LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 95 (Engine Mechanical - 2.2L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement (Automatic Transmission) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 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 .
  2. Disconnect the negative battery cable.
  3. Remove the air inlet duct and resonator (2).
    Fig 1: Removing/Installing Air Inlet Duct & Resonator
    G01580549Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the accelerator and cruise control cable.
    Fig 2: Disconnecting Accelerator & Cruise Control Cable
    G01580550Courtesy 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: Removing Power Steering Pump
    G01580551Courtesy of GENERAL MOTORS CORP.
  7. Disconnect fuel lines.
  8. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (L61) .
  9. Remove the radiator inlet hose (3). Refer to RADIATOR HOSE REPLACEMENT - INLET (2.2L - L61) .
  10. Remove surge tank to cylinder head hose (2).
    Fig 4: Identifying Radiator Inlet Hose & Surge Tank To Cylinder Head Hose
    G01580552Courtesy 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). Refer to RADIATOR HOSE REPLACEMENT - OUTLET (2.2L - L61) .
    Fig 5: Identifying Radiator Outlet Hose
    G01580553Courtesy of GENERAL MOTORS CORP.
  14. Remove the inlet heater hose (1) and outlet heater hose (2). Refer to HEATER HOSE REPLACEMENT - INLET (L61) and HEATER HOSE REPLACEMENT - OUTLET (L61) .
    Fig 6: Identifying Inlet & Outlet Heater Hoses
    G01580554Courtesy 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.
    Fig 7: Unclipping Electrical Harness From Engine
    G01580555Courtesy of GENERAL MOTORS CORP.
  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. Refer to STARTER MOTOR .
  26. Remove the flywheel to torque convertor bolts.
    Fig 8: Removing Flywheel-To-Torque Convertor Bolts
    G01580556Courtesy of GENERAL MOTORS CORP.
  27. Remove the lower transmission bellhousing bolts.
    Fig 9: Removing Lower Transmission Bellhousing Bolts
    G01580557Courtesy of GENERAL MOTORS CORP.
  28. Remove the transmission to engine brace.
    Fig 10: Removing Transmission-To-Engine Brace
    G01580558Courtesy 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. 
scientia non olet · About LEMON Manuals