pump Pulley & Bolts
    G01703386Courtesy of GENERAL MOTORS CORP.
  32. Remove the vacuum booster hose from the engine. Refer to POWER BRAKE BOOSTER CHECK VALVE/HOSE .
  33. Disconnect the A/C vacuum hose from the engine.
  34. Remove the power steering pump bolts and pump from the engine. Lay the power steering pump aside.
  35. Disconnect the upper engine electrical connectors from the following components:
    • The fuel injectors
    • The throttle position (T/P) sensor
    • The idle air control (IAC) valve
    • The EVAP purge solenoid
    • The exhaust gas recirculation (EGR) valve
    • The manifold absolute pressure (MAP) sensor
  36. Remove upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal.
  37. Remove the radiator inlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.1 L) or RADIATOR HOSE REPLACEMENT - INLET (3.8L) .
  38. Remove the radiator outlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.1 L) or RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) .
    Fig 5: Removing Power Steering Pump & Bolts
    G01703387Courtesy of GENERAL MOTORS CORP.
  39. Remove the heater hoses from the drive belt tensioner. Refer to HEATER HOSE REPLACEMENT - INLET (3.1L) or HEATER HOSE REPLACEMENT - INLET (3.8L) and to HEATER HOSE REPLACEMENT - OUTLET (3.1 L) or HEATER HOSE REPLACEMENT - OUTLET (3.8L) .
  40. Remove the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
  41. Install the engine lifting device.
    Fig 6: Removing A/C Compressor
    G01703388Courtesy of GENERAL MOTORS CORP.
  42. Remove the upper transaxle-to-engine bolts (2,3,4,5).
  43. With the aid of an assistant, remove the engine from the vehicle.
  44. Remove the flywheel. Refer to Engine Flywheel Replacement .
  45. Install the engine to the engine stand.
    Fig 7: Removing Upper Transaxle-To-Engine Bolts
    G01703389Courtesy of GENERAL MOTORS CORP.
  46. Remove the oil indicator tube nut from the exhaust manifold.
  47. Remove the oil level indicator tube.
    Fig 8: Removing Oil Level Indicator Tube & Nut
    G01703390Courtesy of GENERAL MOTORS CORP.
  48. Remove the left side engine mount bracket bolts.
    Fig 9: Removing Left Side Engine Mount Bracket Bolts
    G01703391Courtesy of GENERAL MOTORS CORP.
  49. Remove the right side engine mount bracket bolts and the engine mount bracket.
  50. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) .
  51. Remove the ignition control module and the ignition control module bracket. Refer to IGNITION CONTROL MODULE .
  52. Remove the left and right side engine mount strut brackets. Refer to Engine Mount Strut Bracket Replacement - Left on page 6-290  and to Engine Mount Strut Bracket Replacement - Right Upper (L36)  or Engine Mount Strut Bracket Replacement - Right Upper (L67) .
    Fig 10: Removing Right Side Engine Mount Bracket & Bolts
    G01703392Courtesy of GENERAL MOTORS CORP.
  53. Remove the A/C compressor bracket bolts and bracket.
    Fig 11: Removing A/C Compressor Bracket & Bolts
    G01703393Courtesy of GENERAL MOTORS CORP.
  54. Remove the fuel injector sight shield bracket nuts.
  55. Remove the fuel injector sight shield bracket
  56. Remove the EGR valve adapter from the right cylinder head. Refer to REMOVAL (3.8L -- INLET PIPE) .
  57. Remove the upper intake manifold or supercharger. Refer to Intake Manifold Replacement - Upper  or Supercharger Replacement .
    Fig 12: Removing Fuel Injector Sight Shield Bracket & Bolts
    G01703394Courtesy of GENERAL MOTORS CORP.
  58. Remove the generator brace bracket bolts.
  59. Remove the generator brace bracket from the right cylinder head.
  60. Remove the left and the right engine lift brackets.
  61. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  62. Remove the right exhaust manifold, the left exhaust manifold and the exhaust crossover. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.1L) or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) and to EXHAUST MANIFOLD REPLACEMENT - LEFT (3.1L) or EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8L) .
    Fig 13: Removing Generator Bracket & Bolts
    G01703395Courtesy of GENERAL MOTORS CORP.
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