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Removal (Cavalier & Sunfire)

WARNING: This page is about a different car, the 2002 Pontiac Sunfire, 2002 Pontiac Grand Am, 2002 Oldsmobile Alero, and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative and positive battery cable ends from battery. Remove battery retaining bolt and battery. Remove washer solvent container. Install Engine Support Fixture (J-28467-360) and remove pressure from transaxle mounts. See Figure . Raise engine enough to take pressure off of transaxle mounts.
  2. Remove air cleaner and duct assembly from throttle body. Drain cooling system. Remove upper radiator hose.
  3. Remove wire harness from upper transaxle mount bracket. Remove upper transaxle mount bolts. Remove negative battery cable from transaxle housing. Remove starter.
  4. Disconnect pressure line from clutch actuator cylinder. Disconnect backup light switch connector. Remove rear transaxle mount bolts. Disconnect vehicle speed sensor (VSS).
  5. Remove upper transaxle mounting bolts. Disconnect shift cables at transmission shift control and the bracket. Remove cable bracket bolt and bracket.
  6. Remove rack and pinion mounting bolts. Raise and support vehicle. Remove the tire and wheel assemblies. Remove front fender liners. Remove front suspension crossmember. Leave the steering rack in vehicle.
  7. Remove flywheel support arm bracket from flywheel cover to engine lower mount. Remove flywheel housing cover bolts. Remove flywheel housing cover. Using a crisscross sequence, loosen pressure plate bolts, one turn at a time. Remove bolts, pressure plate and clutch disc. See Figure .
  8. Remove axle shafts. See FWD AXLE SHAFTS - "J" & "N" BODIES article in DRIVE AXLES. Remove engine strut from bracket. Remove front lower transaxle mount through-bolt. Attach transaxle case to support stand. Support engine with a suitable axle jack. Remove transaxle-to-engine mount bolts. Remove transaxle from vehicle.
  9. Mark pressure plate in relation to flywheel for installation reference.
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