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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 236 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement (Automatic Transmission) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the hood. Refer to Hood Replacement in Body Front End.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. Remove the air inlet duct and resonator (2). Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls-2.2L.
    Fig 1: Exploded View Of Air Inlet Duct & Resonator
    GM785334Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the accelerator and cruise control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls - 2.2L (L61).
    Fig 2: View Of Cruise Control Cable At Throttle Body Cam Lever
    GM792955Courtesy 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.
    Fig 3: View Of Power Steering Pump
    GM631999Courtesy of GENERAL MOTORS CORP.
  7. Disconnect fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (L61).
  8. Drain the cooling system. Refer to Draining and Filling Cooling System (L61) in Engine Cooling.
  9. Remove the radiator inlet hose (3). Refer to Radiator Hose Replacement - Inlet (2.2L - L61) in Engine Cooling.
  10. Remove surge tank to cylinder head hose (2).
  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). Refer to Radiator Hose Replacement - Outlet (2.2L - L61) in Engine Cooling.
    Fig 4: Radiator Outer & Inlet Hose View
    GM772800Courtesy of GENERAL MOTORS CORP.
    Fig 5: View Of Radiator Outlet Hose
    GM780869Courtesy of GENERAL MOTORS CORP.
  14. Remove the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Hose Replacement - Inlet (L61) and to Heater Hose Replacement - Outlet (L61) in Heating, Ventilation, and Air Conditioning.
    Fig 6: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the following electrical connectors:
    • Idle air control (IAC) motor
    • Throttle position (TP) sensor
    • Manifold absolute pressure (MAP) sensor
    • Crankshaft sensor
    • Camshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • O2 sensor
    • Vehicle speed sensor (VSS)
    • Engine temperature sensor
    • Back-up lamp switch
  16. Unclip the electrical harness from the engine and set aside.
    Fig 7: Engine Electrical Harness View
    GM787414Courtesy of GENERAL MOTORS CORP.
  17. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  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. Refer to Starter Motor Replacement in Engine Electrical.
  26. Remove the flywheel to torque convertor bolts.
    Fig 8: View Of Flywheel To Torque Converter Bolts
    GM475919Courtesy of GENERAL MOTORS CORP.
  27. Remove the lower transmission bellhousing bolts.
    Fig 9: Identifying Lower Transmission To Engine Bolts And Stud
    GM104580Courtesy of GENERAL MOTORS CORP.
  28. Remove the transmission to engine brace.
    Fig 10: Identifying Transmission-To-Engine Brace Bolts
    GM510437Courtesy of GENERAL MOTORS CORP.
  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 and 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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