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Home >> Chevrolet >> 2009 >> HHR SS, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.2L Or 2.4L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Fuel Feed Line
    GM1625417Courtesy of GENERAL MOTORS CORP.
  1. Raise the hood.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) or Fuel Pressure Relief (With CH 48027) .
  5. Disconnect the fuel feed line from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
    6. Fig 2: Identifying EVAP Line
    GM1625606Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the evaporative emission (EVAP) line from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Remove the windshield washer solvent reservoir. Refer to Windshield Washer Solvent Container Replacement .
  8. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) or Cooling System Draining and Filling (GE 47716 Fill) .
  9. Remove the engine drive belt. Refer to Drive Belt Replacement .
  10. Remove the left side engine splash shield. Refer to Engine Splash Shield Replacement .
  11. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LE5, L61) .
    12. Fig 3: View Of Cooling Fan
    GM1625478Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the cooling fan electrical connector.
  13. Lower the vehicle.
    14. Fig 4: Locating ECM/TCM Cover
    GM1631889Courtesy of GENERAL MOTORS CORP.
  14. Remove the engine control module (ECM)/transaxle control module (TCM) cover.
    15. Fig 5: View Of ECM Body Harness Electrical Connector
    GM1639226Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the body harness electrical connector (1) from the ECM.
    16. Fig 6: View Of ECM Engine Harness Electrical Connector
    GM1639228Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the engine harness electrical connectors (1, 2) from the ECM.
    17. Fig 7: Identifying Negative Battery Cable
    GM1631518Courtesy of GENERAL MOTORS CORP.
  17. Open the junction block terminal cover.
  18. Remove the junction block terminal nut (1).
  19. Remove the positive/negative battery cable terminal (2) from the stud.
    20. Fig 8: Identifying Positive Battery Cable Terminal From Junction Block Stud
    GM1631516Courtesy of GENERAL MOTORS CORP.
  20. Remove the positive battery cable terminal (1) from the junction block stud.
  21. Reposition the engine harness as necessary to access the ECM bracket lower bolts.
    22. Fig 9: View Of ECM Bracket Nuts/Bolts
    GM1720487Courtesy of GENERAL MOTORS CORP.
  22. Remove the ECM bracket nuts (1) and bolts (2).
  23. Lift the ECM bracket off of the studs and secure the bracket out of the way.
    24. Fig 10: Identifying Radiator Inlet Hose
    GM1625418Courtesy of GENERAL MOTORS CORP.
  24. Reposition the radiator inlet hose clamp at the engine.
  25. Remove the radiator inlet hose from the engine.
    26. Fig 11: Identifying EVAP Canister Purge Valve Electrical Connector
    GM1625517Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
    27. Fig 12: Identifying Engine Harness Clip
    GM1625460Courtesy of GENERAL MOTORS CORP.
  27. Remove the engine harness clip (1) from the EVAP purge solenoid bracket.
    28. Fig 13: Identifying Radiator Outlet Hose
    GM1631170Courtesy of GENERAL MOTORS CORP.
  28. If the vehicle is equipped with a engine oil cooler perform the following steps, reposition the radiator outlet hose clamp (1) at the water outlet.
  29. Reposition the radiator outlet hose clamp (2) at the oil cooler.
  30. Remove the radiator outlet hose from the water outlet.
  31. Remove the radiator outlet hose from the oil cooler
    32. Fig 14: View Of Radiator Outlet Hose
    GM1713958Courtesy of GENERAL MOTORS CORP.
  32. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the engine.
  33. Remove the radiator outlet hose from the engine.
    34. Fig 15: Identifying CMP Sensor Electrical Connector
    GM1639712Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the intake (2) and exhaust (1) camshaft position (CMP) sensor electrical connectors.
    35. Fig 16: Identifying Heater Inlet & Outlet Hoses
    GM1625419Courtesy of GENERAL MOTORS CORP.
  35. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  36. Remove the heater inlet and outlet hoses from the thermostat housing.
    37. Fig 17: Identifying Coolant Heater Cord
    GM1625669Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the engine coolant heater cord, if necessary.
    38. Fig 18: Identifying Engine Harness Straps
    GM1625676Courtesy of GENERAL MOTORS CORP.
  38. Remove the engine coolant heater cord straps from the engine harness, if equipped.
  39. Reposition the engine coolant heater cord out of the way, if equipped.
    40. Fig 19: Identifying Vacuum Brake Booster Hose
    GM1628035Courtesy of GENERAL MOTORS CORP.
  40. Reposition the brake booster vacuum hose clamp at the intake manifold.
  41. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.
    42. Fig 20: Identifying TAC, Fuel Injector Harness & Generator Electrical Connectors
    GM1623764Courtesy of GENERAL MOTORS CORP.
  42. Disconnect the following electrical connectors:
    • Throttle actuator control (TAC) (1)
    • Manifold absolute pressure (MAP) sensor
    • Fuel injector harness (2)
    • Generator (3)
    43. Fig 21: Identifying Ignition Coil Electrical Connectors
    GM1628020Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the ignition coils electrical connectors (3).
  44. Disconnect the intake (2) and exhaust (1) camshaft position actuator electrical connectors.
    45. Fig 22: Identifying Engine Harness Clips
    GM1631141Courtesy of GENERAL MOTORS CORP.
  45. Remove the engine harness clips (1, 2) from the camshaft cover.
    46. Fig 23: View Of Engine Harness Clip
    GM1625463Courtesy of GENERAL MOTORS CORP.
  46. Remove the engine harness clip nut (2).
  47. Remove the engine harness clip (1) from the transaxle stud.
    48. Fig 24: Identifying Engine Harness Clips
    GM1627740Courtesy of GENERAL MOTORS CORP.
  48. Remove the engine harness clip (1) from the oil level indicator tube bracket.
  49. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  50. Remove the engine harness clips (2, 4) from the intake manifold.
    51. Fig 25: View Of Engine Harness
    GM1622787Courtesy of GENERAL MOTORS CORP.
  51. Remove the starter. Refer to Starter Motor Replacement .
  52. If equipped with a automatic transaxle perform the following steps, remove the positive/negative battery cable ground nut (1).
  53. Remove the positive/negative cable (2) terminal from the stud.
  54. Remove the engine harness ground terminal (3) from the stud.
  55. Disconnect the following electrical connectors:
    • Crankshaft position (CKP) sensor (4)
    • Oil pressure sensor (5)
    • Knock sensor (6)
    56. Fig 26: View Of Engine Harness
    GM1622807Courtesy of GENERAL MOTORS CORP.
  56. If equipped with a manual transaxle perform the following steps, remove the positive/negative battery cable ground nut (2).
  57. Remove the positive/negative cable (3) terminal from the stud.
  58. Remove the engine harness ground terminal (4) from the stud.
  59. Disconnect the following electrical connectors:
    • Crankshaft position (CKP) sensor (1)
    • Oil pressure sensor (5)
    • Knock sensor (6)
    60. Fig 27: Identifying A/C Compressor & Pressure Switch Electrical Connectors
    GM1625475Courtesy of GENERAL MOTORS CORP.
  60. Disconnect the air conditioning (A/C) pressure switch electrical connector (1).
  61. Disconnect the A/C compressor electrical connector (2).
  62. Unbolt and reposition the AC compressor aside. Secure the compressor with tie straps or mechanics wire.
  63. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
    64. Fig 28: View Of Engine Harness Terminal, Nut & Engine Harness Boot
    GM1625472Courtesy of GENERAL MOTORS CORP.
  64. Remove the engine harness ground bolt (7).
  65. Remove the engine harness ground (8) from the engine block.
  66. Lower the vehicle.
  67. Remove the generator nut (2).
  68. Remove the engine harness lead terminal (1) from the generator.
    69. Fig 29: Identifying Engine Harness Clip
    GM1625484Courtesy of GENERAL MOTORS CORP.
  69. If equipped with a automatic transaxle perform the following steps, remove the engine harness clip nut (2) from the engine stud.
  70. Remove the engine harness clip (1) from the stud.
  71. Disconnect the vehicle speed sensor (VSS) electrical connector (4).
  72. Remove the engine harness clip (3) from the speed sensor.
    73. Fig 30: Identifying Engine Harness
    GM1625479Courtesy of GENERAL MOTORS CORP.
  73. If equipped with a automatic transaxle, disconnect the engine harness from the transaxle.
    74. Fig 31: Locating ECT Sensor Electrical Connector
    GM1625483Courtesy of GENERAL MOTORS CORP.
  74. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  75. Remove the connector position assurance (CPA) retainer (2).
  76. Disconnect the engine harness electrical connector (3) from the heater oxygen sensor (HO2S).
    77. Fig 32: Identifying ECT Sensor Electrical Connector
    GM1625486Courtesy of GENERAL MOTORS CORP.
  77. If equipped with a manual transaxle, perform the following steps, disconnect the ECT sensor electrical connector (1).
  78. Remove the CPA retainer (2).
  79. Disconnect the engine harness electrical connector (3) from the HO2S.
    80. Fig 33: Identifying Engine Harness Electrical Connector
    GM1625487Courtesy of GENERAL MOTORS CORP.
  80. If equipped with a automatic transaxle, perform the following steps, remove the CPA retainer (5).
  81. Disconnect the engine harness electrical connector (6) from the park neutral position switch.
  82. Remove the engine harness clip (1) from the transaxle stud.
  83. Remove the CPA retainer (2).
  84. Remove the engine harness electrical connector clip (4) from the transaxle rear mount bracket.
  85. Disconnect the engine harness electrical connector (3) from the HO2S.
    86. Fig 34: View Of Engine/Transaxle Harness Electrical Connector
    GM1625489Courtesy of GENERAL MOTORS CORP.
  86. If equipped with a manual transaxle, disconnect the engine harness electrical connector (1) from the VSS.
  87. Remove the engine harness clip (2) from the transaxle.
  88. Remove the CPA retainer (3).
  89. Remove the engine harness electrical connector clip (5) from the transaxle rear mount bracket.
  90. Disconnect the engine harness electrical connector (4) from the HO2S.
  91. Disconnect the engine harness electrical connector (7) from the back up lamp switch.
  92. Remove the engine harness clip (6) from the transaxle.
  93. Gather all engine harness branches are reposition the harness off to the side, out of the way.
    94. Fig 35: View Of Range Selector Lever Cable
    GM1625581Courtesy of GENERAL MOTORS CORP.
  94. If equipped with a automatic transaxle, disconnect the range selector lever cable from the transaxle lever.
  95. Remove the range selector lever cable from the transaxle bracket.
    96. Fig 36: View Of Range Selector & Shift Lever Cables
    GM1625583Courtesy of GENERAL MOTORS CORP.
  96. If equipped with a manual transaxle, disconnect the range selector and shift lever cables from the transaxle levers.
  97. Remove the range selector and shift lever cables from the transaxle bracket.
    98. Fig 37: View Of Oil Cooler Lines
    GM1720383Courtesy of GENERAL MOTORS CORP.
  98. If equipped with a automatic transaxle, remove the oil cooler line nut.
  99. Remove the oil cooler lines from the transaxle.
    100. Fig 38: Identifying Stabilizer Links
    GM1720288Courtesy of GENERAL MOTORS CORP.
  100. Remove the left and right stabilizer link to strut nuts.
  101. Separate the stabilizer links from the struts. (left side shown, right side similar).
    102. Fig 39: Identifying Steering Gear Outer Tie Rods
    GM1720289Courtesy of GENERAL MOTORS CORP.
  102. Remove the left and right steering gear outer tie rod to knuckle nuts. Discard the nuts.
  103. Using the J 24319-B  , separate the outer tie rods from the steering knuckles. (left side shown, right side similar).
    104. Fig 40: Identifying Ball Joint To Steering Knuckle Bolts & Nuts
    GM1720286Courtesy of GENERAL MOTORS CORP.
  104. Remove the left and right ball joint to steering knuckle bolts and nuts.
  105. Separate the lower ball joints from the steering knuckles. (left side shown, right side similar).
    106. Fig 41: View Of Special Tools J 45341 & J-2619-A Installed
    GM1720291Courtesy of GENERAL MOTORS CORP.
  106. Assemble the J 45341  and the J-2619-A  .
  107. Using the J 45341  and the J-2619-A  , separate the right wheel drive shaft from the transaxle. Repeat for the left side.
  108. Secure the wheel drive shafts out of the way.
    109. Fig 42: Identifying Lower Radiator Support Bolts
    GM1720381Courtesy of GENERAL MOTORS CORP.
  109. Remove the lower radiator support bolts.
  110. Secure the radiator assembly to the radiator core support with bungee cords.
    111. Fig 43: Identifying Engine Mount To Bracket Bolts
    GM1623160Courtesy of GENERAL MOTORS CORP.
  111. Lower the vehicle to about 3 feet off the ground.
  112. Position a engine lift table under the frame.
  113. Place wood blocks on top of the lift table between the table and the frame.
  114. Lower the vehicle until the frame is resting on the blocks of wood.
  115. Remove the engine mount bracket bolts.
    116. Fig 44: Identifying Transaxle Mount To Transaxle Bolts
    GM1623167Courtesy of GENERAL MOTORS CORP.
  116. Remove the transaxle mount to transaxle bolts.
    117. Fig 45: Identifying Frame Bolts
    GM1625598Courtesy of GENERAL MOTORS CORP.
  117. Remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Remove the rear frame bolts.
  118. Slowly raise the vehicle up away from the powertrain assembly.
  119. Slide the lift table out from under the vehicle.
  120. Attach an engine lift hoist to the engine lift hooks.
    121. Fig 46: Identifying Torque Converter Housing Access Plug
    GM1625720Courtesy of GENERAL MOTORS CORP.
  121. If equipped with a automatic transaxle, remove the torque converter housing access plug.
    122. Fig 47: Identifying Torque Converter Bolts
    GM1625721Courtesy of GENERAL MOTORS CORP.
  122. If equipped with a automatic transaxle, remove the torque converter bolts.
    123. Fig 48: Identifying Transaxle Brace
    GM1625684Courtesy of GENERAL MOTORS CORP.
  123. If equipped with a automatic transaxle, remove the transaxle brace bolts and brace.
    124. Fig 49: Identifying Transaxle To Engine Bolts/Stud
    GM1625687Courtesy of GENERAL MOTORS CORP.
  124. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.
    125. Fig 50: Identifying Transaxle To Engine Bolts/Stud
    GM1625689Courtesy of GENERAL MOTORS CORP.
  125. If equipped with a automatic transaxle, remove the transaxle to engine bolts/stud.
  126. Separate the engine from the transaxle.
  127. If equipped with a manual transaxle, remove the clutch pressure plate and disc. Refer to Clutch Pressure and Driven Plate Replacement .
  128. Remove the following components:
    • The engine mount bracket
    • The engine block heater, if equipped
    • The generator
  129. Using the engine hoist, install the engine to a suitable engine stand.
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