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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 148 (Engine Mechanical - 2.2L (L61) (On-Vehicle)) >> Repair Instructions >> Engine Replacement (Automatic Transmission) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the hood.
  2. Disconnect the negative battery cable.
  3. Remove the air inlet duct and resonator (2).
    Fig 1: Air Inlet Duct And Resonator
    G01776733Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the accelerator and cruise control cable.
    5. Fig 2: Disconnecting Accelerator And Cruise Control Cable
    G01776734Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the brake booster hose at the brake booster.
  6. Remove the power steering pump bolts and set pump aside.
    7. Fig 3: Power Steering Pump
    G01776735Courtesy of GENERAL MOTORS CORP.
  7. Disconnect fuel lines.
  8. Drain the cooling system.
  9. Remove the radiator inlet hose (3).
  10. Remove surge tank to cylinder head hose (2).
    11. Fig 4: Surge Tank
    G01776736Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the surge tank to radiator outlet hose (1).
  12. Remove the bolt retaining the surge tank outlet hose to the intake manifold.
  13. Remove the radiator outlet hose (1).
    Fig 5: Radiator Outlet Hose
    G01776737Courtesy of GENERAL MOTORS CORP.
  14. Remove the inlet heater hose (1) and outlet heater hose (2).
    15. Fig 6: Inlet And Outlet Heater Hose
    G01776738Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the following electrical connectors:
    • IAC motor
    • TPS
    • Map sensor
    • Crankshaft sensor
    • Camshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Back-up lamp switch
  16. Unclip the electrical harness from the engine and set aside.
  17. Raise and suitably support the vehicle.
  18. Remove the engine drive belt. Refer to Drive Belt Replacement .
  19. Remove the AC compressor bolts and set the compressor aside.
  20. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  21. Disconnect the generator electrical connectors.
  22. Disconnect the starter electrical connectors.
  23. Drain the engine oil.
  24. Disconnect the front exhaust pipe from the exhaust manifold.
  25. Remove the starter.
  26. Remove the flywheel to torque convertor bolts.
    Fig 7: Flywheel-To-Torque Convertor Bolt
    G01776740Courtesy of GENERAL MOTORS CORP.
  27. Remove the lower transmission bellhousing bolts.
    Fig 8: Transmission Bellhousing Bolts
    G01776741Courtesy of GENERAL MOTORS CORP.
  28. Remove the transmission to engine brace.
  29. Lower the vehicle.
  30. Install J 42451  to the right rear of the cylinder head.
  31. Install an engine hoist to the engine.
  32. Remove the bolts which secure the bracket to the engine mount.
  33. Remove the upper transmission bellhousing bolts.
  34. Separate the engine and the transmission.
  35. Remove the engine from the vehicle.
  36. Remove the engine flywheel.
  37. Mount the engine to an engine stand.
  38. Remove the following components:
    • Oil filter cap and filter. Refer to Engine Oil & Oil Filter Replacement .
    • Exhaust manifold.
    • Exhaust manifold studs.
    • Intake manifold.
    • Intake manifold studs.
    • Engine mount bracket.
    • Engine lift bracket.
    • Camshaft cover and seal.
    • Fuel rail.
    • Engine block heater.
    • Water pump.
    • Drive belt tensioner.
    • Thermostat housing and feed pipe.
    • Generator.
    • Oil level indicator and tube.
    • Crankshaft sensor.
    • Camshaft sensor.
    • Oil pressure sensor.
    • Ignition coil and module assembly.
    • Crankshaft balancer.
  39. Remove the engine from the stand.
  40. Remove J 42451  .
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