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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1244 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 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 in Battery.
  2. Remove the hood. Refer to HOOD REPLACEMENT in Body Front End.
  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 JACKING AND LIFTING in General Information.
  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 in Engine Cooling.
  7. Remove the torque converter covers.
  8. Remove the starter motor. Refer to STARTING SYSTEM in Starter.
  9. Remove the engine flywheel-to-torque converter bolts. Refer to FLYWHEEL TO TORQUE CONVERTER BOLT REPLACEMENT  in Automatic Transaxle - 4T65 - E.
  10. Scribe the torque converter to the flywheel for installation.
  11. Remove the transaxle brace. Refer to AUTOMATIC TRANSMISSION BRACE REPLACEMENT  in Automatic Transaxle - 4T65 - E.
  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 (3.8L) in Engine Exhaust.
  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:
    • Vehicle speed sensor (VSS)
    • Oil pressure sensor
    • Oil level sensor
    • Knock sensors
    • Heated oxygen sensor (H02S)
    Fig 1: Removing Engine Mount
    G02083708Courtesy of GENERAL MOTORS CORP.
  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.
  19. Remove the bolt (6) and the stud (1) which secure the lower transaxle to the engine.
  20. Lower the vehicle while supporting the transaxle.
  21. Remove the air cleaner assembly.
  22. Disconnect the fuel lines from the fuel rail. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 or ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  23. Disconnect the fuel vapor line. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  24. Remove the accelerator and cruise control cables and bracket from the throttle body. Refer to ACCELERATOR CONTROLS CABLE BRACKET REPLACEMENT in Engine Performance - Removal and Installation.
    Fig 2: Removing Lower Transaxle To Engine
    G02083709Courtesy 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 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.
    Fig 3: Removing Water Pump Pulley
    G02083710Courtesy of GENERAL MOTORS CORP.
  31. Remove the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC in Engine Cooling.
  32. Remove the vacuum booster hose from the engine. Refer to POWER BRAKE BOOSTER CHECK VALVE /HOSE in Hydraulic Brakes.
  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:
    • Fuel injectors
    • Throttle position (T/P) sensor
    • Idle air control (IAC) valve
    • EVAP purge solenoid
    • Exhaust gas recirculation (EGR) valve
    • 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 (3.8L) in Engine Cooling.
  38. Remove the radiator outlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in Engine Cooling.
  39. Remove the heater hoses from the drive belt tensioner. Refer to HEATER HOSE REPLACEMENT - INLET (3.8L) and HEATER HOSE REPLACEMENT - OUTLET (3.8L) in Heating, Ventilation and Air Conditioning.
    Fig 4: Removing Power Steering Pump And Bolts
    G02083711Courtesy of GENERAL MOTORS CORP.
  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 5: Removing A/C Compressor
    G02083712Courtesy of GENERAL MOTORS CORP.
  42. Remove the bolts (2,3,4,5) which secure the upper transaxle to the engine.
  43. With assistance remove the engine from the vehicle.
  44. Remove the flywheel. Refer to ENGINE FLYWHEEL REMOVAL  .
  45. Install the engine to the engine stand.
    Fig 6: Removing Upper Transaxle To Engine
    G02083713Courtesy of GENERAL MOTORS CORP.
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