GM Cavalier/Sunfire 1995-2000 Repair Guide

Engine

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REMOVAL & INSTALLATION



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as disconnect the exhaust system or remove the radiator. In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Alwaye tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transaxle, alwaye make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

2.2L Engine
  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Detach the upper radiator hose at the coolant outlet.
  8.  
  9. Disconnect the brake booster vacuum hose.
  10.  
  11. Tag and detach the following electrical connections:

    Idle Air Control (IAC)
     
    Alternator
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Transaxle Converter Clutch (TCC)
     
    Oxygen sensor
     
    Park/Neutral position switch
     
    Engine grounds
     

  12.  
  13. Remove the serpentine drive belt.
  14.  
  15. Disconnect the transaxle shift control cable from the range select lever and bracket.
  16.  
  17. Detach the coolant surge tank hose, then remove the tank.
  18.  
  19. Disconnect the vacuum line near the master cylinder.
  20.  
  21. Install a suitable engine support fixture.
  22.  
  23. Disconnect the lower radiator hose from the water pump.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Remove both front wheel and tire assemblies, then remove both splash shields.
  28.  
  29. Disconnect the exhaust pipe at the manifold and catalytic converter.
  30.  
  31. Remove the engine mount strut.
  32.  
  33. Disconnect the wheel speed sensor wire harness from the control arms.
  34.  
  35. Separate the ball joints from the steering knuckles. Using an appropriate tool, separate the tie rod ends from the struts.
  36.  
  37. Detach the brake lines from the suspension supports.
  38.  
  39. If equipped remove the A/C compressor and support with the lines attached.
  40.  
  41. Tag and detach the following electrical connectors:

    Electronic Ignition Module
     
    Vehicle Speed Sensore (VSS)
     
    Cooling Fan
     
    Starter
     
    A/C compressor
     
    Oil pressure and level sensors
     
    Engine grounds
     

  42.  
  43. Disconnect the power steering linee from the rack and pinion assembly. Detach the flexible coupling joint at the rack and pinion assembly.
  44.  
  45. Disconnect the accelerator control, cruise control (if equipped) and the T.V. cables from the accelerator control bracket.
  46.  
  47. Remove the suspension support assembly.
  48.  
  49. Disconnect the heater hosee at the front of the dash.
  50.  
  51. Remove both drive axles from the transaxle, then position them aside.
  52.  
  53. Disconnect the fuel lines.
  54.  
  55. Detach the cooler linee from the transaxle, then remove the transaxle mount.
  56.  
  57. Remove the engine mount assembly.
  58.  
  59. Place a suitable support under the vehicle. Carefully lower the vehicle so that it rests lightly on the support.
  60.  
  61. Remove the support fixture from the engine, then raise the vehicle, leaving the engine and transaxle assembly on the table.
  62.  
  63. Unfasten the retaining bolts, then separate the engine from the transaxle.
  64.  

To install:
  1. Position the engine to the transaxle, then install the retaining bolts. Refer to Drive Train .
  2.  
  3. Lower the vehicle onto the engine and transaxle assembly.
  4.  
  5. Install a suitable engine support fixture onto the engine.
  6.  
  7. Install the engine mount assembly, then install the transaxle mount.
  8.  
  9. Attach the cooler linee to the transaxle.
  10.  
  11. Connect the fuel lines.
  12.  
  13. Install both drive axles into the transaxle.
  14.  
  15. Connect the heater hoses to the front of the cowl.
  16.  
  17. Install the suspension support assembly.
  18.  
  19. Connect the accelerator, cruise control, and T.V. cables to the accelerator control bracket.
  20.  
  21. Attach the flexible coupling joint to the rack and pinion assembly.
  22.  
  23. Connect the power steering linee to the rack and pinion assembly.
  24.  
  25. Attach the following electrical connectors as tagged during removal:

    Electronic Ignition Module
     
    Vehicle Speed Sensors (VSS)
     
    Cooling Fan
     
    Starter
     
    A/C compressor
     
    Oil pressure and level sensors
     
    Engine grounds
     

  26.  
  27. Install the A/C compressor, if equipped.
  28.  
  29. Connect the brake lines to the suspension support.
  30.  
  31. Fasten the tie rod ends to the struts, then connect the ball joints to the steering knuckles.
  32.  
  33. Connect the wheel speed sensor wire harness to the control arms.
  34.  
  35. Install the engine mount strut.
  36.  
  37. Fasten the exhaust pipe to the exhaust manifold and catalytic converter.
  38.  
  39. Install the splash shields and the wheel and tire assemblies.
  40.  
  41. Carefully lower the vehicle.
  42.  
  43. Connect the lower radiator hose to the water pump.
  44.  
  45. Remove the engine support fixture.
  46.  
  47. Attach the vacuum line, located near the master cylinder.
  48.  
  49. Install the coolant surge tank, then connect the tank's hose.
  50.  
  51. Connect the transaxle shift control cable.
  52.  
  53. Install the serpentine drive belt.
  54.  
  55. Attach the following electrical connectors, as tagged during removal:

    Idle Air Control (IAC)
     
    Alternator
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Transaxle Converter Clutch (TCC)
     
    Oxygen sensor
     
    Park/Neutral position switch
     
    Engine grounds
     

  56.  
  57. Connect the brake booster vacuum hose.
  58.  
  59. Attach the upper radiator hose and the air cleaner outlet duct.
  60.  
  61. Fill the cooling system and crankcase with the correct type and amount of fluids.
  62.  
  63. Connect the negative battery cable, then start the engine. Check for proper operation, fluid levels and/or leaks.
  64.  

2.3L and 2.4L Engines
  1. If equipped with A/C, have an MVAC certified technician recover the A/C refrigerant.
  2.  
  3. Disconnect the negative battery.
  4.  
  5. Properly drain the cooling system into an approved container.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove the left sound insulator, then disconnect the clutch pushrod form the pedal assembly.
  10.  
  11. Disconnect the heater hose at the thermostat assembly, then detach the radiator inlet (upper) hose.
  12.  
  13. Remove the air cleaner assembly and the coolant fan.
  14.  
  15. If equipped with A/C, disconnect the compressor/condenser hose assembly at the compressor, then discard the O-rings.
  16.  
  17. Disconnect the two vacuum hoses from the front of the engine.
  18.  
  19. Tag and detach the following electrical connectors:

    Alternator
     
    A/C compressor (if equipped)
     
    Fuel injector harness
     
    Idle Air Control (IAC) and TP sensor at the throttle body
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    EVAP canister purge solenoid
     
    Starter solenoid
     
    Ground connections
     
    Negative battery cable from the transaxle
     
    Electronic ignition coil and module assembly
     
    Engine Coolant Temperature (ECT) sensor(s)
     
    Oil pressure sensor/switch
     
    Oxygen sensor
     
    Crankshaft Position (CKP) sensor
     
    Back-up lamp switch, then position the harness aside
     

  20.  
  21. Disconnect the power brake vacuum hose from the throttle body. Detach the power brake vacuum tube-to-check valve hose from the tube.
  22.  
  23. Remove the throttle cable and bracket.
  24.  
  25. Unfasten the power steering pump rear bracket, then remove the bracket and vacuum tube as an assembly.
  26.  
  27. Unfasten the power steering pivot bolt, then remove the pump and drive belt. Position the pump aside, with the lines still attached.
  28.  


CAUTION
After relieving the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. To prevent personal injury, cover the fuel line fittings with a shop towel before disconnecting to catch any fuel that may leak out. Place the towel in an approved container when the disconnection is completed.

  1. Carefully disconnect the fuel lines.
  2.  
  3. Disconnect the shift cables. Detach the clutch actuator line.
  4.  
  5. Remove the exhaust manifold and heat shield.
  6.  
  7. Disconnect the radiator outlet (lower) hose from the radiator.
  8.  
  9. Install a suitable engine support fixture.
  10.  
  11. Unfasten the bolt attaching the coolant recovery/surge tank, then position the tank aside with the hoses still connected.
  12.  
  13. Remove the engine mount assembly.
  14.  
  15. Raise and safely support the vehicle, then remove the front wheel and tire assemblies. Remove the right splash shield.
  16.  
  17. Remove the radiator air deflector.
  18.  
  19. Tag and detach the following electrical connections:

    Vehicle Speed Sensor (VSS)
     
    Knock sensor
     
    Starter solenoid
     
    If equipped, both front ABS wheel speed sensors
     

  20.  
  21. Remove the engine mount strut and the transaxle mount.
  22.  
  23. Separate the ball joints from the steering knuckles.
  24.  
  25. Remove the suspension supports, crossmember, and stabilizer shaft as an assembly.
  26.  
  27. Disconnect the heater outlet hose from the radiator outlet pipe.
  28.  
  29. Remove the axle shaft from the transaxle and intermediate shaft, then position aside.
  30.  
  31. If equipped, disconnect the A/C lines from the oil pan.
  32.  
  33. Remove the flywheel housing cover.
  34.  
  35. Position a suitable support below the engine, then carefully lower the car onto the support.
  36.  
  37. Matchmark the threads on the support fixture hooks so that the setting can be duplicated when reinstalling the engine. Remove the engine support fixture J-hooks.
  38.  
  39. Raise the vehicle slowly off the engine and transaxle assembly. If may be necessary to move the engine/transaxle assembly rearward to clear the intake manifold.
  40.  
  41. Noting the position of the bolts, separate the engine from the transaxle.
  42.  

To install:

WARNING
Be sure the retaining bolts are in their correct locations. If not, engine damage may occur.

  1. Assemble the engine to the transaxle. Refer to Drive Train .
  2.  
  3. Position the engine and transaxle assembly under the engine compartment, then slowly lower the vehicle over the assembly until the transaxle mount is indexed, then install the retaining bolt.
  4.  
  5. Install the engine support fixture, making sure to adjust it to the previous setting.
  6.  
  7. Install the engine mount assembly and transaxle mount.
  8.  
  9. Carefully raise the vehicle off the support.
  10.  
  11. Attach the axle shafts to the transaxle.
  12.  
  13. Connect the heater outlet hose to the radiator outlet pipe.
  14.  
  15. Install the suspension supports, crossmember and stabilizer shaft assembly.
  16.  
  17. Attach the ball joints to the steering knuckles, then secure with the nuts.
  18.  
  19. Install the engine strut mount.
  20.  
  21. If equipped, connect the A/C line to the oil pan.
  22.  
  23. Attach the following electrical connectors, as tagged during removal:

    Vehicle Speed Sensor (VSS)
     
    Knock sensor
     
    Starter solenoid
     
    If equipped, both front ABS wheel speed sensors
     

  24.  
  25. Install the flywheel housing cover.
  26.  
  27. Fasten the radiator air deflector.
  28.  
  29. Connect the lower radiator hose.
  30.  
  31. Install the right splash shield, then the front wheel and tire assemblies.
  32.  
  33. Carefully lower the vehicle, then remove the engine support fixture.
  34.  
  35. Install the coolant recovery/surge tank, then secure using the retaining bolt.
  36.  
  37. Attach the following electrical connections, as tagged during removal:

    Alternator
     
    A/C compressor (if equipped)
     
    Fuel injector harness
     
    Idle Air Control (IAC) and TP sensor at the throttle body
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Air Temperature (IAT) sensor
     
    EVAP canister purge solenoid
     
    Starter solenoid
     
    Ground connections
     
    Negative battery cable to the transaxle
     
    Electronic ignition coil and module assembly
     
    Engine Coolant Temperature (ECT) sensor(s)
     
    Oil pressure sensor/switch
     
    Oxygen sensor
     
    Crankshaft Position (CKP) sensor
     
    Back-up lamp switch
     

  38.  
  39. Attach the vacuum hoses.
  40.  
  41. If equipped with A/C, attach the compressor/condenser hose assembly to the compressor.
  42.  
  43. Fasten the clutch actuator line.
  44.  
  45. Install the exhaust manifold and heat shield.
  46.  
  47. Connect the fuel lines.
  48.  
  49. Connect the positive battery cable.
  50.  
  51. Fasten the power steering pump pivot-to-block bolt. Install the power steering pump rear bracket and tension belt.
  52.  
  53. Connect the vacuum hoses to the intake manifold and to the tube from the brake booster.
  54.  
  55. Install the throttle cable and bracket.
  56.  
  57. Install the coolant fan and air cleaner assembly.
  58.  
  59. Attach the radiator outlet (upper) hose. Fill the cooling system with the proper type and quantity of coolant.
  60.  
  61. Connect the clutch pushrod to the pedal assembly, then install the left sound insulator.
  62.  
  63. Attach the heater hose at the thermostat housing.
  64.  
  65. Fill the transaxle with fluid, then fill the crankcase with oil.
  66.  
  67. Connect the negative battery cable.
  68.  
  69. If equipped with A/C, have an MVAC certified technician evacuate, charge and leak test the system.
  70.  
  71. Start the engine and check the fluid levels, proper operation of the engine and/or fluid leakage.
  72.  

 
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