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Home >> Chevrolet >> 2013 >> Sonic RS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 1.8L (LUW, LWE)) >> Repair Instructions - On Vehicle >> Engine Replacement (Manual Transmission) >> Installation Procedure

Installation Procedure

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    Fig 1: Upper Transmission To Engine Bolts
    GM2535571Courtesy of GENERAL MOTORS COMPANY
  1. Remove the engine from the engine stand.
  2. Install the transmission to the engine.
    3. CAUTION:

    Refer to Fastener Caution .

  3. Install the upper transmission to engine bolts (1) and tighten to 60 (44 lb ft).
  4. Place the powertrain into the front frame.
  5. Slowly lower the body onto the powertrain.
    6. Fig 2: Transmission Mount Bolts
    GM2503695Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

  6. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 (37 lb ft) plus 70 degrees.
    7. Fig 3: Right Engine Mount Bolts
    GM2534620Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

  7. Install the right side engine mount bolts (1) and tighten to 50 (37 lb ft) plus 70 degrees.
  8. Perform Powertrain Mount Balancing.
    9. Fig 4: Frame & Bolts
    GM2508892Courtesy of GENERAL MOTORS COMPANY
  9. Install the frame (3) rear bolts (2) and front bolts (1), tighten a little bit.
    10. Fig 5: Frame & Body Through Alignment Hole
    GM2539810Courtesy of GENERAL MOTORS COMPANY
  10. Align the frame and body through alignment hole (1).
    11. Fig 6: Frame & Bolts
    GM2508892Courtesy of GENERAL MOTORS COMPANY
  11. Install the frame (3) rear bolts (2) and tighten to 135 (100 lb ft).
  12. Install the frame (3) front bolts (1) and tighten to 58 (43 lb ft).
    13. Fig 7: Frame Suspension Retaining Bolts
    GM2492995Courtesy of GENERAL MOTORS COMPANY
  13. Install the upper frame suspension retaining bolts (1) on both sides and tighten to 135 (100 lb ft).
  14. Remove the lift table.
    15. Fig 8: Lower Oil Pan To Transmission Lower Bolts
    GM2535570Courtesy of GENERAL MOTORS COMPANY
  15. Install the lower oil pan to transmission lower bolts (1) and tighten to 60 (44 lb ft).
  16. Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV,LUW) .
    17. Fig 9: Steering Linkage Outer Tie Rod
    GM2539785Courtesy of GENERAL MOTORS COMPANY
  17. Inset the wheel drive shaft to the steering knuckle.
    18. CAUTION:

    Refer to Torque-to-Yield Fastener Caution .

  18. Install the NEW steering linkage outer tie rod nut (1) and tighten to 30 (22 lb ft) Plus 128 degrees.
  19. Install the steering linkage outer tie rod to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .
    20. Fig 10: Control Arm Ball Joint To Steering Knuckle Bolt
    GM2497213Courtesy of GENERAL MOTORS COMPANY
  20. Install the control arm ball joint to the steering knuckle. Refer to Lower Control Arm Replacement .
    21. Fig 11: Upper Stabilizer Shaft Link
    GM2539770Courtesy of GENERAL MOTORS COMPANY
  21. Connect the stabilizer shaft link (2).
  22. Install the upper stabilizer shaft link nut (1) and tighten to 65 (48 lb ft).
    23. Fig 12: View Of Brake Rotor, Caliper & Axle Nut
    GM2001521Courtesy of GENERAL MOTORS COMPANY
  23. Insert a brass drift or punch (1) in the cooling fins of the front brake rotor (2).
  24. Rotate the brake rotor until it comes in contact with the brake caliper mount bracket (5).
    25. Fig 13: Wheel Drive Shaft Nut
    GM2498078Courtesy of GENERAL MOTORS COMPANY
  25. Install the NEW wheel drive shaft nut (1) and tighten to 250 (184 lb ft).
    26. Fig 14: Staking Wheel Drive Shaft Nut With Punch
    GM2498125Courtesy of GENERAL MOTORS COMPANY
  26. Using a punch (1), stake the wheel drive shaft nut.
    27. Fig 15: Fuel Feed Pipe
    GM2509366Courtesy of GENERAL MOTORS COMPANY
  27. Remove the CH-807  plug.
  28. Connect the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
  29. Connect the engine coolant sensor from radiator.
    30. Fig 16: Air Conditioning Compressor, Condenser Hose & Nut
    GM2497607Courtesy of GENERAL MOTORS COMPANY
  30. Install air conditioning compressor and condenser hose to the refrigerant hose
  31. Install air conditioning compressor and condenser hose nut (1) tighten nut to 22 (16 lb ft).
    32. Fig 17: Radiator Surge Tank
    GM2534616Courtesy of GENERAL MOTORS COMPANY
  32. Install the radiator surge tank (1). Refer to Radiator Surge Tank Replacement .
  33. Connect the fan connector.
    34. Fig 18: Transmission Range Selector Lever Cable Terminal
    GM2511540Courtesy of GENERAL MOTORS COMPANY
  34. Connect the transmission range selector lever cable terminals (1) to the transmission manual pins.
  35. Press the locking tab rearward in order to lock the transmission range selector lever cable (2) to the cable bracket.
    36. Fig 19: Heater Inlet Hose
    GM2521422Courtesy of GENERAL MOTORS COMPANY
  36. Connect the heater inlet hose to the heater core (1). Refer to Heater Inlet Hose Replacement (LDE, LUW) .
    37. Fig 20: Heater Outlet Hose
    GM2521427Courtesy of GENERAL MOTORS COMPANY
  37. Connect the heater outlet hose to the heater core (1). Refer to Heater Outlet Hose Replacement (LDE, LUW) .
    38. Fig 21: Electrical Vacuum Pump
    GM2534615Courtesy of GENERAL MOTORS COMPANY
  38. If equipped with electrical vacuum pump, connect the electrical connector and install the brake booster hose (1).
    39. Fig 22: Wiring Harness & Ground Nuts
    GM2539765Courtesy of GENERAL MOTORS COMPANY
  39. Install the ground nuts (1) and reposition the wiring harness (2).
    40. Fig 23: Wiring Harness - Top Of Engine
    GM2539762Courtesy of GENERAL MOTORS COMPANY
  40. Clip in the wiring harness plugs (1).
    41. Fig 24: Junction Block
    GM2539757Courtesy of GENERAL MOTORS COMPANY
  41. Install the junction block to the base.
  42. Install the junction block bolts (2) and tighten to 5 (44 lb in).
  43. Install the junction block nut (1) and tighten to 5 (44 lb in).
    44. Fig 25: Body Wiring Harness Connector & Positive Cable Nut
    GM2539751Courtesy of GENERAL MOTORS COMPANY
  44. Install the battery positive cable to the battery positive cable junction block and tighten nut (1) to 5 (44 lb in).
  45. Connect the body wiring master harness connector (2), to the battery positive cable junction block.
    46. Fig 26: Positive Battery Cable & Nut
    GM2504689Courtesy of GENERAL MOTORS COMPANY
  46. Position the positive battery cable to the junction block.
  47. Install the positive battery cable nut (2) and tighten to 10 (89 lb in).
    48. Fig 27: Junction Block & Cover
    GM2539745Courtesy of GENERAL MOTORS COMPANY
  48. Install the junction block cover (1).
    49. Fig 28: Air Cleaner Assembly
    GM2521421Courtesy of GENERAL MOTORS COMPANY
  49. Install the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement .
    50. Fig 29: Lower Intermediate Steering Shaft & Bolt
    GM2534608Courtesy of GENERAL MOTORS COMPANY
  50. Install the lower intermediate steering shaft bolt (1). Refer to Intermediate Steering Shaft Replacement .
  51. Install the battery and battery tray. Refer to Battery Tray Replacement .
  52. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  53. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  54. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging
  55. Fill the cooling system. Refer to Cooling System Draining and Filling .
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