LEMON Manuals: Even more car manuals for everyone
Home >> Pontiac >> 2009 >> G3 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 67 (Engine Mechanical - 1.6L (LDE, LLU, And LXV) Or 1.8L (2H0) - Repair Instructions - On Vehicle) >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2010 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Engine & Transaxle
    GM2049614Courtesy of GENERAL MOTORS CORP.
  1. Assemble the engine to the transaxle.
  2. Place the engine assembly on the supporter.
  3. Raise the vehicle.
  4. Locate the engine assembly with the supporter.
  5. Lower the vehicle.
  6. Install the engine mount. Refer to Engine Mount Replacement .
  7. Install the transaxle mount.
    8. Fig 2: Drive Axle Shafts
    GM2049612Courtesy of GENERAL MOTORS CORP.
  8. Install the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement .
  9. Install the exhaust front pipe. Refer to Front Pipe Replacement .
    10. Fig 3: Reaction Rod
    GM2049602Courtesy of GENERAL MOTORS CORP.
  10. Install the reaction rod (1).
  11. Install and connect the cables and wiring harness related to the automatic transaxle.
  12. Connect the auto transaxle fluid cooler inlet/outlet hoses.
    13. Fig 4: Manual Transaxle Cable Connector
    GM2049611Courtesy of GENERAL MOTORS CORP.
  13. Install and connect the cables and wiring harness related to the manual transaxle.
    14. Fig 5: Coolant & Brake Boost Hoses
    GM2049609Courtesy of GENERAL MOTORS CORP.
  14. Connect the coolant hose (1) to the water pump.
  15. Connect the coolant hose (2) to the thermostat housing.
  16. Connect the heater core coolant inlet/outlet hoses (3) to the coolant distributor.
  17. Connect the ETC-to-coolant tank hose (4).
  18. Connect the brake boost hose (5) to the intake manifold.
    19. CAUTION: Refer to Fastener Caution .
  19. Position the engine harness and connect the following connectors.
    • Crankshaft position (CKP) sensor connector
    • Knock sensor connector
    • Alternator connector
    • Alternator B+ nut
    • Oil level switch connector, if equipped
    • Starter solenoid B+ nut
    • Ground nut
    • Starter solenoid ground nut

      Tighten: 

      • Tighten the alternator B+ nut to 15 N.m (11 lb ft).
      • Tighten the starter solenoid B+ nut to 10.5 N.m (7.7 lb ft).
      • Tighten the ground nut to 12 N.m (8.8 lb ft).
      • Tighten the starter solenoid ground nut to 38 N.m (28 lb ft).

  20. Connect the following:
    • Ignition coil connector
    • Camshaft position sensor (CPS) connectors (right/left)
    • Coolant temperature sensor connector
    • Oxygen sensor connector
    • Ground bolt

      Tighten:  Tighten the ground bolt to 12 N.m (8.8 lb ft).

    • Thermostat heater connector
  21. Connect the following:
    • Oil switch wiring connector
    • A/C compressor connector
    22. Fig 6: Power Steering Pump Pressure Pipe Clamp Bolt
    GM2049606Courtesy of GENERAL MOTORS CORP.
  22. Install the power steering pump pressure line union nut.
  23. Install the power steering pressure pipe retaining clamp bolt (1) to the intake manifold.
  24. Connect the power steering hose to the power steering pump.
    25. Fig 7: A/C Inlet/Outlet Pipe Tightening Bolt
    GM2049605Courtesy of GENERAL MOTORS CORP.
  25. Install the A/C inlet/outlet pipe bolt (1) from the A/C compressor if equipped.
  26. Charge the A/C system. Refer to Refrigerant Recovery and Recharging .
  27. Install the fuse box bolts.
  28. Install the battery and tray. Refer to Battery Tray Replacement .
  29. Install the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY REPLACEMENT .
  30. Connect the fuel pipe to the fuel rail.
  31. Connect the EVAP hose to the EVAP canister solenoid valve.
scientia non olet · About LEMON Manuals