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Home >> Saturn >> 2010 >> Sky Red Line, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.4L - Repair Instructions - On Vehicle) >> Engine Replacement (W/Manual Transmission) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Fuel Feed Pipe & EVAP Quick Connect Fitting
    GM1592525Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the hood. Refer to Hood Replacement .
  3. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging .
  4. Remove the drive belt. Refer to Drive Belt Replacement (With A/C)  or Drive Belt Replacement (Without A/C) .
  5. Remove the radiator. Refer to Radiator Replacement .
  6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH 48027-100) or Fuel Pressure Relief (Without CH 48027-100) .
  7. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (1). Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  9. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) or Air Inlet Grille Panel Replacement (Solstice) .
  10. Remove the transmission. Refer to Transmission Replacement (With ZOK) .
  11. After the transmission is removed, reinstall the bolt from the differential case bracket assembly to body, in order to remove the support from under the rear drive module.
    12. Fig 2: View Of Radiator Inlet Hose
    GM1592523Courtesy of GENERAL MOTORS CORP.
  12. Reposition the radiator inlet hose clamp at the engine.
  13. Remove the radiator inlet hose.
    14. Fig 3: View Of Radiator Outlet Hose
    GM1591816Courtesy of GENERAL MOTORS CORP.
  14. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step 23.
  15. Reposition the radiator outlet hose clamps at the thermostat housing and oil cooler.
  16. Remove the radiator outlet hose from the thermostat housing and oil cooler.
  17. Reposition the outlet hose out of the way.
    18. Fig 4: View Of Surge Tank Outlet Hose
    GM1591818Courtesy of GENERAL MOTORS CORP.
  18. Reposition the surge tank outlet hose clamps at the thermostat housing and oil cooler.
  19. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
    20. Fig 5: View Of Radiator Surge Tank
    GM1590499Courtesy of GENERAL MOTORS CORP.
  20. Reposition the surge tank outlet hose clamp at the surge tank.
  21. Remove the surge tank clip from the oil level indicator tube bracket.
  22. Remove the surge tank outlet hose. Proceed to step 26.
    23. Fig 6: Identifying Radiator Outlet Hose Clip
    GM1714037Courtesy of GENERAL MOTORS CORP.
  23. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the thermostat housing.
  24. Remove the radiator outlet hose from the thermostat housing.
  25. Remove the radiator outlet hose clip (1) from the outlet hose bracket.
    26. Fig 7: Identifying Air Bleed Hose & Clamp
    GM1590504Courtesy of GENERAL MOTORS CORP.
  26. Reposition the surge tank air bleed hose clamp at the engine.
  27. Remove the surge tank air bleed hose (1) from the engine.
  28. Reposition the air bleed hose (2) out of the way.
    29. Fig 8: Identifying Heater Inlet & Outlet Hoses
    GM1592522Courtesy of GENERAL MOTORS CORP.
  29. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  30. Remove the heater inlet (2) and outlet (1) hoses from the thermostat housing.
  31. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  32. Drain the engine oil.
    33. Fig 9: Identifying CKP & Oil Pressure Sensor Electrical Connectors
    GM1589842Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
  34. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
  35. Lower the vehicle.
  36. Remove the positive battery cable clip from the bracket.
  37. Cut the engine harness tie straps.
    38. Fig 10: View Of Negative Battery Cable Ground Bolt
    GM1591855Courtesy of GENERAL MOTORS CORP.
  38. Remove the negative battery cable ground bolt.
  39. Remove the negative battery cable ground terminal and engine harness ground terminal from the cylinder head.
    40. Fig 11: Identifying Engine Harness Electrical Connectors
    GM1590505Courtesy of GENERAL MOTORS CORP.
  40. Disconnect the engine wiring harness electrical connector (1) from the generator.
  41. Reposition the positive battery cable terminal boot (4).
  42. Remove the generator terminal nut (2).
  43. Remove the positive battery cable terminal from the generator (5).
  44. Disconnect the engine wiring harness electrical connector (6) from the A/C compressor.
  45. Reposition the negative/positive battery cable.
    46. Fig 12: Locating A/C Refrigerant Pressure Sensor Electrical Connector
    GM1590533Courtesy of GENERAL MOTORS CORP.
  46. Disconnect the engine wiring harness electrical connector from the A/C refrigerant pressure sensor.
    47. Fig 13: Identifying Windshield Wiper Motor Electrical Connector
    GM1590536Courtesy of GENERAL MOTORS CORP.
  47. Disconnect the engine wiring harness electrical connector from the windshield wiper motor.
  48. Remove the engine harness clip from the wiper motor hole.
    49. Fig 14: View Of Engine Harness Clip To Surge Tank Air Bleed Hose
    GM1590557Courtesy of GENERAL MOTORS CORP.
  49. Remove the engine harness clip from the surge tank air bleed hose.
    50. Fig 15: Identifying Camshaft Position Actuator Solenoid Valve Electrical Connectors
    GM1591651Courtesy of GENERAL MOTORS CORP.
  50. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) actuator.
  51. Disconnect the engine wiring harness electrical connector (2) from the exhaust CMP actuator.
    52. Fig 16: Identifying Cam Cover Engine Harness Clip
    GM1591657Courtesy of GENERAL MOTORS CORP.
  52. Remove the engine harness clip (1) from the camshaft cover.
    53. Fig 17: View Of Ignition Coil Electrical Connectors
    GM1591652Courtesy of GENERAL MOTORS CORP.
  53. Disconnect the engine wiring harness electrical connectors from the ignition coils.
    54. Fig 18: Identifying CPA Retainer & HO2S Electrical Connector
    GM1592538Courtesy of GENERAL MOTORS CORP.
  54. Remove the connector position assurance (CPA) retainers from the heated oxygen sensor (HO2S) electrical connectors.
  55. Disconnect the engine wiring harness electrical connector (1) from the front HO2S.
  56. Disconnect the engine wiring harness electrical connector (2) from the rear HO2S.
  57. Disconnect the engine harness clips (1) from the junction block bracket.
  58. Disconnect the HO2S electrical connector clip (4) from the strut.
    59. Fig 19: View Of Intake CMP Sensor Electrical Connector
    GM1591857Courtesy of GENERAL MOTORS CORP.
  59. Disconnect the engine wiring harness electrical connector from the intake CMP sensor.
    60. Fig 20: View Of CMP Sensor & ECT Sensor Electrical Connectors
    GM1591858Courtesy of GENERAL MOTORS CORP.
  60. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
  61. Remove the engine harness ground terminal bolt (1) and reposition the engine harness ground terminal (2).
  62. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
    63. Fig 21: Locating EVAP Canister Purge Valve Electrical Connector & Harness Clips
    GM1591661Courtesy of GENERAL MOTORS CORP.
  63. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
  64. Disconnect the engine harness clip (2) from the EVAP canister purge solenoid valve bracket.
  65. Disconnect the engine harness clips (3, 4) from the camshaft cover.
  66. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
    67. Fig 22: Identifying Engine Harness Bracket
    GM1591665Courtesy of GENERAL MOTORS CORP.
  67. Remove the engine harness bracket (1) from the intake manifold cover stud.
  68. Disconnect the engine harness clip (2) from the bracket.
    69. Fig 23: View Of Intake Manifold Cover Bracket & Bolts
    GM1694522Courtesy of GENERAL MOTORS CORP.
  69. Remove the intake manifold cover bracket bolts and bracket.
  70. Gather all branches of the engine harness and lay off to the side.
    71. Fig 24: View Of A/C Compressor Line
    GM1765251Courtesy of GENERAL MOTORS CORP.
  71. Remove the A/C compressor line bolt and reposition the line off to the side.
  72. Raise and support the vehicle.
    73. Fig 25: View Of Power Steering Pump, Bracket & Bolts
    GM1765296Courtesy of GENERAL MOTORS CORP.
  73. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
  74. Lower the vehicle.
    75. Fig 26: View Of Left Engine Mount
    GM1592518Courtesy of GENERAL MOTORS CORP.
  75. Remove the left engine mount upper nut.
    76. Fig 27: View Of Right Engine Mount Upper Nut
    GM1592519Courtesy of GENERAL MOTORS CORP.
  76. Remove the right engine mount upper nut.
  77. Install the J 42451-1  to the engine.
  78. Install a suitable engine lifting devise to the engine.
  79. Remove the engine from the vehicle.
  80. Remove the clutch pressure plate and disc. Refer to Clutch Pressure and Driven Plate Replacement .
    81. Fig 28: View Of Flywheel & Bolt (Manual Transmission)
    GM1591936Courtesy of GENERAL MOTORS CORP.
  81. Remove the flywheel bolts and flywheel.
  82. Install the engine to an engine stand.
    83. Fig 29: Identifying A/C Compressor & Bolts
    GM1592623Courtesy of GENERAL MOTORS CORP.
  83. Remove the A/C compressor bolt and compressor.
    84. Fig 30: View Of Catalytic Converter Bracket & Bolt
    GM1592529Courtesy of GENERAL MOTORS CORP.
  84. Remove the catalytic converter to bracket bolt.
    85. Fig 31: View Of Catalytic Converter, Gasket & Nuts
    GM1592527Courtesy of GENERAL MOTORS CORP.
  85. Remove the catalytic converter nuts (1).
  86. Remove the catalytic converter gasket (2) and converter from the engine.
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