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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 (Manual 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 hose from the brake booster.
  6. Remove the power steering pump bolts and set the pump aside.
    Fig 3: View Of Power Steering Pump
    GM631999Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (L61).
  8. Disconnect the transmission shift control cables.
  9. Disconnect the clutch actuator cylinder to the transmission. Refer to Clutch Actuator Cylinder Replacement in Manual Transmission.
  10. Drain the cooling system. Refer to Draining and Filling Cooling System (L61) in Engine Cooling.
  11. Remove the radiator inlet hose (3). Refer to Radiator Hose Replacement - Inlet (2.2L - L61) in Engine Cooling.
    Fig 4: Radiator Outer & Inlet Hose View
    GM772800Courtesy of GENERAL MOTORS CORP.
  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.
  15. Remove the radiator outlet hose (1). Refer to Radiator Hose Replacement - Outlet (2.2L - L61) in Engine Cooling.
    Fig 5: View Of Radiator Outlet Hose
    GM780869Courtesy of GENERAL MOTORS CORP.
  16. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Hose Replacement - Inlet (L61) and to Heater Hose Replacement - Outlet (L61) in Heating, Ventilation, and Air Conditioning.
    17. Fig 6: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy 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.
    Fig 7: Engine Electrical Harness View
    GM787414Courtesy of GENERAL MOTORS CORP.
  19. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  20. Remove the front suspension crossmember. Refer to Crossmember Replacement in Frame and Underbody.
  21. Remove the drive axles. Refer to Wheel Drive Shaft Replacement in Front Wheel Drive Shafts.
  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. Refer to Exhaust Manifold Replacement (2.2L (L61)) in Engine Exhaust.
  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. Refer to Transmission Mount Replacement - Rear and Transmission Mount Replacement - Side in Manual Transmission.
  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 and 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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