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Home >> Chevrolet >> 2005 >> Malibu Maxx >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. With the tires in the straight forward position, remove the key from the ignition.
  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. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
    4. Fig 1: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  4. Secure the cooling module to the upper body structure.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 2.2L (L61).
    6. Fig 2: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel lines from the fuel rail.
  7. Drain the cooling system. Refer to Draining and Filling Cooling System (L61) in Engine Cooling.
  8. Remove the radiator inlet hose. Refer to Radiator Hose Replacement - Inlet (L61) in Engine Cooling.
  9. Remove the surge tank to cylinder head hose. Refer to Surge Tank Hose/Pipe Replacement - Inlet (L61) and Surge Tank Hose/Pipe Replacement - Outlet (L61) in Engine Cooling.
  10. Remove the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet (L61) in Engine Cooling.
    11. Fig 3: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  11. 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.
    12. Fig 4: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the following harness connectors:
    • The electronic throttle control
    • The map sensor
    • The crankshaft sensor
    • The oil pressure sensor
    • The purge solenoid
    • The ignition coil and module assembly
    • The O2 sensor
    • The vehicle speed sensor
    • The engine temperature sensor
    • The back-up lamp switch
  13. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  14. Remove the engine drive belt. Refer to Drive Belt Replacement .
  15. Remove the AC compressor bolts and set the compressor aside.
    16. Fig 5: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the starter harness connectors (3, 4, 5).
  17. Disconnect the generator harness connectors.
  18. Drain the engine oil.
  19. Disconnect the front exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement (2.2L Engine) in Engine Exhaust.
  20. Disconnect the transmission harness connectors.
  21. Disconnect the transmission shift cable from the transmission.
  22. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  23. Remove the engine mount. Refer to Engine Mount Replacement .
    24. Fig 6: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  24. Remove the side transmission mount. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
    25. Fig 7: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    26. Fig 8: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
    27. Fig 9: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.
  27. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
    28. Fig 10: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement in Front Suspension.
    29. Fig 11: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  30. Use a paint pen or magic marker in order to mark the frame to body position.
    31. Fig 12: View Of Frame Bolts
    GM851651Courtesy of GENERAL MOTORS CORP.
  31. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
  32. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  33. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
  34. Slowly lower the table to the floor.
  35. Attach the engine lift hoist to the engine lift hooks.
    36. Fig 13: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  36. Remove the starter.
  37. If applicable, remove the torque converter to flywheel bolts.
  38. Remove the transmission to engine bolts.
  39. Separate the engine from the transmission.
  40. If applicable, remove the clutch pressure plate and disk.
  41. Remove the following components:
    • The exhaust manifold and catalytic converter assembly
    • The exhaust manifold studs
    • The engine mount bracket
    • The engine block heater
    • The thermostat housing and feed pipe
    • The generator
  42. Remove the engine from the engine lift.
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