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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 598 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  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.
  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 cover. Refer to TORQUE CONVERTER COVER REPLACEMENT in AUTOMATIC TRANSAXLE-4T65-E
  8. Remove the starter motor. Refer to 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.
    Fig 1: Engine Mount Lower Nuts
    G01764324Courtesy of GENERAL MOTORS CORP.
  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 (HO2) 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.
  19. Remove the bolt (6) and the stud (1) which secure the lower transaxle to the engine.
    20. Fig 2: Lower Transaxle To The Engine Bolt And Stud
    G01764325Courtesy of GENERAL MOTORS CORP.
  20. Lower the vehicle while supporting the transaxle.
  21. Remove the air cleaner assembly.

    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 FUEL SYSTEMS
    23. Fig 3: Fuel Lines
    G01764326Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the fuel vapor line.
  24. Remove the throttle and cruise control cables and bracket from the throttle body.
  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.
    Fig 4: Water Pump Pulley And Bolts
    G01764327Courtesy of GENERAL MOTORS CORP.
  28. Remove the right and left engine mount struts. Refer to Engine Mount Strut Replacement - Right  or 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 in ENGINE COOLING .
  32. Remove the vacuum booster hose from the engine. Refer to VACUUM BRAKE BOOSTER CHECK VALVE AND/OR 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.
    Fig 5: Power Steering Pump And Bolts
    G01764328Courtesy of GENERAL MOTORS CORP.
  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.
  40. Remove the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
    Fig 6: A/C Compressor
    G01764329Courtesy of GENERAL MOTORS CORP.
  41. Install the engine lifting device.
  42. Remove the bolts (2,3,4,5) which secure the upper transaxle to the engine.
    43. Fig 7: Upper Transaxle To The Engine Bolts
    G01764330Courtesy of GENERAL MOTORS CORP.
  43. With assistance remove the engine from the vehicle.
  44. Remove the flywheel. Refer to Engine Flywheel Replacement 
  45. Install the engine to the engine stand.
  46. Remove the oil indicator tube nut from the exhaust manifold.
  47. Remove the oil level indicator tube.
    Fig 8: Oil Level Indicator Tube
    G01764331Courtesy of GENERAL MOTORS CORP.
  48. Remove the left side engine mount bracket bolts.
    Fig 9: Left Side Engine Mount Bracket Bolts
    G01764332Courtesy 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 engine mount strut brackets from the left side and the right side. Refer to Engine Mount Strut Bracket Replacement - Left  and to Engine Mount Strut Bracket Replacement - Right Upper (L36) 
    Fig 10: Engine Mount Strut Brackets
    G01764333Courtesy of GENERAL MOTORS CORP.
  53. Remove the A/C compressor bracket bolts and bracket.
    Fig 11: A/C Compressor Bracket Bolts And Bracket
    G01764334Courtesy of GENERAL MOTORS CORP.
  54. Remove the bracket nuts from the fuel injector sight shield.
  55. Remove the bracket from the fuel injector sight shield.
    56. Fig 12: Fuel Injector Sight Shield
    G01764335Courtesy of GENERAL MOTORS CORP.
  56. Remove the EGR valve adapter from the right cylinder head. Refer to EGR VALVE PIPE
  57. Remove the upper intake manifold or the supercharger. Refer to Intake Manifold Replacement - Upper  or to Supercharger Replacement 
  58. Remove the generator brace bracket bolts.
  59. Remove the generator brace bracket from the right cylinder head.
    60. Fig 13: Generator Brace Bracket Bolts
    G01764336Courtesy of GENERAL MOTORS CORP.
  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 (3.8L) and EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8L) in EXHAUST SYSTEM .
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