LEMON Manuals: Even more car manuals for everyone
Home >> Pontiac >> 2009 >> Vibe Base, 2.4 0, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Engine Mechanical - 1.8L (Lay)) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Install the engine wire harness.
  2. Install the flywheel sub-assembly for the manual transaxle.
  3. Install the drive plate and ring gear subassembly for the automatic transaxle.
  4. Install clutch disc assembly for the manual transaxle.
  5. Install clutch cover assembly for the manual transaxle.
  6. Inspect and adjust clutch cover assembly for the manual transaxle.
  7. Install the transaxle assembly.
  8. Install the starter assembly.
  9. Install the flywheel housing side cover.
    10. Fig 1: Identifying Front Engine Mounting Insulator Bolt
    GM2016924Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER CAUTION .
  10. Install the front engine mounting insulator with the nut and bolt.

    Tighten:  Tighten the nut and bolt to 73 N.m (54 lb ft).

    11. Fig 2: Identifying Rear Engine Mounting Insulator Through Bolt
    GM2016938Courtesy of GENERAL MOTORS CORP.
  11. Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

    Tighten:  Tighten the bolt to 65 N.m (50 lb ft).

    12. Fig 3: Identifying Left Side Engine Mounting Insulator Bolts
    GM2016939Courtesy of GENERAL MOTORS CORP.
  12. Temporarily install the engine mounting insulator LH with the 4 bolts.
    13. IMPORTANT: Perform this procedure only when replacement of the engine mounting insulator is necessary.
  13. Install the 4 bolts.

    Tighten:  Tighten the bolts to 52 N.m (38 lb ft).

    14. Fig 4: View Of Engine Mounting Insulator Bolts - Right Side
    GM2016944Courtesy of GENERAL MOTORS CORP.
  14. Install the engine mounting insulator RH with the 3 bolts.

    Tighten:  Tighten the bolts to 52 N.m (38 lb ft).

    15. Fig 5: View Of Radiator Surge Tank Assembly Bolts
    GM2016941Courtesy of GENERAL MOTORS CORP.
  15. Install the radiator reserve tank with the 3 bolts.

    Tighten:  Tighten the bolts to 7.0 N.m (62 lb in).

    16. Fig 6: Identifying Right Side Engine Mounting Insulator
    GM2016940Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Perform this procedure only when replacement of the engine mounting insulator is necessary.
  16. Install the relay block assembly.
  17. Install the engine assembly with transaxle.
  18. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
    19. IMPORTANT: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
    IMPORTANT:
    • Make sure that the engine is clear of all wiring and hoses.
    • While raising the engine into the vehicle, do not allow it to contact the vehicle.
  19. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.
    20. Fig 7: Identifying Left Side Engine Mounting Insulator Through Bolt & Nut
    GM2016922Courtesy of GENERAL MOTORS CORP.
  20. Install the engine mounting insulator LH with the through bolt and nut.

    Tighten:  Tighten the bolt and nut to 56 N.m (41 lb ft).

    21. Fig 8: Identifying Mounting Bolts
    GM2016947Courtesy of GENERAL MOTORS CORP.
  21. Install the engine mounting insulator RH with the bolt and 2 nuts.

    Tighten: 

    • Tighten the nut A to 95 N.m (70 lb ft)
    • Tighten the nut B to 52 N.m (38 lb ft)
    • Tighten the bolt to 95 N.m (70 lb ft)

  22. Temporarily install center engine mounting member sub-assembly.
  23. Install the front suspension crossmember sub-assembly.
  24. Fully tighten the center engine mounting member sub-assembly.
  25. Remove the 2 engine hangers with the 2 bolts.
    26. Fig 9: Identifying Wire Harness Bracket Bolt
    GM2016945Courtesy of GENERAL MOTORS CORP.
  26. Install the wire harness bracket with the bolt.

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

  27. Install the drive plate and torque converter clutch setting bolt for the automatic transaxle.
  28. Install the flywheel housing under cover for the automatic transaxle.
  29. Install the front drive shaft hole snap ring LH.
  30. Install the front drive shaft assembly LH. Refer to Front Wheel Drive Shaft Replacement - Left Side .
  31. Install the front drive shaft assembly RH. Refer to Front Wheel Drive Shaft Replacement - Right Side .
    32. Fig 10: Identifying Front axle Hub Nut
    GM2016956Courtesy of GENERAL MOTORS CORP.
  32. Install the steering knuckle with axle hub LH by aligning the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.
    33. IMPORTANT: Perform the same procedure for the LH side.
  33. Install the steering knuckle with axle hub RH.
  34. Install the front lower No. 1 suspension arm sub-assembly LH.
    35. IMPORTANT: Perform the same procedure for the LH side.
  35. Install the front lower No. 1 suspension arm sub-assembly RH.
  36. Install front stabilizer link assembly LH.
    37. IMPORTANT: Perform the same procedure for the LH side.
  37. Install the front stabilizer link assembly RH.
  38. Connect the tie rod end sub-assembly LH.
    39. IMPORTANT: Perform the same procedure for the LH side.
  39. Connect the tie rod end sub-assembly RH.
  40. Install the front speed sensor LH.
  41. Install the front speed sensor RH.
  42. Install the front axle shaft LH nut.
  43. Install the front axle shaft RH nut.
  44. Install the front exhaust pipe assembly.
  45. Install the No. 1 steering column hole cover sub-assembly.
  46. Install the No. 2 steering intermediate shaft assembly.
  47. Install the column hole cover silencer sheet.
    48. Fig 11: View Of Bolt & Clamp (Manual Transaxle)
    GM2016913Courtesy of GENERAL MOTORS CORP.
  48. Install the wire harness.
  49. Install the ground wire to the engine compartment wire with the bolt and clamp for the manual transaxle.

    Tighten:  Tighten to 13 N.m (10 lb ft).

    50. Fig 12: Identifying Bolt & Clamp (Automatic Transaxle)
    GM2016917Courtesy of GENERAL MOTORS CORP.
  50. Install the ground wire to the engine compartment wire with the bolt and clamp for the automatic transaxle.

    Tighten:  Tighten to 26 N.m (19 lb ft).

    51. Fig 13: Identifying Wire Harness Retainer Nuts
    GM2016963Courtesy of GENERAL MOTORS CORP.
  51. Install the wire harness with the 2 nuts.

    Tighten:  Tighten the nuts to 8.4 N.m (74 lb in).

  52. Connect the 3 connectors and wire harness clamp to the engine room junction block.
    53. Fig 14: Locating Engine Control Computer Connector
    GM2016965Courtesy of GENERAL MOTORS CORP.
  53. Connect the connector to the ECU with the clamp and lock lever.
    54. Fig 15: Identifying Clutch Release Cylinder Assembly Bolts
    GM2016967Courtesy of GENERAL MOTORS CORP.
  54. Install the clutch release cylinder assembly with the 5 bolts and clutch tube bracket for the manual transaxle.

    Tighten: 

    • Tighten bolt A to 12 N.m (9 lb ft)
    • Tighten bolt B to 12 N.m (9 lb ft)
    • Tighten bolt C to 8.0 N.m (71 lb in)

  55. Install the compressor with pulley assembly with air conditioning system.
  56. Install the generator assembly. Refer to Generator Replacement (1.8L)
  57. Install the V-ribbed belt. Refer to Drive Belt Replacement .
    58. IMPORTANT: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull on the pipe and connector to make sure that they are securely connected.
  58. Connect the fuel tube connector and fuel pipe.
    59. Fig 16: Identifying No. 1 Fuel Pipe Clamp & Claw
    GM2016544Courtesy of GENERAL MOTORS CORP.
  59. Engage the claw and install the No. 1 fuel pipe clamp.
    60. Fig 17: Identifying Heater Inlet Hose
    GM2016902Courtesy of GENERAL MOTORS CORP.
  60. Connect the inlet heater water hose with the clamp.
    61. Fig 18: Identifying Heater Outlet Hose
    GM2016901Courtesy of GENERAL MOTORS CORP.
  61. Connect the outlet heater water hose with the clamp.
  62. Connect the union to check valve hose with the clamp.
    63. Fig 19: Identifying Cooler Hoses & Oil Cooler Tube
    GM2016899Courtesy of GENERAL MOTORS CORP.
  63. Connect the 2 oil cooler hoses with the clamp-for automatic transaxle.
    64. Fig 20: Identifying Connector Tube Hose & Union
    GM2016894Courtesy of GENERAL MOTORS CORP.
  64. Connect the union to connector tube hose.
    65. Fig 21: Identifying Fuel Vapor Feed Hose Assembly
    GM2016893Courtesy of GENERAL MOTORS CORP.
  65. Connect the fuel vapor feed hose assembly.
    66. Fig 22: Identifying Manual Transmission Shift Control Cables
    GM2016885Courtesy of GENERAL MOTORS CORP.
  66. Install the transmission control cable to the control cable bracket with 2 new clips-for manual transaxle.
  67. Install the transmission control cable to the transaxle with the 2 clips-for manual transaxle.
    68. Fig 23: Identifying Automatic Transmission Shift Control Cable
    GM2016891Courtesy of GENERAL MOTORS CORP.
  68. If equipped with automatic transmission secure the control cable onto the control cable bracket with the clip.
  69. Connect the control cable onto the control shaft lever with the nut.

    Tighten:  Tighten the nut to 12 N.m (9 lb ft).

  70. Connect the control cable to the cable support.
  71. Connect the clamp of the control cable with the bolt.

    Tighten:  Tighten the bolt to 12 N.m (9 lb ft).

    72. Fig 24: Identifying Lower Radiator Hose & Clamp
    GM2016883Courtesy of GENERAL MOTORS CORP.
  72. Connect the No. 2 radiator hose with the clamp.
    73. Fig 25: Identifying Radiator Hose & Clamp
    GM2016972Courtesy of GENERAL MOTORS CORP.
  73. Connect the No. 1 radiator hose with the clamp.
  74. Connect the clamp.
  75. Install the battery carrier with the 4 bolts.

    Tighten:  Tighten the bolts to 19 N.m (14 lb ft).

    76. Fig 26: Identifying Radiator Pipe Bracket Bolts
    GM2016881Courtesy of GENERAL MOTORS CORP.
  76. Connect the radiator pipe with the 2 bolts.

    Tighten:  Tighten the bolts to 8.8 N.m (78 lb in).

    77. Fig 27: Identifying Wire Harness Clamps At Battery Carrier
    GM2016878Courtesy of GENERAL MOTORS CORP.
  77. Connect the 2 wire harness clamps.
  78. Install the battery clamp with the bolt and nut.

    Tighten: 

    • Tighten the bolts to 6.5 N.m (58 lb in).
    • Tighten the nut to 3.5 N.m (31 lb in).

  79. Connect the battery cables.

    Tighten:  Tighten to 5.4 N.m (48 lb in).

    80. Fig 28: Identifying Air Cleaner Case & Engine Wire Harness Clamp
    GM2016875Courtesy of GENERAL MOTORS CORP.
  80. Install the air cleaner case with the 3 bolts.

    Tighten:  Tighten the bolts to 7.0 N.m (62 lb in).

  81. Install the wire harness clamp to the air cleaner case.
  82. Install the air cleaner assembly.
  83. Add transaxle oil for the manual transaxle.
  84. Add automatic transaxle fluid for the automatic transaxle.
  85. Inspect transaxle fluid level for the automatic transaxle.
  86. Inspect for automatic transaxle fluid leak for the automatic transaxle.
  87. Inspect the shift lever position for the automatic transaxle.
  88. Adjust the shift lever position for the automatic transaxle.
  89. Add the engine coolant. Refer to Cooling System Draining and Filling .
  90. Add the engine oil.
  91. Inspect the engine oil level.
  92. Inspect the for fuel leak.
  93. Inspect the for engine coolant leak.
  94. Inspect the for oil leak.
  95. Inspect the for exhaust gas leak.
  96. Install the engine under cover LH.
  97. Install the engine under cover RH.
  98. Install the front wheels.

    Tighten:  Tighten to 103 N.m (76 lb ft).

  99. Inspect the ignition timing.
  100. Inspect the engine idle speed.
  101. Inspect the CO/HC.
  102. Adjust the front wheel alignment. Refer to Wheel Alignment Measurement .
    103. Fig 29: View Of Engine & Rear Clips
    GM2016873Courtesy of GENERAL MOTORS CORP.
    NOTE: Be sure to engage the clips securely. Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
  103. Engage the 4 clips to install the No. 2 cylinder head cover.
  104. Check the ABS speed sensor signal.
scientia non olet · About LEMON Manuals