Alero, Grand Am 1999-2005

Engine

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Removal & Installation



2.2L Engine
Automatic Transaxle
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Air inlet duct and resonator
     
    Accelerator and cruise control cable
     
    Hose from the brake booster
     
    Power steering pump bolts and set the pump aside
     
    Fuel lines
     
    Transmission shift control cables
     
    Transmission shift control cables from the bracket
     
    Clutch actuator cylinder from the transmission
     

  4.  
  5. Drain the cooling system.

    Radiator inlet hose
     
    Hose from the surge tank to the cylinder head
     
    Outlet hose from the surge tank to the radiator
     
    Bolt retaining the surge tank outlet hose to the intake manifold
     
    Radiator outlet hose
     
    Heater hoses
     

  6.  
  7. Disconnect the following electrical connectors:

    Idle Air Control (IAC) motor
     
    Throttle Position (TPS) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    Oxygen (O 2 S) sensor
     
    Vehicle speed sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Back-up lamp switch
     
    Electrical harness from the engine and set the harness aside
     

  8.  
  9. Remove or disconnect the following:

    Upper transmission bellhousing bolts
     

  10.  
  11. Raise the vehicle.

    Engine drive belt
     
    AC compressor bolts and set the compressor aside
     
    Crankshaft balancer
     
    Alternator and starter electrical connectors
     

  12.  
  13. Drain the engine oil.

    Front exhaust pipe from the exhaust manifold
     
    Starter
     
    Flywheel-to-torque converter bolts
     
    Lower transmission bellhousing bolts
     
    Transmission to engine brace
     

  14.  
  15. Lower the vehicle.
  16.  
  17. Install an engine hoist to the engine.

    Front engine mount
     
    Upper transmission bellhousing bolts
     
    Engine and the transmission
     
    Engine
     

  18.  

To install:

  1. Installation is the reverse of removal. Please note the following torques:

    Upper bell housing bolts and tighten to 66 ft. lbs. (90 Nm)
     
    Front engine mount and tighten the bolts to 81 ft. lbs. (110 Nm)
     
    Lower bell housing bolts and tighten to 66 ft. lbs. (90 Nm)
     
    Torque convertor bolts and tighten to 46 ft. lbs. (62 Nm)
     
    Brace from the transmission to the engine bolts to 53 ft. lbs. (72 Nm)
     
    A/C compressor. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Power steering pump bolts to 19 ft. lbs. (25 Nm)
     

  2.  
  3. Refill the cooling system and engine oil.
  4.  
  5. Start the engine and check for proper operation.
  6.  

Manual Transaxle
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Air inlet duct and resonator
     
    Accelerator and cruise control cable
     
    Hose from the brake booster
     
    Power steering pump bolts and set the pump aside
     
    Fuel lines
     
    Transmission shift control cables
     
    Transmission shift control cables from the bracket
     
    Clutch actuator cylinder from the transmission
     

  4.  
  5. Drain the cooling system.

    Radiator inlet hose
     
    Hose from the surge tank to the cylinder head
     
    Outlet hose from the surge tank to the radiator
     
    Bolt retaining the surge tank outlet hose to the intake manifold
     
    Radiator outlet hose
     
    Heater hoses
     

  6.  
  7. Disconnect the following electrical connectors:

    Idle Air Control (IAC) motor
     
    Throttle Position (TPS) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    Oxygen (O 2 S) sensor
     
    Vehicle speed sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Back-up lamp switch
     
    Electrical harness from the engine and set the harness aside
     

  8.  
  9. Raise the vehicle.
  10.  
  11. Remove or disconnect the following:

    Front suspension crossmember
     
    Drive axles
     
    Engine drive belt
     
    AC compressor bolts and set the compressor aside.
     
    Alternator and starter electrical connectors
     

  12.  
  13. Drain the engine oil.

    Front exhaust pipe from the exhaust manifold
     

  14.  
  15. Use a block of wood to support the front of the engine at the front of the oil pan.
  16.  
  17. Lower the vehicle onto an engine support table.

    Front engine mount
     
    Bolts which secure the transmission mounts to the frame
     

  18.  
  19. Raise the vehicle away from the engine and transmission assembly.
  20.  
  21. Install an engine hoist to the engine.

    Transmission bellhousing bolts
     
    Engine and the transmission
     

  22.  

To install:

  1. Installation is the reverse of removal. Please note the following torques:

    Engine to the transaxle. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Transaxle mount. Torque the bolt to 81 ft. lbs. (110 Nm).
     
    Engine mount nuts and bolts to 49 ft. lbs. (66 Nm) and the engine mount bolts to 81 ft. lbs. (110 Nm)
     
    A/C compressor. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Power steering pump. Torque the bolts to 25 ft. lbs. (34 Nm).
     

  2.  
  3. Refill the cooling system and engine oil.
  4.  
  5. Start the engine and check for proper operation.
  6.  

2.4L Engine
Automatic Transaxle
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Fuel rail assembly
     
    Air intake duct and bracket
     
    Ignition coil assembly
     
    Camshaft Position (CMP) sensor
     
    Power steering pump. DO NOT remove the lines.
     
    Oil pressure sending switch
     
    Cruise control assembly
     

  10.  
  11. Install an engine support fixture.

    Engine mount assembly
     
    Fuel pressure regulator vacuum line
     

  12.  
  13. Raise the engine with the engine support fixture J-hook.

    Engine mount bracket
     
    Accessory drive belt
     
    Front wheels
     
    Right front splash shield
     
    Crankshaft balancer
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Exhaust Gas Recirculation (EGR) sensor electrical connector
     
    Evaporator canister electrical connector
     
    Alternator
     
    Accelerator cable and bracket
     
    Starter motor
     
    Exhaust manifold heat shield
     
    Exhaust pipe from the manifold
     
    Engine intake coolant pipe
     
    Torque converter cover
     
    Torque converter bolts
     
    Oxygen Sensor (O 2 S)
     
    A/C compressor. DO NOT remove the hoses.
     
    Oil pan-to-bell housing bolts
     
    Transaxle mount
     
    Transaxle bolts
     

  14.  
  15. Install an engine lifting device and a transaxle support.
  16.  
  17. Raise the engine slightly and separate it from the transaxle to remove it from the vehicle.
  18.  

To install:


WARNING
Be sure the retaining bolts are in their correct locations. If not, engine damage may occur.

  1. Install or connect the following:

    Engine to the transaxle. Torque the bolts to 75 ft. lbs. (100 Nm).
     
    Transaxle mount. Torque the through bolt to 55 ft. lbs. (75 Nm).
     
    Oil pan-to-bell housing bolts. Torque the bolts to 17 ft. lbs. (23 Nm).
     
    A/C compressor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    O 2 S
     
    Torque converter bolts. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    Torque converter cover. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Intake coolant pipe
     
    Exhaust pipe to the manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Exhaust manifold heat shield. Torque the bolts to 124 inch lbs. (14 Nm).
     
    Starter motor. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Accelerator cable and bracket
     
    Alternator
     
    Fuel pressure regulator vacuum line
     
    Evaporator canister electrical connector
     
    EGR sensor electrical connector
     
    IAT sensor electrical connector
     
    MAP sensor electrical connector
     
    Crankshaft balancer. Torque the bolt to 129 ft. lbs. (175 Nm).
     
    Right front splash shield
     
    Front wheels
     
    Accessory drive belt
     
    Engine mount bracket. Torque the bolts to 96 ft. lbs. (130 Nm).
     
    Engine mount assembly. Torque the bolts to 49 ft. lbs. (66 Nm).
     
    Cruise control assembly
     
    Oil pressure sending switch
     
    Power steering pump. Torque the bolts to 19 ft. lbs. (26 Nm).
     
    CMP sensor
     
    Ignition coil assembly
     
    Air intake assembly
     
    Fuel rail assembly
     

  2.  
  3. Refill the cooling system and engine oil.
  4.  
  5. Start the engine and check for proper operation.
  6.  

Manual Transaxle
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the engine oil.
  8.  
  9. Discharge and recover the refrigerant.
  10.  
  11. Remove or disconnect the following:

    Air cleaner duct
     
    Air cleaner
     
    Underhood fuse block
     
    Air cleaner bracket
     
    Shift cables at the shift control
     
    Shift cables from the bracket and remove the bracket
     
    Back up lamp switch electrical connection
     
    Vehicle Speed Sensor (VSS) electrical connection
     
    Engine controls harness
     
    Vacuum lines
     
    Fuel line quick disconnect fittings
     
    Radiator hoses
     
    Heater hoses from the core
     
    Slave cylinder hydraulic line
     
    Evaporative (EVAP) solenoid
     
    Ground cables at the rear of the engine block
     
    Power steering pump with lines attached and position the pump aside
     
    Electrical connector from the A/C compressor and the Crankshaft Position (CKP) sensor and position the harness aside
     
    Starter with the wires attached and position it aside
     
    Surge tank bypass hose from the engine
     
    Cruise and accelerator cables from the throttle body
     
    Cruise control module
     

  12.  
  13. Tie the radiator to the hood latch panel with mechanics wire
  14.  
  15. Raise and support the vehicle. Safety strap the front of the vehicle to the hoist.

    Oil filter
     
    Front splash shields
     
    Front closeout panel
     
    Lower radiator support
     
    Right front brake hose
     
    Retaining nut from the Brake Pressure Modulator Valve (BPMV) at the mounting bracket
     
    Wheel Speed Sensors (WSS)
     
    WSS harnesses from the control arm retainers and the frame retainers and position them aside
     
    Driveshafts
     
    Ball joints from the control arms
     
    Outer tie rod ends from the control arms
     
    Catalytic converter from the exhaust manifold
     
    A/C compressor hose from the A/C compressor
     
    Bolt from the power steering pressure line retainer
     

  16.  
  17. Lower the vehicle until the front suspension crossmember rests on the support table. Position a three inch block of wood between the front of the oil pan and the crossmember.

    Front engine mount-to-bracket bolts
     
    Front suspension crossmember retaining bolts
     

  18.  
  19. Carefully raise the vehicle off of the engine/transaxle assembly. Install the engine hoist to the engine/transaxle assembly.

    Front and rear transaxle mount through-bolts
     
    2 side transaxle mount lower nuts
     
    Engine/transaxle assembly off of the front suspension crossmember
     
    Transaxle from the engine
     
    Clutch drive plate and clutch driven plate
     
    Flywheel
     

  20.  
  21. Mount the engine on a suitable engine stand.
  22.  

To install:

  1. Remove the engine from the engine stand
  2.  
  3. Install or connect the following:

    Flywheel
     
    Clutch driven plate and clutch drive plate
     
    Transaxle to the engine
     

  4.  
  5. Lower the engine/transaxle assembly on to the front suspension crossmember.

    2 side transaxle mount lower nuts and tighten the nuts to 60 ft. lbs. (44 Nm)
     
    Front and rear transaxle mount through-bolts. Tighten the through-bolts to 75 ft. lbs. (55 Nm).
     

  6.  
  7. Remove the engine hoist from the engine/transaxle assembly.
  8.  
  9. Carefully lower the vehicle on to the engine/transaxle assembly.

    Front suspension crossmember retaining bolts
     
    Front engine mount-to-bracket bolts
     
    Power steering pressure line retainer bolt.
     
    A/C compressor hose to the A/C compressor
     
    Catalytic converter to the exhaust manifold
     
    Outer tie rod ends to the control arms
     
    Ball joints to the control arms
     
    Driveshafts
     
    WSS harnesses to the frame retainers and the control arm retainers
     
    Wheel speed sensors
     
    Retaining nut to the BPMV at the mounting bracket
     
    Right front brake hose to the vehicle
     
    Lower radiator support
     
    Front closeout panel and the panel fasteners
     
    Front splash shields
     
    New oil filter
     

  10.  
  11. Remove the safety straps from the front of the vehicle and the hoist. Lower the vehicle. Untie the radiator from the hood latch panel.

    Cruise control module
     
    Cruise and accelerator cables to the throttle body
     
    Surge tank bypass hose to the engine
     
    Starter
     
    Connectors to the A/C compressor and the CKP sensor
     
    Power steering pump
     
    Ground cables at the rear of the engine block
     
    EVAP solenoid
     
    Slave cylinder hydraulic line
     
    Heater hoses to the heater core
     
    Radiator hoses
     
    Fuel line fittings
     
    Vacuum lines
     
    Engine controls harness
     
    VSS
     
    Back up lamp switch
     
    Shift cable bracket and the shift cables to the bracket
     
    Shift cables at the shift control
     
    Air cleaner bracket
     
    Underhood fuse block
     
    Air cleaner
     
    Air cleaner duct
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Refill the crankcase.
  16.  
  17. Recharge the A/C system.
  18.  
  19. Start the vehicle and verify no leaks.
  20.  
  21. Check and/or adjust the wheel alignment.
  22.  

3.1L Engines

Please note that the engine and transaxle are removed as an assembly from under the vehicle.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Air cleaner assembly
     
    Upper and lower radiator hoses
     
    Coolant inlet line from the coolant surge tank
     
    Vacuum hoses from the Evaporative Emissions (EVAP) canister purge valve, vacuum modulator and power brake booster
     
    Heater outlet hose from the water pump
     
    Accessory drive belt
     
    Control cables from the throttle body lever and intake manifold bracket
     
    Ignition coil assembly electrical connectors
     
    Heated Oxygen Sensor (HO 2 S) electrical connector
     
    Fuel injector electrical connectors
     
    Idle Air Control (IAC) valve electrical connector
     
    Throttle Position Sensor (TPS) electrical connector
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Park/neutral position switch electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Ground wire from the transaxle
     
    Alternator
     
    Power steering lines from the power steering pump
     
    Fuel lines from the fuel rail
     
    Cooling fan assembly
     
    Shift control cable from the transaxle shift lever and cable bracket
     
    Transaxle vent tube
     
    Vacuum hose from the vacuum reservoir
     

  10.  
  11. Install an engine support fixture.
  12.  
  13. Loosen, but do not remove the top 2 A/C compressor mounting bolts.
  14.  
  15. Remove or disconnect the following:

    Front wheels
     
    Right and left inner fender splash shields
     
    Engine mount strut
     
    Anti-lock Brake System (ABS) sensor wires from the Wheel Speed Sensors (WSS)
     
    Lower ball joints from the steering knuckles
     
    Suspension support assembly
     
    Halfshafts from the transaxle
     
    Oil filter and oil filter adapter
     
    Flywheel cover
     
    Starter motor
     
    Heater hoses from the heater core
     
    Knock sensor electrical connector
     
    2 Crankshaft Position (CKP) sensor electrical connectors
     
    Oil level sensor electrical connector
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Ground wires from the transaxle
     
    A/C compressor and move it aside with the refrigerant lines connected
     
    Vacuum reservoir tank
     
    Exhaust pipe from the exhaust manifold
     
    Engine mount strut bracket from the engine
     
    Transaxle cooler lines from the radiator
     
    Transaxle oil fill tube
     

  16.  
  17. Lower the vehicle until the powertrain assembly is resting on an engine table.
  18.  
  19. Remove or disconnect the following:

    Transaxle mount-to-body bolts
     
    Intermediate bracket from the right engine mount
     
    Engine support fixture
     

  20.  
  21. Raise the vehicle leaving the powertrain assembly on the engine table.
  22.  
  23. Separate the engine from the transaxle.
  24.  

To install:

  1. Install the transaxle to the engine. Torque the bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Lower the vehicle over the powertrain assembly.
  4.  
  5. Install or connect the following:

    Engine support fixture
     
    Intermediate bracket to the right engine mount
     
    Transaxle mount-to-body bolts. Torque the bolts to 49 ft. lbs. (66 Nm).
     
    Transaxle oil fill tube
     
    Transaxle cooler lines to the radiator
     
    Engine mount strut bracket to the engine. Torque the bolts to 44 ft. lbs. (60 Nm).
     
    Exhaust pipe to the exhaust manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Vacuum reservoir tank
     
    A/C compressor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Ground wires to the transaxle
     
    VSS electrical connector
     
    Oil level sensor electrical connector
     
    CKP electrical connectors
     
    Knock sensor electrical connector
     
    Heater hoses to the heater core
     
    Starter motor. Torque the bolts to 32 ft. lbs. (43 Nm).
     
    Flywheel cover. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Oil filter and oil filter adapter
     
    Halfshafts to the transaxle
     
    Suspension support assembly. Torque the bolts to 89 ft. lbs. (120 Nm).
     
    Lower ball joints to the steering knuckles, using new cotter pins. Torque the nuts to 41 ft. lbs. (55 Nm).
     
    WSS electrical connectors
     
    Engine mount strut. Torque the bolts to 44 ft. lbs. (60 Nm) plus an additional 90 degree turn.
     
    Right and left inner fender splash shields
     
    Front wheel
     
    Top 2 A/C compressor mounting bolts. Torque the bolts to 37 ft. lbs. (50 Nm).
     

  6.  
  7. Remove the engine support fixture.
  8.  
  9. Install or connect the following:

    Vacuum hose to the vacuum reservoir
     
    Transaxle vent tube to the transaxle
     
    Shift control cable to the transaxle shift lever and cable bracket
     
    Cooling fan assembly
     
    Fuel lines to the fuel rail
     
    Power steering lines to the power steering pump
     
    Alternator. Torque the nut to 37 ft. lbs. (50 Nm).
     
    Ground wire to the transaxle
     
    EGR valve electrical connector
     
    Park/neutral position switch electrical connector
     
    ECT electrical connector
     
    TPS electrical connector
     
    IAC electrical connector
     
    Fuel injector electrical connectors
     
    HO 2 S electrical connector
     
    Ignition coil assembly electrical connector
     
    Control cables to the throttle body lever and intake manifold bracket
     
    Accessory drive belt
     
    Heater outlet hose to the water pump
     
    Vacuum hoses to the EVAP canister purge valve, vacuum modulator and power brake booster
     
    Coolant inlet line to the coolant surge tank
     
    Upper and lower radiator hoses
     
    Air cleaner assembly
     
    Negative battery cable
     

  10.  
  11. Check and fill all the engine fluids as necessary.
  12.  
  13. Start the vehicle and bleed the power steering system.
  14.  

3.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Air cleaner assembly
     
    Hood
     
    Accessory drive belt
     
    Hoses from the surge tank
     
    Cruise control module
     
    Upper wiring harness from the engine
     
    Throttle and cruise control cables
     
    Starter motor
     
    A/C compressor and move it aside with the lines attached
     
    Lower wiring harness from the engine components
     
    Catalytic converter from the rear exhaust manifold
     
    Torque converter cover
     
    Torque converter-to-flywheel bolts
     
    Engine splash shields
     
    Transaxle-to-engine brace and the 2 outer transaxle mounting bolts
     
    Upper and lower radiator hoses
     
    Fuel lines from the engine
     
    Vacuum hose from the power brake booster
     
    Heater hoses
     

  8.  
  9. Install an engine hoist and raise the engine slightly.
  10.  
  11. Remove or disconnect the following:

    Engine mount and bracket
     
    Power steering pump
     
    Transaxle-to-engine bolts
     
    Engine from the vehicle
     

  12.  

To install:

  1. Install or connect the following:
    CAUTION
    To avoid personal injury and/or damage to the vehicle, replace the throttle cable with a new one any time the engine has been removed from the vehicle.



    Engine. Torque the upper transaxle-to-engine bolts to 66 ft. lbs. (90 Nm).
     
    Engine support fixture and remove the engine hoist
     
    Power steering pump. Torque the bolts to 25 ft. lbs. (34 Nm).
     
    Engine mount bracket and mount. Torque the bolts to 43 ft. lbs. (58 Nm) and the nuts to 35 ft. lbs. (47 Nm).
     
    Heater hoses
     
    Fuel lines
     
    Vacuum hose to the power brake booster
     
    Upper and lower radiator hoses
     
    Both outer transaxle to engine bolts. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Transaxle to the engine brace. Torque the bolts to 32 ft. lbs. (43 Nm).
     
    Engine splash shields
     
    Flexplate to the torque converter. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    Torque converter cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Catalytic converter to the exhaust manifold. Torque the bolts to 25 ft. lbs. (34 Nm).
     
    A/C compressor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Starter motor. Torque the bolts to 32 ft. lbs. (43 Nm).
     
    Lower and upper wiring harnesses
     



    Cruise control and throttle cables
     
    Cruise control module
     
    Accessory drive belt
     
    Hoses to the surge tank
     
    Hood. Torque the bolts to 13 ft. lbs. (17 Nm).
     
    Air cleaner assembly
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Refill the crankcase.
  6.  
  7. Start the engine and inspect for coolant and/or oil leaks.
  8.  
  9. Stop the engine and recheck the fluid levels after the engine has cooled.
  10.  

 
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