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Home >> Chevrolet >> 2013 >> Sonic RS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 1.8L (LUW, LWE)) >> Repair Instructions - On Vehicle >> Engine Replacement (Manual Transmission) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the battery and battery tray. Refer to Battery Tray Replacement .
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  4. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  5. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  6. Drain the cooling system. Refer to Cooling System Draining and Filling .
    7. Fig 1: Lower Intermediate Steering Shaft & Bolt
    GM2534608Courtesy of GENERAL MOTORS COMPANY
  7. Remove the lower intermediate steering shaft bolt (1) and slide the shaft away from steering column. Refer to Intermediate Steering Shaft Replacement .
    8. Fig 2: Air Cleaner Assembly
    GM2521421Courtesy of GENERAL MOTORS COMPANY
  8. Remove the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement .
    9. Fig 3: Junction Block & Cover
    GM2539745Courtesy of GENERAL MOTORS COMPANY
  9. Remove the junction block cover (1).
    10. Fig 4: Positive Battery Cable & Nut
    GM2504689Courtesy of GENERAL MOTORS COMPANY
  10. Remove the positive battery cable nut (1) from the junction block.
  11. Remove the positive battery cable (2) from the junction block.
    12. Fig 5: Body Wiring Harness Connector & Positive Cable Nut
    GM2539751Courtesy of GENERAL MOTORS COMPANY
  12. Remove the positive cable nut (1) and battery positive cable, from the battery positive cable junction block.
  13. Disconnect the body wiring master harness connector (2), from the battery positive cable junction block.
    14. Fig 6: Junction Block
    GM2539757Courtesy of GENERAL MOTORS COMPANY
  14. Remove the junction block nut (1).
  15. Remove the junction block bolts (2).
  16. Disconnect the wiring harness from the junction block base.
  17. Remove the junction block (3) from the base.
  18. Disconnect the wiring harness plug from the front compartment fuse block.
    19. Fig 7: Wiring Harness - Top Of Engine
    GM2539762Courtesy of GENERAL MOTORS COMPANY
  19. Reposition the wiring harness (1) on top of the engine.
    20. Fig 8: Wiring Harness & Ground Nuts
    GM2539765Courtesy of GENERAL MOTORS COMPANY
  20. Remove the ground nuts (1) and reposition the wiring harness (2) aside.
    21. Fig 9: Electrical Vacuum Pump
    GM2534615Courtesy of GENERAL MOTORS COMPANY
  21. If equipped with electrical vacuum pump, disconnect the electrical connector and remove the brake booster hose (1).
    22. Fig 10: Heater Inlet Hose
    GM2521422Courtesy of GENERAL MOTORS COMPANY
  22. Disconnect the heater inlet hose (1) from the heater core. Refer to Heater Inlet Hose Replacement (LDE, LUW) .
    23. Fig 11: Heater Outlet Hose
    GM2521427Courtesy of GENERAL MOTORS COMPANY
  23. Disconnect the heater outlet hose (1) from the heater core. Refer to Heater Outlet Hose Replacement (LDE, LUW) .
    24. Fig 12: Transmission Range Selector Lever Cable Terminal
    GM2511540Courtesy of GENERAL MOTORS COMPANY
  24. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual pin.
  25. Press the locking tab forward in order to release the transmission range selector lever cable (2) from the cable bracket.
    26. Fig 13: Radiator Surge Tank
    GM2534616Courtesy of GENERAL MOTORS COMPANY
  26. Remove the radiator surge tank (1) and position aside. Refer to Radiator Surge Tank Replacement .
  27. Disconnect the fan connector.
    28. Fig 14: Air Conditioning Compressor, Condenser Hose & Nut
    GM2497607Courtesy of GENERAL MOTORS COMPANY
  28. Remove air conditioning compressor and condenser hose nut (1).
  29. Remove air conditioning compressor and condenser hose (2) from refrigerant hose.
    30. Fig 15: Fuel Feed Pipe
    GM2509366Courtesy of GENERAL MOTORS COMPANY
  30. Disconnect the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
  31. Install and close the fuel feed pipe with CH-807  plug.
  32. Disconnect the engine coolant sensor from radiator.
    33. Fig 16: View Of Brake Rotor, Caliper & Axle Nut
    GM2001521Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Perform steps 33 through 41 to both sides.

  33. Insert a brass drift or punch (1) in the cooling fins of the front brake rotor (2).
  34. Rotate the brake rotor until it comes in contact with the brake caliper mount bracket (5).
    35. Fig 17: Wheel Drive Shaft Nut
    GM2498078Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Use a suitable tool to release the crimping on the wheel drive shaft retaining nut.
    • The wheel drive shaft retaining nut (1) must be discarded after removal.
  35. Remove and discard the wheel drive shaft nut (1). Replace with NEW only.
    36. Fig 18: Upper Stabilizer Shaft Link
    GM2539770Courtesy of GENERAL MOTORS COMPANY
  36. Remove the upper stabilizer shaft link nut (1).
  37. Disconnect the stabilizer shaft link (2).
    38. Fig 19: Steering Linkage Outer Tie Rod
    GM2539785Courtesy of GENERAL MOTORS COMPANY
  38. Remove the steering linkage outer tie rod nut (1).
  39. Separate the steering linkage outer tie rod (2) from the steering knuckle. Steering Linkage Outer Tie Rod Replacement .
  40. Separate the control arm ball joint from the steering knuckle. Refer to Lower Control Arm Replacement .
    41. Fig 20: Wheel Lug Nuts & Remover
    GM2739004Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Reverse the wheel lug nuts and washers so the flat part of the wheel nut is facing the washers.

  41. Using the J-45859  remover (2), separate the wheel drive shaft from the steering knuckle (1).
  42. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
  43. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV,LUW) .
    44. Fig 21: Lower Oil Pan To Transmission Lower Bolts
    GM2535570Courtesy of GENERAL MOTORS COMPANY
  44. Remove the lower oil pan to transmission lower bolts (1).
    45. Fig 22: Front Frame Bolts
    GM2539786Courtesy of GENERAL MOTORS COMPANY
  45. Remove the frame front bolts (1).
    46. NOTE:

    Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.

  46. Position a engine support table under the powertrain assembly.
    47. Fig 23: Frame Suspension Retaining Bolts
    GM2492995Courtesy of GENERAL MOTORS COMPANY
  47. Remove the upper frame suspension retaining bolts (1) on both sides.
    48. Fig 24: Right Engine Mount Bolts
    GM2534620Courtesy of GENERAL MOTORS COMPANY
  48. Mark the location of the bolts (1) before removing.
  49. Remove the right side engine mount bolts (1). Refer to Engine Mount Replacement .
    50. Fig 25: Transmission Mount Bolts
    GM2503695Courtesy of GENERAL MOTORS COMPANY
  50. Mark the location of the bolts (1) before removing.
  51. Remove the transmission mount bolts (1) - left side. Refer to Engine Mount Replacement .
  52. Disconnect any additional electrical connections as necessary.
  53. Raise the vehicle until the powertrain is clear for removal.
    54. Fig 26: Upper Transmission To Engine Bolts
    GM2535571Courtesy of GENERAL MOTORS COMPANY
  54. Remove the upper transmission to engine bolts (1) and separate the engine and transmission.
  55. Disconnect any electrical connectors as needed.
  56. Install the engine to the engine stand.
  57. Transfer parts as needed.
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