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Removal Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion Red Line. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the tires in the straight forward position, remove the key from the ignition.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. Remove the air outlet duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.0L (LSJ).
  4. Secure the cooling module to the upper body structure.
    5. Fig 1: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 2.0L (LSJ).
  6. Disconnect the fuel line from the fuel rail.
    7. Fig 2: View Of Fuel Line
    GM1387192Courtesy of GENERAL MOTORS CORP.
  7. Drain the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) in Engine Cooling.
  8. Remove the radiator inlet hose.
  9. Remove the surge tank to cylinder head pipe. Refer to Surge Tank Hose/Pipe Replacement - Inlet and Surge Tank Hose/Pipe Replacement - Outlet in Engine Cooling.
  10. Remove the radiator outlet hose.
  11. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Hose Replacement - Inlet (2.2L (L61)) or Heater Hose Replacement - Inlet (2.0L (LSJ)) and to Heater Hose Replacement - Outlet (2.2L (L61)) or Heater Hose Replacement - Outlet (2.0L (LSJ)) in Heating, Ventilation and Air Conditioning.
    12. Fig 3: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the following harness connectors:
    • TMAP sensor
    • ETC
    • Map sensor
    • BARO sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil modules
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid
    • Back-up lamp switch
  13. Remove the engine drive belt. Refer to Drive Belt Replacement .
  14. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  15. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  16. Disconnect the compressor and condenser hose assembly from the compressor.
    17. Fig 4: View Of Compressor & Condenser Hose Assembly
    GM865182Courtesy of GENERAL MOTORS CORP.
  17. Remove the AC compressor bolts and set the compressor aside.
  18. Disconnect the starter harness connectors (3,4,5).
    19. Fig 5: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the generator harness connectors.
  20. Drain the engine oil.
  21. Disconnect the front exhaust pipe from the exhaust manifold. Refer toExhaust Manifold Replacement (LSJ) or Exhaust Manifold Replacement (L61) in Engine Exhaust.
  22. Disconnect the transmission shift cable from the transmission.
  23. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  24. Remove the engine mount. Refer to Engine Mount Replacement .
    25. Fig 6: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  25. Remove the left transmission mount. Refer to Transmission Mount Replacement - Left in Manual Transmission - MU3.
    26. Fig 7: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    27. Fig 8: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
    28. Fig 9: Tie Rod To Knuckle View
    GM854972Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.
  28. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
    29. Fig 10: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement in Front Suspension.
    30. Fig 11: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
    31. Fig 12: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  31. Use a paint pen or magic marker in order to mark the frame to body position.
  32. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
  33. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  34. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
    35. Fig 13: View Of Frame
    GM851651Courtesy of GENERAL MOTORS CORP.
  35. Slowly lower the table to the floor.
  36. Attach the engine lift hoist to the engine lift hooks.
  37. Remove the starter.
    38. Fig 14: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  38. Remove the transmission to engine bolts.
  39. Separate the engine from the transmission.
  40. Remove the clutch pressure plate and disk.
  41. Remove the following components:
    • Exhaust manifold
    • Exhaust manifold studs
    • Engine mount bracket
    • Fuel rail
    • Thermostat housing and feed pipe
    • Generator
  42. Remove the engine from the engine lift.
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