LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2009 >> HHR SS, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.2L Or 2.4L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Transaxle To Engine Bolts/Stud
    GM1625689Courtesy of GENERAL MOTORS CORP.
  1. Using a engine hoist, remove the engine from the engine stand.
  2. Install the following components:
    • The engine mount bracket
    • The engine block heater, if equipped
    • The generator
  3. If equipped with a manual transaxle, install the clutch pressure plate and disc. Refer to Clutch Pressure and Driven Plate Replacement .
  4. Install the engine to the transaxle.
    5. CAUTION: Refer to Fastener Caution .
  5. If equipped with a automatic transaxle, install the transaxle to engine bolts/stud.

    Tighten:  Tighten the bolt/stud to 75 N.m (55 lb ft).

    6. Fig 2: Identifying Transaxle To Engine Bolts/Stud
    GM1625687Courtesy of GENERAL MOTORS CORP.
  6. If equipped with a manual transaxle, install the transaxle to engine bolts/stud.

    Tighten:  Tighten the bolt/stud to 75 N.m (55 lb ft).

    7. Fig 3: Identifying Transaxle Brace
    GM1625684Courtesy of GENERAL MOTORS CORP.
  7. If equipped with a automatic transaxle, install the transaxle brace and bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    8. Fig 4: Identifying Torque Converter Bolts
    GM1625721Courtesy of GENERAL MOTORS CORP.
  8. If equipped with a automatic transaxle, install the torque converter bolts.

    Tighten:  Tighten the bolts to 62 N.m (46 lb ft).

    9. Fig 5: Torque Converter Housing Access Plug
    GM1625720Courtesy of GENERAL MOTORS CORP.
  9. If equipped with a automatic transaxle, install the torque converter housing access plug.
    10. Fig 6: Identifying Frame Bolts
    GM1625598Courtesy of GENERAL MOTORS CORP.
  10. Remove the engine lift hoist from the engine lift hooks.
  11. Slide the lift table under the vehicle.
  12. Slowly lower the vehicle until the frame bolts align with the holes in the body.
  13. Install the frame bolts.

    Tighten:  Tighten the bolts to 100 N.m (74 lb ft) plus an additional 180 degrees using the J 45059  .

    14. Fig 7: Identifying Transaxle Mount To Transaxle Bolts
    GM1623167Courtesy of GENERAL MOTORS CORP.
  14. Install the transaxle mount to transaxle bolts.
  15. Tighten the transaxle mount to transaxle bolts in the following sequence:
    1. Rear
    2. Middle
    3. Front

      Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    16. Fig 8: Identifying Engine Mount To Bracket Bolts
    GM1623160Courtesy of GENERAL MOTORS CORP.
  16. Install the engine mount bracket bolts.
  17. Tighten the engine mount to bracket bolts in the following sequence:
    1. Middle
    2. Rear
    3. Front

      Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  18. Raise the vehicle until the lift table can be removed from under the vehicle.
  19. Remove the lift table.
    20. Fig 9: Identifying Lower Radiator Support Bolts
    GM1720381Courtesy of GENERAL MOTORS CORP.
  20. Unsecure the radiator assembly from the radiator core support.
  21. Install the lower radiator support bolts.

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    22. Fig 10: View Of Special Tools J 45341 & J-2619-A Installed
    GM1720291Courtesy of GENERAL MOTORS CORP.
  22. Unsecure the wheel drive shaft.
  23. Install the J 44394-A  into the right transaxle output shaft seal.
  24. Install the right wheel drive shaft into the transaxle until the drive shaft splines are past the seal, remove the J 44394-A  , then fully install the drive shaft.
  25. Verify that the wheel drive shaft is properly engaged:
    • Grasp the inner tripot housing and pull the inner housing outward. Do NOT pull on the wheel drive shaft.
    • The wheel drive shaft will remain firmly in place when properly engaged.
  26. Repeat steps 22 through 25 for the left side.
    27. Fig 11: Identifying Ball Joint To Steering Knuckle Bolts & Nuts
    GM1720286Courtesy of GENERAL MOTORS CORP.
  27. Install the left and right lower ball joints to the steering knuckles.
  28. Install the ball joint to steering knuckle bolts and nuts.

    Tighten: 

    • Tighten the nut a first pass to 50 N.m (37 lb ft), then loosen the nut 3/4 of a turn.
    • Tighten the nut a final pass to 50 N.m (37 lb ft) plus an additional 30 degrees using the J 45059  .

    29. Fig 12: Identifying Steering Gear Outer Tie Rods
    GM1720289Courtesy of GENERAL MOTORS CORP.
  29. Install the left and right outer tie rods to the steering knuckles.
  30. Install the NEW left and right steering gear outer tie rod to knuckle nuts.

    Tighten:  Tighten the nut to 25 N.m (18 lb ft) plus an additional 90 degrees using the J 45059  .

    31. Fig 13: Identifying Stabilizer Links
    GM1720288Courtesy of GENERAL MOTORS CORP.
  31. Install the left and right stabilizer links to the struts.
  32. Install the stabilizer link to strut nuts.

    Tighten:  Tighten the nut to 65 N.m (48 lb ft).

  33. Lower the vehicle.
    34. Fig 14: View Of Oil Cooler Lines
    GM1720383Courtesy of GENERAL MOTORS CORP.
  34. If equipped with a automatic transaxle, install the oil cooler lines to the transaxle.
  35. Install the oil cooler line nut.

    Tighten:  Tighten the nut to 7 N.m (62 lb in).

    36. Fig 15: View Of Range Selector & Shift Lever Cables
    GM1625583Courtesy of GENERAL MOTORS CORP.
  36. If equipped with a manual transaxle, install the range selector and shift lever cables to the transaxle bracket.
  37. Install the range selector and shift lever cables to the transaxle levers.
    38. Fig 16: View Of Range Selector Lever Cable
    GM1625581Courtesy of GENERAL MOTORS CORP.
  38. If equipped with a automatic transaxle, install the range selector lever cable to the transaxle bracket.
  39. Connect the range selector lever cable to the transaxle lever.
    40. Fig 17: View Of Engine/Transaxle Harness Electrical Connector
    GM1625489Courtesy of GENERAL MOTORS CORP.
  40. Gather all engine harness branches and position the harness over the engine.
  41. If equipped with a manual transaxle perform the following steps, install the engine harness clip (6) to the transaxle.
  42. Connect the engine harness electrical connector (7) to the back up lamp switch.
  43. Connect the engine harness electrical connector (4) to the HO2S.
  44. Install the engine harness electrical connector clip (5) to the transaxle rear mount bracket.
  45. Install the engine harness clip (2) to the transaxle.
  46. Install the CPA retainer (3).
  47. Connect the engine harness electrical connector (1) to the VSS.
    48. Fig 18: Identifying Engine Harness Electrical Connector
    GM1625487Courtesy of GENERAL MOTORS CORP.
  48. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
  49. Install the CPA retainer (2).
  50. Install the engine harness electrical connector clip (4) to the transaxle rear mount bracket.
  51. Install the engine harness clip (1) to the transaxle stud.
  52. Connect the engine harness electrical connector (6) to the park neutral position switch.
  53. Install the CPA retainer (5).
    54. Fig 19: Identifying ECT Sensor Electrical Connector
    GM1625486Courtesy of GENERAL MOTORS CORP.
  54. If equipped with a manual transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
  55. Install the CPA retainer (2).
  56. Connect the ECT sensor electrical connector (1).
    57. Fig 20: Locating ECT Sensor Electrical Connector
    GM1625483Courtesy of GENERAL MOTORS CORP.
  57. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (3) to the HO2S.
  58. Install the CPA retainer (2).
  59. Connect the ECT sensor electrical connector (1).
    60. Fig 21: Identifying Engine Harness
    GM1625479Courtesy of GENERAL MOTORS CORP.
  60. If equipped with a automatic transaxle, connect the engine harness to the transaxle.
    61. Fig 22: Identifying Engine Harness Clip
    GM1625484Courtesy of GENERAL MOTORS CORP.
  61. If equipped with a automatic transaxle, install the engine harness clip (3) to the speed sensor.
  62. Connect the VSS electrical connector (4).
  63. Install the engine harness clip (1) to the stud.
  64. Install the engine harness clip nut (2) to the engine stud.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    65. Fig 23: View Of Engine Harness Terminal, Nut & Engine Harness Boot
    GM1625472Courtesy of GENERAL MOTORS CORP.
  65. Install the engine harness lead terminal (1) to the generator.
  66. Install the generator nut (2).

    Tighten:  Tighten the nut to 20 N.m (14 lb ft).

  67. Raise and support the vehicle.
  68. Install the engine harness ground (8) to the engine block.
  69. Install the engine harness ground bolt (7).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    70. Fig 24: Identifying A/C Compressor & Pressure Switch Electrical Connectors
    GM1625475Courtesy of GENERAL MOTORS CORP.
  70. Unsecure the A/C compressor and position to the engine block. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 22 N.m (16 lb ft).

  71. Connect the A/C compressor electrical connector (2).
  72. Connect the A/C pressure switch electrical connector (1).
  73. Raise and support the vehicle.
    74. Fig 25: View Of Engine Harness
    GM1622807Courtesy of GENERAL MOTORS CORP.
  74. If equipped with a manual transaxle perform the following steps, install the engine harness ground terminal (4) to the stud.
  75. Install the positive/negative cable (3) terminal to the stud.
  76. Install the positive/negative battery cable ground nut (2).

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

  77. Connect the following electrical connectors:
    • CKP sensor (1)
    • Oil pressure sensor (5)
    • Knock sensor (6)
    78. Fig 26: View Of Engine Harness
    GM1622787Courtesy of GENERAL MOTORS CORP.
  78. If equipped with a automatic transaxle perform the following steps, install the engine harness ground terminal (3) to the stud.
  79. Install the positive/negative cable (2) terminal to the stud.
  80. Install the positive/negative battery cable ground nut (1).

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

  81. Connect the following electrical connectors:
    • CKP sensor (4)
    • Oil pressure sensor (5)
    • Knock sensor (6)
  82. Install the starter. Refer to Starter Motor Replacement .
    83. Fig 27: Identifying Engine Harness Clips
    GM1627740Courtesy of GENERAL MOTORS CORP.
  83. Install the engine harness clips (2, 4) to the intake manifold.
  84. Lower the vehicle.
  85. Install the engine harness clip (1) to the oil level indicator tube bracket.
    86. Fig 28: View Of Engine Harness Clip
    GM1625463Courtesy of GENERAL MOTORS CORP.
  86. Install the engine harness clip (1) to the transaxle stud.
  87. Install the engine harness clip nut (2).

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    88. Fig 29: Identifying Engine Harness Clips
    GM1631141Courtesy of GENERAL MOTORS CORP.
  88. Install the engine harness clips (1, 2) to the camshaft cover.
    89. Fig 30: Identifying Ignition Coil Electrical Connectors
    GM1628020Courtesy of GENERAL MOTORS CORP.
  89. Connect the intake (2) and exhaust (1) camshaft position actuator electrical connectors.
  90. Connect the ignition coils electrical connectors (3).
    91. Fig 31: Identifying TAC, Fuel Injector Harness & Generator Electrical Connectors
    GM1623764Courtesy of GENERAL MOTORS CORP.
  91. Connect the following electrical connectors:
    • TAC (1)
    • MAP sensor
    • Fuel injector harness (2)
    • Generator (3)
    92. Fig 32: Identifying Vacuum Brake Booster Hose
    GM1628035Courtesy of GENERAL MOTORS CORP.
  92. Install the brake booster vacuum hose to the intake manifold.
  93. Position the brake booster vacuum hose clamp at the intake manifold.
    94. Fig 33: Identifying Engine Harness Straps
    GM1625676Courtesy of GENERAL MOTORS CORP.
  94. Position the engine coolant heater cord, if equipped.
  95. Install the engine coolant heater cord straps to the engine harness, if equipped.
    96. Fig 34: Identifying Coolant Heater Cord
    GM1625669Courtesy of GENERAL MOTORS CORP.
  96. Connect the engine coolant heater cord, if equipped.
    97. Fig 35: Identifying Radiator Outlet Hose
    GM1713958Courtesy of GENERAL MOTORS CORP.
  97. If the vehicle is not equipped with a engine oil cooler, install the radiator outlet hose to the engine.
  98. Position the radiator outlet hose clamp at the engine.
    99. Fig 36: Identifying Radiator Outlet Hose
    GM1631170Courtesy of GENERAL MOTORS CORP.
  99. If the vehicle is equipped with a engine oil cooler perform the following steps, install the radiator outlet hose to the oil cooler.
  100. Install the radiator outlet hose to the water outlet.
  101. Position the radiator outlet hose clamp (2) at the oil cooler.
  102. Position the radiator outlet hose clamp (1) at the water outlet.
    103. Fig 37: Identifying Heater Inlet & Outlet Hoses
    GM1625419Courtesy of GENERAL MOTORS CORP.
  103. Install the heater inlet and outlet hoses to the thermostat housing.
  104. Position the heater inlet and outlet hose clamps at the thermostat housing.
    105. Fig 38: Identifying CMP Sensor Electrical Connector
    GM1639712Courtesy of GENERAL MOTORS CORP.
  105. Connect the intake (2) and exhaust (1) CMP sensor electrical connectors.
    106. Fig 39: Identifying Engine Harness Clip
    GM1625460Courtesy of GENERAL MOTORS CORP.
  106. Install the engine harness clip (1) to the EVAP purge solenoid bracket.
    107. Fig 40: Identifying EVAP Canister Purge Valve Electrical Connector
    GM1625517Courtesy of GENERAL MOTORS CORP.
  107. Connect the EVAP purge solenoid electrical connector (1).
    108. Fig 41: Identifying Radiator Inlet Hose
    GM1625418Courtesy of GENERAL MOTORS CORP.
  108. Install the radiator inlet hose to the engine.
  109. Position the radiator inlet hose clamp at the engine.
    110. Fig 42: View Of ECM Bracket Nuts/Bolts
    GM1720487Courtesy of GENERAL MOTORS CORP.
  110. Position and install the ECM bracket to the studs.
  111. Install the ECM bracket nuts (1) and bolts (2).

    Tighten: 

    • Tighten the bolts to 25 N.m (18 lb ft).
    • Tighten the nuts to 10 N.m (89 lb in).

    112. Fig 43: Identifying Positive Battery Cable Terminal & Junction Block Stud
    GM1631516Courtesy of GENERAL MOTORS CORP.
  112. Install the positive battery cable terminal (1) to the junction block stud.
    113. Fig 44: Identifying Negative Battery Cable
    GM1631518Courtesy of GENERAL MOTORS CORP.
  113. Install the positive/negative battery cable terminal (2) to the stud.
  114. Install the junction block terminal nut (1).

    Tighten:  Tighten the nut to 15 N.m (11 lb ft).

  115. Close the junction block terminal cover.
    116. Fig 45: View Of ECM Engine Harness Electrical Connector
    GM1639228Courtesy of GENERAL MOTORS CORP.
  116. Connect the engine harness electrical connectors (1, 2) to the ECM.
    117. Fig 46: View Of ECM Body Harness Electrical Connector
    GM1639226Courtesy of GENERAL MOTORS CORP.
  117. Connect the body harness electrical connector (1) to the ECM.
    118. Fig 47: Locating ECM/TCM Cover
    GM1631889Courtesy of GENERAL MOTORS CORP.
  118. Install the ECM/TCM cover.
  119. Raise the vehicle.
    120. Fig 48: View Of Cooling Fan
    GM1625478Courtesy of GENERAL MOTORS CORP.
  120. Connect the cooling fan electrical connector.
  121. Install the catalytic converter. Refer to Catalytic Converter Replacement (LE5, L61) .
  122. Install the left side engine splash shield. Refer to Engine Splash Shield Replacement .
  123. Install the engine drive belt. Refer to Drive Belt Replacement .
  124. Install the windshield washer solvent reservoir. Refer to Windshield Washer Solvent Container Replacement .
    125. Fig 49: Identifying EVAP Line
    GM1625606Courtesy of GENERAL MOTORS CORP.
  125. Connect the EVAP line to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
    126. Fig 50: View Of Fuel Feed Line
    GM1625417Courtesy of GENERAL MOTORS CORP.
  126. Connect the fuel feed line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  127. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  128. Perform the engine prelubing procedure. Refer to Engine Prelubing .
  129. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) or Cooling System Draining and Filling (GE 47716 Fill) .
  130. Check the automatic transaxle fluid, if equipped, add as needed. Refer to Transmission Fluid Check .
  131. Check the manual transaxle fluid, if equipped, add as needed. Refer to Transmission Fluid Check .
  132. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  133. Close the hood.
  134. Check the front alignment. Refer to Wheel Alignment Measurement .
scientia non olet · About LEMON Manuals