Engine Removal Chevrolet Cavalier I

TROUBLE SHOOTING

Note. To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

1.6L (98")

1. Mark hinges for reinstallation and remove hood. Disconnect battery cables. Remove battery cable clips along right frame rail. Drain cooling system. Disconnect radiator hoses at engine and heater hoses at heater.
2. Disconnect engine wiring harness at firewall connector. Remove radiator upper support, radiator and fan. Remove air cleaner. Disconnect fuel line at rubber hose connection along left frame rail.
3. Disconnect automatic transmission throttle valve linkage. Disconnect accelerator cable at carburetor. If equipped, remove A/C compressor bolts and position compressor aside leaving hoses connected.
4. Raise vehicle. Disconnect exhaust pipe at manifold. Remove flywheel/converter housing inspection cover. Remove drive plate-to-converter bolts. Remove flywheel/converter housing-to-engine bolts.
5. Lower vehicle. Support transmission. Remove safety straps from front engine mounts and remove engine mount nuts. Install engine lift and remove engine.

1.8L (111") Diesel

1. Disconnect battery cables. Drain cooling system. Remove radiator. Disconnect all wiring connected to engine. Disconnect accelerator cable. Disconnect fuel hoses.
2. Disconnect TV cable. Disconnect heater hose at thermostat. If equipped, remove power steering pump with bracket and set aside. Disconnect vacuum hose to master cylinder. Remove motor mount nuts.
3. Raise vehicle. Remove engine shock-type strut. Disconnect exhaust pipe at manifold. Remove right-hand engine-to-transmission support bolts. Remove dust cover.
4. Remove torque converter bolts. Remove transmission rear crossmember-to-frame bolts. Remove bellhousing bolts. Reinstall crossmember bolts. Lower vehicle. Remove oil filter. Install engine lift and remove engine.

2.0L (122")

1. Disconnect battery cable. Drain cooling system. Remove air cleaner. Remove window washer bottle.
2. Disconnect accelerator and TV cables. Disconnect ECM harness at engine. Disconnect radiator and heater hoses at engine. Disconnect all vacuum hoses at engine. Disconnect engine harness at bulkhead connector.
3. Remove exhaust heat shield. If equipped, remove A/C adjustment bolt at motor mount. Remove alternator and power steering belts. Disconnect fuel lines. Raise vehicle.
4. Remove inner fender splash shield. If equipped, remove A/C brace and compressor. Remove flywheel shield. Remove starter wires, front brace, and starter. Remove drive plate-to-converter bolts.
5. Remove crankshaft pulley and hub. Remove oil filter. Disconnect engine-to-transmission bracket. Disconnect right rear motor mount. Disconnect exhaust pipe at manifold and center hanger. Loosen muffler hanger.
6. Disconnect TV/shift cable bracket. Remove 2 lower bellhousing bolts. Lower vehicle. Disconnect right front motor mount. Remove alternator and adjusting brace. Disconnect master cylinder and move aside. Attach engine lift.
7. Remove right front motor mount bracket. Remove upper bellhousing bolts. Remove power steering pump while lifting engine. Remove engine.

2.5L (151") Front Wheel Drive - Manual

1. Disconnect battery cables. Raise vehicle. Remove front engine mount-to-cradle nuts. Remove forward exhaust pipe. Remove starter motor with wiring attached and position aside.
2. Remove flywheel inspection cover. Lower vehicle. Remove air cleaner. Remove all bellhousing-to-engine bolts.
3. Remove forward torque reaction rod from engine and radiator core support. If equipped, remove A/C compressor and position aside with hoses attached.
4. Remove vacuum hoses at canister. If equipped, remove power steering hose. Remove all vacuum hoses and electrical connectors at solenoid. Remove heater blower motor. Disconnect accelerator cable. Drain cooling system.
5. Disconnect heater and radiator hoses at engine. Disconnect engine wiring harness at bulkhead connector.
6. Install engine lift and lift engine slightly. Remove heater hose and fuel line from intake manifold. Remove engine.

2.5L (151") Front Wheel Drive - Automatic

1. Disconnect battery cables. Drain cooling system. Remove air cleaner and heat tube. Disconnect engine wiring harness connector. Disconnect all vacuum hoses. Remove throttle and transaxle linkage at EFI assembly and intake manifold.
2. Remove upper radiator hose. If equipped, remove A/C compressor from brackets and position aside with hoses connected. Remove front engine strut assembly. Disconnect heater hose at intake manifold. Remove transaxle-to-engine bolts, leaving top 2 bolts in place.
3. Remove front mount-to-cradle nuts. Remove forward exhaust pipe. Remove flywheel cover and starter. Remove drive plate-to-converter bolts. Remove power steering pump with bracket and position aside. Remove remaining heater hose and lower radiator hose.
4. Remove 2 rear transaxle support bracket bolts. Remove fuel line at fuel filter. With floor jack and block of wood under transaxle, raise engine until front mount studs clear cradle.
5. Attach engine lift to engine and tension slightly. Remove 2 remaining transaxle-to-engine bolts. Remove engine.

2.5L (151") Rear Wheel Drive

1. Remove negative battery cable. Mark hinges for reassembly and remove hood. Drain cooling system. Remove A/C compressor with brackets and hoses connected and place aside.
2. Remove upper and lower radiator hoses from engine. Remove fan assembly. If equipped with manual transmission, remove upper half of fan shroud. If equipped with automatic transmission, remove fan shroud and radiator.
3. Remove power steering hoses from pump. Disconnect bulkhead connector. Disconnect fuel lines at flex hoses. Disconnect brake vacuum hose at filter.
4. Remove ground strap from rear of cylinder head. From inside vehicle, remove right-hand hush panel. Disconnect wiring harness from ECM harness connector.
5. Remove right-hand splash shield from right fender and feed ECM harness out from inside vehicle. Disconnect heater hoses from heater core. Disconnect throttle cable and canister hose from EFI assembly. Raise vehicle. Remove flywheel cover.
6. Remove drive plate-to-converter bolts. Remove transmission-to-engine bolts.
7. Remove exhaust pipe at manifold. Remove exhaust pipe support at bellhousing. Disconnect catalytic converter at tailpipe joint. Remove converter and exhaust pipe assembly.
8. Remove starter. Remove clutch fork return spring. Remove motor mount through bolts.
9. Lower vehicle. Attach engine lift. Support transmission with floor jack and block of wood.
10. On manual transmissions, swing engine slightly to right to remove clutch swing arm from ball. On all models, remove engine from engine compartment.

2.8L (173") Front Wheel Drive

1. Disconnect battery cables. Remove air cleaner. Drain cooling system. Remove engine strut bracket from radiator support and swing rearward. If A/C equipped, remove AIR pump and bracket.
2. Remove A/C compressor from bracket and set aside. Disconnect vacuum hoses from all non-engine mounted components. Disconnect accelerator cable and detent cable, if equipped. Disconnect engine harness from ECM and pull connector through front of dash.
3. Disconnect radiator and heater hoses from engine. Remove power steering pump and bracket from engine, if equipped.
4. Disconnect fuel lines at rubber hose connections at left side of engine compartment. Raise vehicle.
5. Remove engine front mount-to-cradle and mount-to-engine bracket retaining nuts at right side of vehicle. Disconnect battery cables from engine at starter and transaxle housing bolt.
6. Remove starter. Remove transaxle cover plate and drive plate-to-converter bolts. Remove crankshaft lower pulley and all belts. Disconnect exhaust pipe.
7. Remove 1 lower transaxle-to-engine bolt from rear of engine. Disconnect power steering cutoff switch, if equipped.
8. Lower vehicle. Remove exhaust crossover pipe. Remove remaining transaxle-to-engine bolts. Make note of ground stud location. Place support under transaxle rear extension. Install engine lift and remove engine.

2.8L (173") Rear Wheel Drive

1. Disconnect battery cables. Remove air cleaner. Mark hinges for reassembly and remove hood. Drain cooling system. Remove lower radiator hose. Remove upper fan shroud. Remove upper radiator hose and coolant recovery hose.
2. Disconnect transmission cooler lines at radiator. Remove radiator. Remove fan assembly. Remove heater hoses.
3. Disconnect throttle and cruise control detent linkages from carburetor. Disconnect all vacuum lines to engine. Remove distributor cap. Remove all wiring to engine.
4. Remove power steering pump and position aside with hoses connected. Raise vehicle. Remove exhaust pipes at manifolds. Remove converter cover. Remove drive plate-to-converter bolts. Disconnect starter wires.
5. Remove transmission-to-engine bolts. Remove motor mount through bolts. Disconnect fuel lines at fuel pump.
6. Lower vehicle. Remove bracket holding AIR to converter pipes. Support transmission with jack. Attach engine lift. Remove engine, disconnecting wire from bracket at left rear of engine.

3.8L (229")

1. Mark hinges for reinstallation and remove hood. Disconnect battery cables. Drain coolant. Remove air cleaner. Disconnect radiator and heater hoses. Remove radiator and fan shroud.
2. Disconnect wiring at starter, alternator, temperature and oil pressure switches, and distributor.
3. Disconnect accelerator linkage at intake manifold. Disconnect inlet fuel line at pump. If equipped, remove hoses at vapor canister. Disconnect brake vacuum hose at manifold, if equipped.
4. If equipped, remove power steering pump and A/C compressor with hoses attached and place aside. Raise vehicle. Drain crankcase. Disconnect exhaust pipe at manifold and, if equipped, converter bracket at transmission rear mount.
5. Remove starter. Remove flywheel/converter shield. Remove drive plate-to-converter bolts. Remove motor mount through bolts. Remove bellhousing bolts.
6. Lower vehicle. Raise transmission, using suitable jack. Attach engine lift. Raise engine slightly. Remove motor mount-to-engine brackets. Remove engine assembly.

3.8L (231")

1. Mark hinges for reinstallation and remove hood. Disconnect battery cables. Remove air cleaner. Drain cooling system.
2. If A/C equipped, disconnect compressor ground wire from mounting bracket. Remove electrical connector from compressor clutch. Remove compressor-to-mounting bracket bolts and position compressor aside.
3. Remove fan, pulleys, and belts. Disconnect radiator and heater hoses from engine. Remove fan shroud assembly. Remove power steering pump-to-mounting bracket bolts and position aside.
4. Remove and plug fuel pump hoses. Disconnect battery ground cable from engine. Disconnect vacuum lines from engine. Disconnect accelerator cable and downshift or accelerator valve cable at carburetor.
5. Disconnect oil and coolant sending unit switch connections at engine. Disconnect engine-to-body ground strap at engine. Raise vehicle. Disconnect starter motor.
6. Disconnect starter cable shield. Disconnect exhaust pipes from exhaust manifolds and support exhaust system. Remove converter cover. Remove drive plate-to-converter attaching bolts. Remove transmission-to-engine attaching bolts.
7. Remove motor mount bolts. Remove cruise control brackets, if equipped. Lower vehicle and support transmission. Attach engine lift and raise vehicle enough to remove mount through bolts.
8. Raise engine and transmission alternately until engine can be disengaged from transmission. Remove engine.

4.3L (262") Diesel FWD

1. Drain cooling system. Remove serpentine belt and, if A/C equipped, vacuum pump belt. Remove air cleaner. Cover air intake opening. Disconnect negative battery cables. Disconnect engine ground strap from rear of right cylinder head to cowl.
2. Raise vehicle. Remove flywheel cover. Remove drive plate-to-converter bolts. Disconnect exhaust pipe from rear exhaust manifold. Remove engine -to-transaxle brace. Remove engine mount-to-cradle nuts.
3. Disconnect all wiring from engine. Disconnect lower oil cooler line and plug. Remove power steering pump and bracket assembly and position aside, leaving hoses connected.
4. Lower vehicle. Remove heater water return pipe. If equipped, remove A/C compressor and position aside with hoses connected.
5. Disconnect all fuel and vacuum lines from engine. Plug all fuel lines. Disconnect throttle and TV cables at injection pump and cable bracket. Position cables aside. Remove upper oil cooler hose and plug openings. Remove exhaust crossover pipe heat shield.
6. Disconnect transaxle filler tube and position aside. Remove exhaust crossover pipe. Remove engine mounting strut and strut brackets. Attach engine lift. CAUTION: Use washers under lift chain and bolt heads. Torque bolts to 20 ft. lbs. (27 N.m) in aluminum heads.
7. Support transaxle rear extension with jack. Remove transaxle-to-engine bolts. Remove engine.

5.0L (305")

1. Mark hinges for reassembly and remove hood. Disconnect battery cables. Remove air cleaner. Drain cooling system. Disconnect radiator and heater hoses. Remove radiator and fan shroud.
2. Disconnect all wiring to engine. Disconnect accelerator linkage at intake manifold. Disconnect all fuel lines at fuel pump. Disconnect all vacuum hoses to engine. If equipped, remove power steering pump and A/C compressor, placing aside with hoses connected.
3. Raise vehicle on hoist. Drain crankcase. Disconnect exhaust pipes at manifold. Remove starter. Remove flywheel/converter housing cover.
4. Remove bolts attaching drive plate-to-converter. Remove motor mount through bolts. Remove bellhousing bolts.
5. Lower vehicle. Raise transmission using a floor jack. Attach engine lift to engine. Raise engine slightly. Remove motor mount-to-engine brackets. Remove engine.

5.7L (350") Gasoline

1. Disconnect negative battery cable. Drain coolant. Remove air cleaner. Disconnect left and right AIR hoses at check valves. Disconnect AIR management hose at check valve. Remove AIR pump belt.
2. Remove A/C compressor wiring and rear braces at exhaust and intake manifolds. Remove AIR pulley, AIR management valve adapter at pump, and AIR pump. Disconnect upper radiator hose at thermostat and power steering reservoir brace.
3. Disconnect alternator wiring. Remove alternator and brace. Disconnect AIR pipe at intake and power steering reservoir brace.
4. Remove power steering reservoir brace and pump lower bracket. Position reservoir, brace, power steering pump, and A/C wiring to front.
5. Disconnect fuel lines. Disconnect A/C compressor and idler pulley bracket nuts at water pump. Remove lower A/C mounting bolt. Moving bracket forward, remove A/C compressor upper bolt and compressor. Place compressor aside with hoses attached.
6. Disconnect fuel line lower bracket. Remove idler pulley bracket. Disconnect lower radiator hose and heater hose at water pump.
7. Place hoses and fuel lines to side. Disconnect accelerator, TV, and cruise control cables from brackets and Throttle Body Injection (TBI) unit. Disconnect brake vacuum hose and PCV at intake cover. Disconnect wiring at TBI, front ground stud, coolant sensor, and EGR solenoid.
8. Disconnect tach filter and ground wires. Remove wiring, plug wires, and distributor cap from distributor. Disconnect heater hose from intake. Mark distributor location and remove. Remove oil sending unit.
9. Remove wire bracket at rear intake bolt. Remove crankshaft pulley. Raise vehicle. Disconnect crossover pipe at manifold and converter. Disconnect crossover hanger. Disconnect converter air management pipe at right exhaust manifold.
10. Disconnect starter and sensor wiring. Disconnect wiring at head, block, oil pan, water temperature sensor, oil temperature sensor, and oxygen sensor.
11. Disconnect battery and engine grounds from rear of block. Remove bellhousing cover. Remove drive plate-to-converter bolts. Remove bellhousing bolts. Support engine.
12. Remove right and left motor mount-to-block bolts. Lower vehicle. Support transmission. Attach engine lift and remove engine, disconnecting wires at rear of left head.

5.7L (350") Diesel

1. Drain cooling system. Remove air cleaner. Cover air intake port. Mark hinges for reassembly and remove hood.
2. Disconnect negative battery cables at batteries. Disconnect engine ground strap from right cylinder head to cowl. Disconnect ground wires at inner fender panel.
3. Remove radiator hoses. Remove engine and transmission oil cooler lines. Remove heater hoses. Disconnect power steering hoses from steering gear. Remove A/C compressor from engine and position aside with hoses and brackets connected.
4. Disconnect fuel line at fuel pump. Disconnect all wiring to engine. Remove hairpin clip at bellcrank. Remove throttle and TV cables from intake manifold and position aside. Remove upper radiator support. Remove radiator.
5. Raise vehicle. Disconnect exhaust pipes at manifolds. Remove converter cover. Remove bolts attaching drive plate-to-converter. Remove motor mount through bolts. Disconnect 3 transmission-to-engine bolts on right side.
6. Disconnect starter wiring and remove starter. Lower vehicle. Secure chain lift to engine. Place a board on top of a jack and raise transmission slightly. Remove 3 bolts attaching transmission-to-engine on left side. Remove engine.

LUBRICATION

Note. For lubrication and pressure specifications, see appropriate ENGINES article.

4-CYLINDER

TORQUE SPECIFICATIONS (4-CYLINDER)

V8

TORQUE SPECIFICATIONS (V8)