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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1676 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Front Cover Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Buick Regal. 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. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  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 in Engine Cooling.
  5. Lower the vehicle.
  6. Loosen the water pump pulley bolts.
  7. Remove the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT  .
  8. Remove the water pump pulley.
  9. Remove the power steering pump bolts and reposition the pump.
    Fig 1: Removing Power Steering Pump
    G01968488Courtesy of GENERAL MOTORS CORP.
  10. Raise the vehicle.
  11. Remove the crankshaft balancer. Refer to CRANKSHAFT BALANCER REPLACEMENT  .
    IMPORTANT: Be careful not to damage the crankshaft.
  12. 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 2: Removing Crankshaft Front Oil Seal
    G01968489Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the electrical connectors from the following:
    • Camshaft position (CMP) sensor
    • Crankshaft position (CKP) sensor
    • Oil pressure sensor
  14. Remove the crankshaft position sensor shield.
    Fig 3: Removing Crankshaft Position Sensor Shield
    G01968490Courtesy of GENERAL MOTORS CORP.
  15. Remove the radiator outlet hose from the water pump. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in Engine Cooling.
  16. Lower the vehicle.
  17. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE  .
  18. 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.
  19. Remove the oil filter.
    Fig 4: Removing Oil Filter
    G01968491Courtesy of GENERAL MOTORS CORP.
  20. Remove the engine mount bracket for oil pan access. Refer to ENGINE MOUNT AND BRACKET REPLACEMENT  .
  21. Disconnect the oil level sensor electrical connector.
  22. Remove the oil level sensor.
  23. Remove the oil pan-to-engine front cover bolts.
  24. Loosen the remaining oil pan bolts to gain access for the engine front cover removal. DO NOT remove the remaining oil pan bolts.
  25. Remove the crankshaft position sensor.
    Fig 5: Removing Crankshaft Position Sensor
    G01968492Courtesy of GENERAL MOTORS CORP.
  26. Remove the engine front cover bolts.
    Fig 6: Removing Engine Front Cover & Bolts With Oil Filter Adapter
    G01968493Courtesy of GENERAL MOTORS CORP.
  27. Remove the engine front cover with the oil filter adapter as one assembly.
  28. Remove the engine front cover gasket.
    Fig 7: Removing Engine Front Cover Gasket
    G01968494Courtesy 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 8: Removing Oil Filter Adapter & Pressure Relief Valve From Engine Front Cover
    G01968495Courtesy of GENERAL MOTORS CORP.
  30. If replacing the engine front cover, remove the water pump from the engine front cover.
    Fig 9: Removing Water Pump Bolts From Engine Front Cover
    G01968496Courtesy 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  .
    Fig 10: Removing Oil Pump Cover & Gear Set From Engine Front Cover
    G01968497Courtesy of GENERAL MOTORS CORP.
  32. Inspect the oil pump cover and gear set. Refer to OIL PUMP CLEANING AND INSPECTION  .
  33. If replacing the engine front cover, remove the camshaft position sensor from the engine front cover.
    Fig 11: Removing Camshaft Position Sensor From Engine Front Cover
    G01968498Courtesy of GENERAL MOTORS CORP.
  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.
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