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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 (Manual 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
    G01776752Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the accelerator and cruise control cable.
    5. Fig 2: Accelerator And Cruise Control Cable
    G01776753Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the hose from the brake booster.
  6. Remove the power steering pump bolts and set the pump aside.
    7. Fig 3: Power Steering Pump
    G01776754Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel lines.
  8. Disconnect the transmission shift control cables.
  9. Disconnect the clutch actuator cylinder to the transmission.
  10. Drain the cooling system.
  11. Remove the radiator inlet hose (3).
  12. Remove the hose from the surge tank to the cylinder head (2).
  13. Disconnect the outlet hose from the surge tank to the radiator (1).
  14. Remove the bolt retaining the cooling system fill hose to the intake manifold.
    Fig 4: Radiator Inlet Hose
    G01776755Courtesy of GENERAL MOTORS CORP.
  15. Remove the radiator outlet hose (1).
    Fig 5: Radiator Outlet Hose
    G01776756Courtesy of GENERAL MOTORS CORP.
  16. Remove the inlet (1) and outlet (2) heater hoses.
    17. Fig 6: Inlet And Outlet Heater Hoses
    G01776757Courtesy of GENERAL MOTORS CORP.
  17. 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
  18. Unclip the electrical harness from the engine and set the harness aside.
  19. Raise and suitably support the vehicle.
  20. Remove the front suspension crossmember.
  21. Remove the drive axles.
  22. Remove the engine drive belt. Refer to Drive Belt Replacement .
  23. Remove the AC compressor bolts and set the compressor aside.
  24. Disconnect the generator electrical connectors.
  25. Disconnect the starter electrical connectors.
  26. Drain the engine oil.
  27. Disconnect the front exhaust pipe from the exhaust manifold.
  28. Use a block of wood to support the front of the engine at the front of the oil pan.
  29. Lower the vehicle onto an engine support table.
  30. Remove the bolts which secure the bracket to the engine mount.
  31. Remove the bolts which secure the transmission mount to the frame.
  32. Raise the vehicle away from the engine and transmission assembly.
  33. Install J 42451  to the right rear of the cylinder head.
  34. Install an engine hoist to the engine.
  35. Remove the transmission bellhousing bolts.
  36. Separate the engine and the transmission.
  37. Remove the clutch pressure plate and disk.
  38. Remove the engine flywheel.
  39. Mount the engine to an engine stand.
  40. Remove the following components:
    • Oil filter cap and filter. Refer to Engine Oil & Oil Filter Replacement .
    • Exhaust manifold studs
    • Exhaust manifold
    • Intake manifold studs
    • Intake manifold
    • 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
  41. Remove the engine from the stand.
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