Pulling engine assembly

Tiny
CORY2427
  • MEMBER
  • 2004 CHEVROLET CAVALIER
  • 2.2L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 120,432 MILES
Just need a how to on pulling engine out through top.
Monday, April 29th, 2019 AT 11:57 AM

5 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good afternoon,

Huge project. I hope you have a hoist for removing the motor.

Roy

Engine Replacement (Automatic Transmission)

Tools Required
- J 42451 Engine Lift Bracket

Removal Procedure

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1. Remove the hood.
2. Disconnect the negative battery cable.
3. Remove the air inlet duct and resonator (2).

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4. Disconnect the accelerator and cruise control cable.
5. Disconnect the brake booster hose at the brake booster.

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6. Remove the power steering pump bolts and set pump aside.
7. Disconnect fuel lines.
8. Drain the cooling system.

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9. Remove the radiator inlet hose (3).
10. Remove surge tank to cylinder head hose (2).
11. Disconnect the surge tank to radiator outlet hose (1).
12. Remove the bolt retaining the surge tank outlet hose to the intake manifold.

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13. Remove the radiator outlet hose (1).

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14. Remove the inlet heater hose (1) and outlet heater hose (2).
15. Disconnect the following electrical connectors:
IAC motor
TPS
Map sensor
Crankshaft sensor
Camshaft sensor
Oil pressure sensor
Purge solenoid
Ignition coil and module assembly
O2 sensor
Vehicle speed sensor
Engine temperature sensor
Back-up lamp switch

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16. Unclip the electrical harness from the engine and set aside.
17. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
18. Remove the engine drive belt.
19. Remove the AC compressor bolts and set the compressor aside.
20. Remove the crankshaft balancer.
21. Disconnect the generator electrical connectors.
22. Disconnect the starter electrical connectors.
23. Drain the engine oil.
24. Disconnect the front exhaust pipe from the exhaust manifold.
25. Remove the starter.

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26. Remove the flywheel to torque converter bolts.

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27. Remove the lower transmission bellhousing bolts.

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28. Remove the transmission to engine brace.
29. Lower the vehicle.
30. Install J 42451 to the right rear of the cylinder head.
31. Install an engine hoist to the engine.
32. Remove the bolts which secure the bracket to the engine mount.
33. Remove the upper transmission bellhousing bolts.
34. Separate the engine and the transmission.
35. Remove the engine from the vehicle.
36. Remove the engine flywheel.
37. Mount the engine to an engine stand.
38. Remove the following components:
Oil filter cap and filter.
Exhaust manifold
Exhaust manifold studs
Intake manifold
Intake manifold studs
Engine mount bracket
Engine lift bracket
Camshaft cover and seal
Fuel rail
Engine block heater
Water pump
Drive belt tensioner
Thermostat housing and feed pipe
Generator
Oil level indicator and tube
Crankshaft sensor
Camshaft sensor
Oil pressure sensor
Ignition coil and module assembly
Crankshaft balancer
39. Remove the engine from the stand.
40. Remove J 42451.
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Monday, April 29th, 2019 AT 12:27 PM
Tiny
CORY2427
  • MEMBER
  • 270 POSTS
How do you get all flywheel bolts out? Is there a wrong way to hook any electrical wires up or do they only fit on what they came off? It is harder putting other motor in.
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Monday, April 29th, 2019 AT 1:10 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
There are three flywheel bolts. You have to rotate the engine to access all of them.

The wire connectors are keyed so they cannot be installed in the wrong position.

Roy
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Monday, April 29th, 2019 AT 1:18 PM
Tiny
CORY2427
  • MEMBER
  • 270 POSTS
Can I leave manifold on and just take it apart from flange pipe side where it goes into manifold?
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Monday, April 29th, 2019 AT 5:59 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Yes, you can. There should still be enough room for it to come out

Roy
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Tuesday, April 30th, 2019 AT 2:18 AM

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