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HOMESERVICE MANUALSCHEVROLET2002CAVALIER BASE, 4D SEDAN, 2.4 TREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALMECHANICALENGINE MECHANICAL - 2.4L (ON-VEHICLE)REPAIR INSTRUCTIONSENGINE REPLACEMENT (MANUAL TRANSMISSION)REMOVAL PROCEDURE
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 T

Removal Procedure

2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Removal Procedure
  1. Disconnect the negative battery cable.
  2. Drain cooling system.
  3. Recover the refrigerant if equipped with A/C.
  4. Disconnect the heater hose at the thermostat housing.
  5. Disconnect the radiator inlet (upper) hose.
  6. Remove the air cleaner assembly.
  7. Remove the cooling fan.
  8. Remove the compressor/condenser hose assembly at the compressor and discard the O-rings, if the vehicle is A/C equipped.
  9. Disconnect the vacuum hoses from the front of the engine.
  10. Remove the generator electrical connection.
  11. Remove the A/C compressor electrical connection if equipped.
  12. Remove the injector harness electrical connection.
  13. Remove the IAC sensor electrical connection at the throttle body.
    Fig 1: IAC Sensor Electrical Connector
    G01777658Courtesy of GENERAL MOTORS CORP.
  14. Remove the TP sensor electrical connection at the throttle body.
    Fig 2: TP Sensor Electrical Connector
    G01777659Courtesy of GENERAL MOTORS CORP.
  15. Remove the MAP sensor electrical connection.
    16. Fig 3: MAP Sensor Electrical Connector
    G01777660Courtesy of GENERAL MOTORS CORP.
  16. Remove the EVAP Canister Purge solenoid electrical connection.
  17. Remove the ground connections.
    Fig 4: Ground Connections
    G01777661Courtesy of GENERAL MOTORS CORP.
  18. Remove the negative battery cable from the transmission.
    Fig 5: Ground Connections
    G01777662Courtesy of GENERAL MOTORS CORP.
  19. Remove the electronic ignition coil and module assembly electrical connection.
    Fig 6: Electronic Ignition Coil And Module Assembly Connector
    G01777663Courtesy of GENERAL MOTORS CORP.
  20. Remove the engine coolant temperature sensor electrical connection.
    Fig 7: Engine Coolant Temperature Sensor Electrical Connector
    G01777664Courtesy of GENERAL MOTORS CORP.
  21. Remove the oil pressure sensor/switch electrical connection.
    Fig 8: Oil Pressure Sensor/Switch Electrical Connector
    G01777665Courtesy of GENERAL MOTORS CORP.
  22. Remove the oxygen sensor (O2S) electrical connection.
    23. Fig 9: Oxygen Sensor (O2S) Electrical Connector
    G01777666Courtesy of GENERAL MOTORS CORP.
  23. Remove the crankshaft position sensor.
  24. Remove the back up lamp switch electrical connection and position the harness aside.
  25. Remove the camshaft position sensor electrical connection.
    26. Fig 10: Camshaft Position Sensor Electrical Connector
    G01777667Courtesy of GENERAL MOTORS CORP.
  26. Remove the power brake vacuum hose from the throttle body.
  27. Remove the following components:
    • The accelerator control cable (1)
    • The cruise control cable (2)
    28. Fig 11: Accelerator & Cruise Control Cables
    G01777668Courtesy of GENERAL MOTORS CORP.
  28. Remove the power steering bolts.
  29. Remove the power steering pump. Position the pump aside with the lines attached.
    CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
    30. Fig 12: Power Steering Pump
    G01777669Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the fuel lines.
  31. Remove the shift control housing and position aside.
    Fig 13: Shift Control Housing
    G01777670Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the clutch actuator line.
  33. Remove the exhaust manifold and heat shield.
  34. Disconnect the radiator outlet (lower) hose from the radiator.
  35. Install the J 28467-360  .
  36. Remove the surge tank. Position the tank aside with the hoses connected.
  37. Remove the engine mount assembly. Refer to Engine Mount Replacement .
  38. Raise and support the vehicle.
  39. Remove the front wheel and tire assemblies.
  40. Remove the right engine splash shield.
  41. Remove the VSS electrical connection.
  42. Remove the knock sensor electrical connection.
  43. Remove the starter.
  44. Remove the both of the front ABS wheel speed sensor electrical connections.
    45. Fig 14: Front ABS Wheel Speed Sensor Electrical Connector
    G01777672Courtesy of GENERAL MOTORS CORP.
  45. Remove the engine mount strut. Refer to Engine Mount Strut Replacement .
  46. Unroute the ABS wheel speed sensor.
  47. Remove the transmission mount.
  48. Separate the ball joints from the steering knuckles.
  49. Remove the suspension support upper bolts.
    Fig 15: Suspension Support Upper Bolts
    G01777675Courtesy of GENERAL MOTORS CORP.
  50. Remove the suspension support lower bolts.
    Fig 16: Suspension Support Lower Bolts
    G01777676Courtesy of GENERAL MOTORS CORP.
  51. Remove the suspension support center bolts and the support.
    52. Fig 17: Suspension Support Center Bolts And Support
    G01777677Courtesy of GENERAL MOTORS CORP.
  52. Disconnect the heater outlet hose from the radiator outlet pipe.
  53. Remove the wheel drive shaft from the transmission and intermediate shaft (manual transmission only). Position the axle shaft aside.
  54. Remove the flywheel housing cover.
  55. Position suitable support below the engine and lower the car into the support.
  56. Mark the threads on the support fixture hooks in order to duplicate the setting when reinstalling the engine.
  57. Remove the engine support fixture J-hooks.
  58. Raise the vehicle slowly off of the engine and transmission assembly. It may be necessary to move the engine/transmission assembly rearward in order to clear the intake manifold.
  59. Separate the engine from the transmission.
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.