Powertrain Assembly Removal

TOOLS REQUIRED:  SA9127E Gauge Bar Set

1. Disconnect negative battery cable and remove coolant bottle cap.
   NOTE: The engine's cooling system thermostat will not function correctly once it is contacted by oil. If oil is found in the cooling system, it must be flushed and the thermostat's cartridge replaced.
2. Drain engine coolant. Drains are located at right front corner of the engine block and right hand side of radiator.
3. Remove air induction system inlet hose or air cleaner assembly. Cover the throttle body opening with a shop towel.
   Fig 1: Draining Engine Coolant

   Courtesy of GENERAL MOTORS CORP.
4. Disconnect electrical and vacuum connectors where applicable:
   • Engine coolant temperature (ECT) sensor.
   • Oxygen sensor and clip at transaxle front mount bracket.
   • Idle air control (IAC) valve.
   • Ignition coil (two different connectors).
   • Throttle position (TP) sensor.
   • MAP sensor.
   • EGR solenoid.
   • Brake booster hose at brake booster or intake manifold.
     Fig 2: Electrical And Vacuum Connectors

     Courtesy of GENERAL MOTORS CORP.
   • Ground connectors (two, located at transaxle attachment studs at rear side of cylinder block.)
   • Injector connector(s).
     Fig 3: Ground Connectors

     Courtesy of GENERAL MOTORS CORP.
     NOTE: The transaxle electrical connectors and shift cable(s) can also be removed after the vehicle is on a hoist and the left-hand side splash shield is removed.
   • Automatic/manual transaxle connectors:
     • Neutral safety/selector switch (three connectors).
     • Valve body actuator connector.
     • Turbine speed sensor.
     • Transaxle temperature sensor.
     • Back-up light switch (manual transaxle).
       Fig 4: Automatic/Manual Transaxle Connectors

       Courtesy of GENERAL MOTORS CORP.
5. Disconnect accelerator cable assembly.
   CAUTION: CATCH LEAKING FUEL IN A CONTAINER WHENEVER FUEL LINES ARE LOOSENED OR DISCONNECTED.

   Fig 5: Disconnecting Fuel Line

   Courtesy of GENERAL MOTORS CORP.
6. Disconnect the fuel line.
   1. Fuel pressure can be bled into an approved container using Gauge Bar Set SA9127E.
   2. Disconnect the fuel supply line. Fuel line can be tied to brake master cylinder lines to prevent fuel spill.
      Fig 6: Disconnect The Fuel Supply Line

      Courtesy of GENERAL MOTORS CORP.
7. Disconnect the upper radiator hose at cylinder head outlet and deaeration hose at engine.
   NOTE: It is not necessary to discharge the A/C compressor during powertrain removal.
8. Remove A/C compressor (if equipped) bolts and tie the compressor to the front crossbar. Leave both A/C mounting brackets mounted on the engine.
   NOTE: Pinch the plastic connector tabs and pull on the line. Wrap the end of the lines in a clean shop towel to prevent debris entry.
9. Disconnect the automatic transaxle cooler lines at transaxle and plug.
   Fig 7: Disconnect The Automatic Transaxle Cooler Lines At Transaxle And Plug

   Courtesy of GENERAL MOTORS CORP.
10. Disconnect the automatic transaxle shifter cable.
    Fig 8: Automatic Transaxle Shifter Cable

    Courtesy of GENERAL MOTORS CORP.
11. Manual transaxle shifter cables and clutch hydraulic system.
    1. Remove the two hydraulic damper to clutch housing stud nuts and slide damper and bracket assembly off studs.
    2. Rotate clutch actuator 1/4 turn counter clockwise while pushing toward housing to disengage the bayonet connector and remove from clutch housing.
    3. Tie clutch hydraulic system to battery tray. Do not kink or pinch the nylon hydraulic lines.
       Fig 9: Remove The Two Hydraulic Damper To Clutch Housing Stud Nuts

       Courtesy of GENERAL MOTORS CORP.
12. Using safety wire or plastic tie straps, tie the radiator, condenser, and fan module to the front vehicle crossbar. The safety wire or plastic tie straps can be routed around the two fan shroud supports and around the crossbar.
    Fig 10: Tying The Radiator, Condenser, And Fan Module To The Front Vehicle Crossbar

    Courtesy of GENERAL MOTORS CORP.