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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 95 (ENGINE MECHANICAL - 2.2L)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSENGINE REPLACEMENT (MANUAL TRANSMISSION)REMOVAL PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Removal Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Removal Procedure
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the hood. Refer to HOOD REPLACEMENT .
  2. Disconnect the negative battery cable.
  3. Remove the air inlet duct and resonator (2).
  4. Disconnect the accelerator and cruise control cable.
    Fig 1: Disconnecting Accelerator & Cruise Control Cables
    G01580569Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the hose from the brake booster.
  6. Remove the power steering pump bolts and set the pump aside.
    Fig 2: Removing Power Steering Pump
    G01580570Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel lines.
  8. Disconnect the transmission shift control cables.
  9. Disconnect the clutch actuator cylinder to the transmission. Refer to CLUTCH ACTUATOR CYLINDER REPLACEMENT .
  10. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (L61) .
  11. Remove the radiator inlet hose (3). Refer to RADIATOR HOSE REPLACEMENT - INLET (2.2L - L61) .
  12. Remove the hose from the surge tank to the cylinder head (2).
  13. Disconnect the outlet hose from the surge tank to the radiator (1).
  14. Remove the bolt retaining the cooling system fill hose to the intake manifold.
    Fig 3: Identifying Hoses
    G01580571Courtesy of GENERAL MOTORS CORP.
  15. Remove the radiator outlet hose (1). Refer to RADIATOR HOSE REPLACEMENT - OUTLET (2.2L - L61) .
    Fig 4: Identifying Radiator Outlet Hose
    G01580572Courtesy of GENERAL MOTORS CORP.
  16. Remove the inlet (1) and outlet (2) heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET (L61) and HEATER HOSE REPLACEMENT - OUTLET (L61) .
    Fig 5: Identifying Heater Inlet & Outlet Hoses
    G01580573Courtesy of GENERAL MOTORS CORP.
  17. 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
  18. Unclip the electrical harness from the engine and set the harness aside.
    19. Fig 6: Unclipping Electrical Harness
    G01580574Courtesy of GENERAL MOTORS CORP.
  19. Raise and suitably support the vehicle.
  20. Remove the front suspension crossmember. Refer to FRONT SUSPENSION CROSSMEMBER REPLACEMENT .
  21. Remove the drive axles. Refer to AXLE SHAFT .
  22. Remove the engine drive belt. Refer to Drive Belt Replacement .
  23. Remove the AC compressor bolts and set the compressor aside.
  24. Disconnect the generator electrical connectors.
  25. Disconnect the starter electrical connectors.
  26. Drain the engine oil.
  27. Disconnect the front exhaust pipe from the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT (2.2L (L61)) .
  28. Use a block of wood to support the front of the engine at the front of the oil pan.
  29. Lower the vehicle onto an engine support table.
  30. Remove the bolts which secure the bracket to the engine mount.
  31. Remove the bolts which secure the transmission mount to the frame. Refer to TRANSMISSION MOUNT REPLACEMENT - REAR and TRANSMISSION MOUNT REPLACEMENT - SIDE .
  32. Raise the vehicle away from the engine and transmission assembly.
  33. Install J 42451  to the right rear of the cylinder head.
  34. Install an engine hoist to the engine.
  35. Remove the transmission bellhousing bolts.
  36. Separate the engine and the transmission.
  37. Remove the clutch pressure plate and disk.
  38. Remove the engine flywheel.
  39. Mount the engine to an engine stand.
  40. Remove the following components:
    • Oil filter cap and filter. Refer to Engine Oil and Oil Filter Replacement .
    • Exhaust manifold studs
    • Exhaust manifold
    • Intake manifold studs
    • Intake manifold
    • 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
  41. Remove the engine from the stand.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.