GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Classic 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Engine Replacement

Tools Required

J 42451 Engine Lift Bracket

Removal Procedure

    Object Number: 785334 Size: SH
  1. Remove the hood. Refer to Hood Replacement in Body Front End.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove the air inlet duct and resonator (2). Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L.

    4. Object Number: 792955 Size: SH
  4. Disconnect the accelerator and cruise control cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 2.2L (L61).
  5. Disconnect the brake booster hose at the brake booster.

    6. Object Number: 631999 Size: SH
  6. Remove the power steering pump bolts and set pump aside.
  7. Disconnect fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (L61).
  8. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    9. Object Number: 772800 Size: SH
  9. Remove the radiator inlet hose (3). Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  10. Remove surge tank to cylinder head hose (2).
  11. Disconnect the surge tank to radiator outlet hose (3).

    12. Object Number: 780869 Size: SH
  12. Remove the radiator outlet hose (1). Refer to Radiator Outlet Hose Replacement in Engine Cooling.

    13. Object Number: 786506 Size: SH
  13. Remove the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement in HVAC.
  14. Remove the bolt retaining the surge tank outlet hose to the intake manifold.
  15. Disconnect the following electrical connectors:
    16. • 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

    Object Number: 787414 Size: SH
  16. Unclip the electrical harness from the engine and set aside.
  17. Remove the upper transmission bellhousing bolts.
  18. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  19. Remove the engine drive belt. Refer to Drive Belt Replacement .
  20. Remove the AC compressor bolts and set the compressor aside.
  21. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  22. Disconnect the generator electrical connectors.
  23. Disconnect the starter electrical connectors.
  24. Drain the engine oil.
  25. Disconnect the front exhaust pipe from the exhaust manifold.
  26. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

    27. Object Number: 475919 Size: SH
  27. Remove the flywheel to torque convertor bolts.

    28. Object Number: 104580 Size: SH
  28. Remove the lower transmission bellhousing bolts.

    29. Object Number: 510437 Size: SH
  29. Remove the transmission to engine brace.
  30. Lower the vehicle.
  31. Install J 42451 or equivalent to the right rear of the cylinder head.
  32. Install an engine hoist to the engine.
  33. Remove the front engine mount.
  34. Remove the upper transmission bellhousing bolts.
  35. Separate the engine and the transmission.
  36. Remove the engine from the vehicle.
  37. Remove the engine flywheel.
  38. Mount the engine to an engine stand.
  39. Remove the following components:
    40. • Oil filter cap and filter--Refer to Engine Oil and Oil Filter Replacement .
    • Exhaust manifold
    • Exhaust manifold studs
    • Intake manifold
    • Intake manifold studs
    • Engine mount bracket
    • Engine lift brackets
    • 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
  40. Remove the engine from the stand.
  41. Remove J 42451 or equivalent to the right rear of the cylinder head.

Installation Procedure
  1. Install J 42451 or equivalent to the right rear of the cylinder head.
  2. Mount the engine to a stand.
  3. Install the following components:
    4. • 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 brackets
    • 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
  4. Install an engine hoist to the engine.
  5. Remove the engine from the engine stand.
  6. Install the flywheel. Refer to Engine Flywheel Replacement .
  7. Install the engine to the vehicle.
  8. Remove J 42451 or equivalent to the right rear of the cylinder head.
  9. Align the engine to the transmission.

    10. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 104580 Size: SH
  10. Install the upper bell housing bolts

    11. Tighten
    Tighten the bolts to 90 N·m (66 lb ft).

  11. Install the front engine mount. Refer to Engine Mount Bracket Replacement - Right Side .
  12. Remove the engine hoist.
  13. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  14. Install the lower bell housing bolts.

    15. Tighten
    Tighten the bolts to 90 N·m (66 lb ft).


    Object Number: 475919 Size: SH
  15. Install the torque convertor bolts.

    16. Tighten
    Tighten the torque convertor bolts to 62 N·m (46 lb ft).

  16. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.

    17. Object Number: 510437 Size: SH
  17. Install the brace from the transmission to the engine.

    18. Tighten
    Tighten the brace bolts to 72 N·m (53 lb ft).

  18. Connect the front exhaust pipe to the exhaust manifold.
  19. Connect the generator electrical connectors.
  20. Connect the starter electrical connectors.
  21. Install the AC compressor to the engine.
  22. Install the engine drive belt. Refer to Drive Belt Replacement .
  23. Lower the vehicle.
  24. Connect the following electrical connectors:
    25. • 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

    Object Number: 772800 Size: SH
  25. Install the radiator inlet hose (3). Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  26. Install the surge tank to cylinder head hose (2).
  27. Connect the surge tank to radiator outlet hose (3).

    28. Object Number: 780869 Size: SH
  28. Install the radiator outlet hose (1). Refer to Radiator Outlet Hose Replacement in Engine Cooling.

    29. Object Number: 786506 Size: SH
  29. Install the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement in HVAC.
  30. Install the bolt securing the surge tank outlet hose to the intake manifold.

    31. Object Number: 631999 Size: SH
  31. Install the power steering pump.

    32. Tighten
    Tighten the power steering pump bolts to 25 N·m (18 lb ft).


    Object Number: 792955 Size: SH
  32. Connect the accelerator and cruise control cables. Refer to Accelerator Control Cable Replacement in Engine Controls - 2.2L (L61).
  33. Connect the brake booster hose.
  34. Connect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.2L (L61).

    35. Object Number: 785334 Size: SH
  35. Install the air inlet duct and resonator (2). Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
  36. Fill the engine with oil. Refer to Approximate Fluid Capacities in Maintenance and Lubrication
  37. Connect the negative battery cable . Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  38. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  39. Install the hood. Refer to Hood Replacement in Body Front End.