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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1814 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (2.2L (L61) and 3.5L (L66)) .
  2. Disconnect the air intake temperature (IAT) sensor connector.
  3. Loosen the clamp air cleaner assembly.
  4. Remove the pushpin attachment from the outlet resonator/duct assembly to the support bracket.
  5. Loosen the clamp at the throttle body assembly.
  6. Disconnect the positive crankcase ventilation (PCV) fresh air vent hose at the cam cover.
  7. Remove the outlet resonator/duct assembly.
    8. Fig 2: Cover Throttle Body Opening With A Shop Towel
    GM897640Courtesy of GENERAL MOTORS CORP.
  8. Cover the throttle body opening with a shop towel. Use shop air to remove any dirt around the throttle body and intake manifold to cylinder head.
    9. Fig 3: Identifying Connectors & Bolts On Top Of Fuse Block
    GM934982Courtesy of GENERAL MOTORS CORP.
  9. Remove the underhood fuse block (UHFB) fuse cover by separating the clips on each side.
  10. Remove the UHFB fuse cover.
  11. Remove the inner UHFB fuse cover.
  12. Loosen the three connectors through bolts (1) at the top of the UHFB.
  13. Remove the battery and the electronic power steering feed wire connection nut and remove the wire from the UHFB stud.
  14. Release the tabs on each side of the UHFB with a screwdriver.
  15. Raise the UHFB from the connectors. Disconnect the electrical connectors on each side of UHFB.
  16. Remove the UHFB from the vehicle.
  17. Remove the battery cable and the harness attachment clips the on side of battery tray/UHFB bracket assembly.
  18. Remove the main connectors from the UHFB housing.
  19. Lay the battery positive cable wire over the engine. The battery cables will be removed with powertrain assembly.
  20. Remove the electrical harness clips to battery tray.
  21. Remove the UHFB and the battery tray bolts.
  22. Remove the UHFB and the battery tray.
    23. Fig 4: View Of Battery Tray Bracket Bolts
    GM951487Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the electrical connectors at the transaxle control module (TCM), if equipped.
  24. Remove the engine-to-body ground bolt.
  25. Disconnect the connector for the rear O2 sensor.
  26. Remove the vacuum hose with the check valve from the booster and lay across the engine.
  27. Disconnect the 8-way electrical connector.
  28. Remove the main engine harness gray connector and lay over the engine assembly. This will allow the engine harness to be removed the with powertrain.
    29. NOTE: Do not remove the shifter cable from the bracket before removing the cable from the transaxle range switch. Damage to the manual shift linkage may occur.
  29. If equipped with the automatic range transaxle, disconnect the shifter cable plastic retainer by using a screwdriver. Slightly pry between the shifter cable plastic retainer and the transaxle range switch.
    30. Fig 5: Locating Shift Level Cables
    GM982570Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use too much force when disconnecting the shift cables or damage may result.
  30. Disconnect the shift lever cables from the shift control housing by prying with even pressure using a J 36346  or equivalent manual transmission only. See Special Tools .
  31. Disconnect the shift lever cables from the shift lever cable bracket manual transmission only.
    32. Fig 6: Disconnecting/Connecting Clutch Hydraulic Line
    GM986882Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the pressure line from the clutch actuator cylinder by removing the C-clip then pulling the line away from the clutch actuator cylinder manual transmission only.
    33. Fig 7: Locating Back-Up Lamp Switch & Front Wheel Speed Sensor (WSS)
    GM987188Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the back-up lamp switch (1) and the front wheel speed sensor (WSS) (2) manual transmission only.
    34. Fig 8: View Of Radiator Inlet Hose At Engine
    GM931402Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Place a shop towel on the generator to prevent coolant from entering the generator assembly.
  34. Drain the coolant. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (GE 47716 Fill) .
  35. Disconnect the upper radiator hose at the engine cylinder head.
    36. Fig 9: Disconnecting/Connecting Radiator Hose And Clamp From Thermostat Pipe Assembly
    GM931384Courtesy of GENERAL MOTORS CORP.
  36. Disconnect the lower radiator hose at the coolant pipe.
    37. Fig 10: Removing & Installing Surge Tank Cap
    GM931323Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the degas hose at surge tank.
  38. Disconnect the surge hose at the bottom of the surge tank.
  39. Disconnect the heater hoses from the heater core at the front of the dash.
    40. Fig 11: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
  40. Relieve the fuel system pressure using the Fuel Pressure Relief .
  41. Disconnect the SA9127E  after the pressure has been relieved.
  42. Remove the safety clip and disconnect the fuel line transfer line at the quick connect from the fuel line using the SA9805E  .
  43. Disconnect the purge hoses at the rear of the purge solenoid.
  44. Remove the headlamp assemblies.
    45. Fig 12: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The radiator/condenser/fan assembly will stay in the vehicle during engine removal.
  45. Using long tie straps, secure the radiator/condenser fan assembly to the radiator support assembly.
    46. Fig 13: View Of Tire/Wheel Assembly & Wheel Lug Nuts
    GM933764Courtesy of GENERAL MOTORS CORP.
    CAUTION: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
  46. Raise the vehicle.
  47. Remove the front left-hand (LH) wheel.
  48. Remove the front LH wheel inner splash shield.
    IMPORTANT: A piece of hardwood should be used between the transaxle case and cradle assembly. This wood will support the transaxle when the LH mount bolts are removed.
  49. Install a piece of hardwood 1 x 2 x 4 between the transaxle case and the engine cradle assembly.
  50. Remove the front right-hand (RH) wheel.
  51. Remove the wheel inner splash shield.
    52. NOTE: Do not install wood under the oil pan plug boss. Damage to the oil pan may occur.
    IMPORTANT: A piece of hardwood should be used between the oil pan assembly and the engine cradle. This wood will support the engine when the RH mount bolts are removed.
  52. Install a piece of hardwood 1 x 2 x 4 between the engine oil pan and engine cradle assembly near the crankshaft.
    53. Fig 14: View Of Drive Belt Tensioner Tool
    GM951829Courtesy of GENERAL MOTORS CORP.
  53. Install the accessory J 44811  tool onto the tensioner.
  54. Remove the accessory drive belt.
  55. Disconnect the electrical connector at the A/C compressor.
  56. Disconnect the electrical connector at the A/C pressure transducer on-line.
  57. Remove the A/C compressor bolts.
  58. Support the compressor and the line assembly to the body with support straps.
  59. Remove the pushpins that retain the air deflector assembly to the cradle.
    60. Fig 15: Disconnecting/Connecting Transaxle Lines
    GM949017Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When the transaxle lines are disconnected, new seals must be installed into the transaxle to prevent the potential for leak.
    IMPORTANT: Fluid will leak when the lines are disconnected. Place a drip pan to collect the transaxle oil.
  60. Drain the transaxle fluid.
  61. If equipped with automatic, disconnect the transaxle lines from the transaxle.
  62. Disconnect the rear oxygen sensor (O2S).
  63. Remove the exhaust pipe-to-manifold flange bolts.
  64. Remove the exhaust pipe to intermediate pipe nuts.
  65. Remove the converter pipe assembly and the support intermediate pipe assembly.
  66. Remove the propshaft bolts to the power take-off unit (PTU) - AWD Only.
  67. Remove the propshaft bolts at the rear axle assembly - AWD Only.
  68. Remove the propshaft support bracket-to-body bolts - AWD Only.
  69. Remove the propshaft assembly - AWD Only.
    70. NOTE: Do not remove the shifter cable from the bracket before removing the cable from the transaxle range switch. Damage to the manual shift linkage may occur.
  70. If equipped with automatic, remove the shifter cable from the bracket assembly.
    71. Fig 16: Removing/Installing Steering Shaft To Intermediate Shaft
    GM927947Courtesy of GENERAL MOTORS CORP.
  71. Remove the steering gear to the intermediate shaft bolt.
    72. Fig 17: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  72. Remove the tie rod to knuckle nuts.
  73. Separate the tie rod assemblies from the knuckle assemblies using the SA91100C  .
  74. Remove the lower control arm cotter pins and the nuts to knuckle assembly.
  75. Separate the J 43828  .
    76. IMPORTANT: The stabilizer links will stay in the vehicle connected to the strut assembly on the engine removal.
  76. Remove the lower stabilizer link nuts to the stabilizer bar.
  77. Remove the LH axle shaft assembly from the transaxle.
  78. Disconnect the RH shaft assembly from the intermediate drive shaft using the J 45341  tool with the appropriate slide tool.
  79. Lower the vehicle.
  80. Remove the RH engine mount to the engine bracket bolts. The engine should rest on the wood blocks.
    81. Fig 18: Left Transmission Mount & Bolts
    GM928777Courtesy of GENERAL MOTORS CORP.
  81. Remove the LH transaxle mount to the transaxle bolts, the transaxle should rest on the wood blocks.
  82. Raise the vehicle on the hoist.
    83. Fig 19: Powertrain Assembly On Engine Support Table
    GM952078Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.
  83. Position the engine support table under the powertrain assembly.
    84. IMPORTANT: Blocks of wood can be used between the front of cradle and the oil pan to table to level powertrain during the removal.
  84. With the table positioned, fully raise the table to contact with powertrain assembly.
  85. Remove the cradle to body bolts.
    86. IMPORTANT: When lowering the engine/transaxle assembly, verify all brake lines, shifter cable and other components are free during the removal.
  86. Lower the engine table and raise the body on the hoist until the engine/transaxle and the cradle assembly is free from the vehicle.
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