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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 737 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
  3. If applicable, install the clutch pressure plate and disk.
  4. Align the engine to the transmission.
    5. Fig 1: Identifying Engine-To-Transmission Bolt Tightening Sequence
    GM851293Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
    IMPORTANT: The number 3 bolt location is not used.
  5. Secure the engine to the transmission.

    Tighten:  Tighten the transmission to engine bolts to 75 N.m (55 lb ft).

  6. If applicable, install the torque converter bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    7. Fig 2: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  7. Install the starter. Refer to Starter Motor Replacement .
  8. Remove the engine lift from the engine.
  9. Raise and position the frame and powertrain assembly to the vehicle.
  10. Hand start all the frame bolts while aligning the frame to the paint marks.
  11. Tighten the frame bolts.

    Tighten:  Tighten the frame bolts to 100 N.m (74 lb ft plus 180 degrees).

  12. Remove the lift table.
    13. Fig 3: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  13. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement .
    14. Fig 4: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  14. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
    15. Fig 5: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
  15. Connect the intermediate steering shaft to the steering gear. Refer to Steering Gear Replacement .
    16. Fig 6: View Of Tie Rod End & Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  16. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
    17. Fig 7: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  17. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .
    18. Fig 8: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  18. Install the side transmission mount. Refer to the following:
    19. Fig 9: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  19. Install the engine mount. Refer to Engine Mount Replacement .
  20. Remove the wood blocks between the powertrain and frame.
  21. Connect the transmission shift cable to the transmission.
  22. Connect the transmission harness connector.
    23. Fig 10: View Of Exhaust Takedown Pipe
    GM878834Courtesy of GENERAL MOTORS CORP.
  23. Connect the exhaust takedown pipe to the exhaust manifold.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

  24. Connect the generator harness connectors.

    Tighten:  Tighten the generator terminal nut to 20 N.m (15 lb ft).

    25. Fig 11: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  25. Connect the starter harness connectors (3, 4, 5).

    Tighten: 

    • Tighten the battery terminal nut to 17 N.m (13 lb ft).
    • Tighten the S-terminal nut to 3 N.m (27 lb in).

  26. Install the AC compressor to the engine. Refer to Air Conditioning Compressor Replacement (L61, LE5) .
  27. Install the engine drive belt. Refer to Drive Belt Replacement .
  28. Connect the following harness connectors:
    • IAC motor
    • TPS
    • MAP sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    29. Fig 12: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement (L61, LE5) and Heater Outlet Hose Replacement (L61, LE5) .
  30. Install the radiator outlet hose. Refer to Radiator Inlet Hose Replacement (LE5, L61) .
  31. Connect the fuel line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  32. Connect the brake booster hose at the brake booster.
    33. Fig 13: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  33. Release the cooling module from the upper body structure.
  34. Install the air inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  35. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  36. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations .
  37. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill LE5, L61) .
  38. Road test the vehicle.
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