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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 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. Remove the hood. Refer to HOOD REPLACEMENT in Body Front End.
  3. Remove the cross vehicle brace. Refer to BRACE REPLACEMENT -- CROSS VEHICLE in Body Front End.
  4. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  5. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  6. Drain the engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  7. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  8. Remove the torque converter covers.
  9. Remove the starter motor. Refer to STARTER in Starters.
  10. Remove the engine flywheel-to-torque converter bolts. Refer to TRANSAXLE (2003) in Removal & Installation - A/T.
  11. Scribe the torque converter to the flywheel for installation.
  12. Remove the transaxle brace. Refer to TRANSAXLE BRACE in Removal & Installation - A/T.
  13. Remove the engine mount lower nuts.
    Fig 1: Removing Engine Mount Lower Nuts
    G01969282Courtesy of GENERAL MOTORS CORP.
  14. Remove the three-way catalytic converter pipe from the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L) in Engine Exhaust.
  15. Remove the oil level sensor harness retainer bolt.
  16. Remove the oil level harness retainer from the engine.
  17. 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)
  18. Remove the oil filter adapter housing. Refer to OIL FILTER ADAPTER AND BYPASS VALVE ASSEMBLY REPLACEMENT  .
  19. Remove the engine ground nut and engine ground from the transaxle stud.
  20. Remove the bolt (6) and the stud (1) which secure the lower transaxle to the engine.
    Fig 2: Removing Bolt & Stud Securing Lower Transaxle To Engine
    G01969283Courtesy of GENERAL MOTORS CORP.
  21. Lower the vehicle while supporting the transaxle.
  22. Remove the air cleaner assembly.
  23. Disconnect the fuel lines from the fuel rail. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
  24. Disconnect the fuel vapor line. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
  25. Remove the accelerator and cruise control cables and bracket from the throttle body.
  26. Loosen the water pump pulley bolts.
  27. Remove the drive belt. Refer to DRIVE BELT REPLACEMENT (L36)  or DRIVE BELT REPLACEMENT (L67)  .
  28. Remove the water pump pulley bolts and the water pump pulley.
    Fig 3: Removing Bolts & Water Pump Pulley
    G01969284Courtesy of GENERAL MOTORS CORP.
  29. Remove the right and left engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - RIGHT  and ENGINE MOUNT STRUT REPLACEMENT - LEFT  .
  30. Remove the engine mount brackets from the radiator support. Refer to ENGINE MOUNT STRUT BRACKET REPLACEMENT - UPPER RADIATOR SUPPORT  .
  31. Disconnect the positive battery cable.
  32. Remove the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC in Engine Cooling.
  33. Remove the vacuum booster hose from the engine. Refer to VACUUM BRAKE BOOSTER CHECK VALVE AND/OR HOSE in Disc & Drum.
  34. Disconnect the A/C vacuum hose from the engine.
  35. Remove the power steering pump bolts and pump from the engine. Lay the power steering pump aside.
    Fig 4: Removing Power Steering Pump & Mounting Bolts
    G01969285Courtesy of GENERAL MOTORS CORP.
  36. 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
  37. Remove upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal.
  38. Remove the radiator inlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.
  39. Remove the radiator outlet hose from the engine. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in Engine Cooling.
  40. Remove the heater hoses from the drive belt tensioner. Refer to or HEATER HOSE REPLACEMENT - INLET (3.8L) and or HEATER HOSE REPLACEMENT - OUTLET (3.8L) in Heating Ventilation and Air Conditioning.
  41. Remove the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
    Fig 5: Removing A/C Compressor & Mounting Bolts
    G01969286Courtesy of GENERAL MOTORS CORP.
  42. Install the engine lifting device.
  43. Remove the bolts (2, 3, 4, 5) which secure the upper transaxle to the engine.
    Fig 6: Locating Bolts Securing Upper Transaxle To Engine
    G01969287Courtesy of GENERAL MOTORS CORP.
  44. With assistance remove the engine from the vehicle.
  45. Remove the flywheel. Refer to ENGINE FLYWHEEL REMOVAL  .
  46. Install the engine to the engine stand.
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