Cavalier, Sunfire 2001-2005

Engine

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Removal & Installation



Automatic Transaxle
2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil and coolant.
  4.  
  5. Recover the refrigerant from the A/C system.
  6.  
  7. Matchmark the bolts and remove the hood.
  8.  
  9. Remove or disconnect the following:

    Both battery cables
     
    Air cleaner assembly
     
    Brake booster vacuum line
     
    Fuel injector sight shield
     
    Accelerator and cruise control cables
     
    Engine wiring harness
     
    Cruise control module
     
    A/C line from the accumulator
     
    Accessory drive belt
     
    Coolant surge tank
     
    Upper and lower radiator hoses
     
    Fuel feed and return lines from the engine
     
    Coolant pipe assembly
     
    Wheels
     
    Wheel well splash shields
     
    Engine mount strut
     
    Torque converter dust cover
     
    Exhaust pipe from the manifold
     
    Starter motor
     
    A/C compressor and bracket
     
    Torque converter bolts
     
    Transmission-to-engine support brace
     
    Upper front engine mount
     
    Transmission-to-engine bolts
     
    Transmission from the engine
     

  10.  
  11. Lift the engine from the vehicle.
  12.  

To install:

  1. Position the engine in the vehicle, and hand tighten the upper transmission bolts.
  2.  
  3. Install or connect the following:

    Transmission-to-engine bolts. Torque the bolts to 43 ft. lbs. (58 Nm).
     
    Upper front engine mount. Torque the bolts to 55 ft. lbs. (75 Nm).
     
    Transmission-to-engine brace. Torque the bolts to 71 ft. lbs. (96 Nm).
     
    Torque converter bolts. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    A/C compressor bracket
     
    A/C compressor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Starter motor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Exhaust pipe to the manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Torque converter dust cover
     
    Engine mount strut. Torque the bolts to 74 ft. lbs. (100 Nm) plus an additional turn of 90 degrees.
     
    Wheel well splash shields
     
    Wheels
     
    Coolant pipe assembly
     
    Fuel feed and return lines
     
    Upper and lower radiator hoses
     
    Coolant surge tank. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Accessory drive belt
     
    A/C line to the accumulator
     
    Cruise control module
     
    Engine wiring harness
     
    Accelerator and cruise control cables
     
    Brake booster vacuum line
     
    Air cleaner assembly
     
    Hood. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Battery cables
     

  4.  
  5. Evacuate and recharge the A/C system.
  6.  
  7. Refill the engine oil and coolant.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Install the fuel injector sight shield.
  12.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the hood.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the air inlet duct and resonator
  12.  
  13. Disconnect the accelerator and cruise control cable.
  14.  
  15. Disconnect the hose from the brake booster.
  16.  
  17. Remove the power steering pump bolts and move the pump aside.
  18.  
  19. Disconnect the fuel lines.
  20.  
  21. Disconnect the transmission shift control cables.
  22.  
  23. Disconnect the clutch actuator cylinder from the transmission.
  24.  
  25. Remove the radiator inlet hose.
  26.  
  27. Disconnect the hose from the surge tank to the cylinder head.
  28.  
  29. Disconnect the outlet hose from the surge tank to the radiator.
  30.  
  31. Remove the bolt attaching the cooling system fill hose to the intake manifold.
  32.  
  33. Remove the radiator outlet hose.
  34.  
  35. Disconnect the heater hoses.
  36.  
  37. Disconnect the following electrical connectors:

    Idle Air Control (IAC) motor
     
    Throttle Position (TPS) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft position (CKP) sensor
     
    Camshaft (CMP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    Oxygen (O 2 S) sensor
     
    Vehicle Speed (VSS) Sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Back-up lamp switch
     

  38.  
  39. Disconnect the electrical harness from the engine and set the harness aside.
  40.  
  41. Remove the accessory drive belt.
  42.  
  43. Remove the A/C compressor bolts and set the compressor aside.
  44.  
  45. Remove the crankshaft balancer.
  46.  
  47. Disconnect the alternator electrical connectors.
  48.  
  49. Disconnect the starter electrical connectors.
  50.  
  51. Disconnect the front exhaust pipe from the manifold.
  52.  
  53. Remove the front wheel drive shafts.
  54.  
  55. Remove the starter.
  56.  
  57. Remove the flywheel to torque converter bolts.
  58.  
  59. Remove the lower transmission bellhousing bolts.
  60.  
  61. Remove the transmission-to-engine brace.
  62.  
  63. Install engine lift bracket J 4251 to the right rear of the cylinder head.
  64.  
  65. Install an engine hoist to the engine.
  66.  
  67. Remove the bolts which attach the bracket to the engine mount.
  68.  
  69. Remove the bolts which attach the transmission mount to the frame.
  70.  
  71. Raise the vehicle away from the engine and transmission assembly.
  72.  
  73. Remove the transmission bellhousing bolts.
  74.  
  75. Separate the engine and the transmission.
  76.  
  77. Remove the engine from the vehicle. Heated Oxygen (HO 2 S) sensor
  78.  

To install:

  1. Install the engine lift bracket to the right rear of the cylinder head.
  2.  
  3. Attach an engine hoist to the engine.
  4.  
  5. Install the upper engine to the transmission bolts. Torque the bolts to 66 ft. lbs. (90 Nm).
  6.  
  7. Install the engine and transmission assembly.
  8.  
  9. Remove the engine hoist.
  10.  
  11. Remove the engine support fixture.
  12.  
  13. Install the lower engine to the transmission bolts. Torque the bolts to 66 ft. lbs. (90 Nm).
  14.  
  15. Install the torque converter bolts and tighten to 46 ft. lbs. (62 Nm).
  16.  
  17. Install the starter.
  18.  
  19. Install the brace that attaches the transmission to the engine. Tighten the brace bolts to 53 ft. lbs. (72 Nm).
  20.  
  21. Connect the front exhaust pipe to the manifold.
  22.  
  23. Connect the alternator electrical connectors.
  24.  
  25. Connect the starter electrical connectors.
  26.  
  27. Install the A/C compressor to the engine.
  28.  
  29. Install the engine drive belt.
  30.  
  31. Install the front wheel drive shafts.
  32.  
  33. Connect the following electrical connectors:

    IAC motor
     
    TPS
     
    MAP sensor
     
    CKP sensor
     
    CMP sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    O 2 sensor
     
    VSS
     
    ECT
     

  34.  
  35. Install the radiator inlet hose.
  36.  
  37. Connect the hose from the surge tank to the cylinder head.
  38.  
  39. Connect the outlet hose from the surge tank to the radiator.
  40.  
  41. Install the bolt attaching the cooling system fill hose to the intake manifold.
  42.  
  43. Install the radiator outlet hose.
  44.  
  45. Install the heater hoses.
  46.  
  47. Connect the transmission shift control cables.
  48.  
  49. Connect the clutch actuator cylinder to the transmission.
  50.  
  51. Install the power steering pump and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  52.  
  53. Connect the accelerator and cruise control cable.
  54.  
  55. Connect the brake booster hose at the brake booster.
  56.  
  57. Connect fuel lines.
  58.  
  59. Install the air inlet duct and resonator.
  60.  
  61. Fill the engine with oil.
  62.  
  63. Connect the negative battery cable .
  64.  
  65. Fill the cooling system.
  66.  
  67. Install the hood.
  68.  

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Matchmark the bolts and remove the hood.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Recover the refrigerant.
  8.  
  9. Drain the engine oil.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly
     
    Brake booster vacuum line
     
    Fuel injector sight shield
     
    Accelerator and cruise control cables
     
    Engine wiring harness
     
    Cruise control module
     
    A/C line from the accumulator
     
    Accessory drive belt
     
    Coolant surge tank
     
    Upper and lower radiator hoses
     
    Fuel feed and return lines
     
    Coolant pipe assembly
     
    Wheels
     
    Wheel well splash shields
     
    Engine mount strut
     
    Torque converter cover
     
    Exhaust pipe from the manifold
     
    Starter motor
     
    A/C compressor
     
    Torque converter bolts
     
    Transmission-to-engine brace
     
    Upper front engine mount
     
    Transmission-to-engine bolts
     

  14.  
  15. Separate the engine from the transmission and lift the engine from the vehicle.
  16.  

To install:

  1. Position the engine in the vehicle.
  2.  
  3. Hand tighten the upper transmission bolts.
  4.  
  5. Install or connect the following:

    Upper front engine mount. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    Lower transmission-to-engine bolts. Torque all bolts to 55 ft. lbs. (75 Nm).
     
    Transmission-to-engine brace. Torque the bolts to 71 ft. lbs. (96 Nm).
     
    Torque converter bolts. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    A/C compressor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Starter motor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Exhaust pipe to the manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Torque converter cover
     
    Engine mount strut. Torque the bolts to 74 ft. lbs. (100 Nm).
     
    Wheel well splash shields
     
    Wheels
     
    Coolant pipe assembly
     
    Fuel feed and return lines
     
    Upper and lower radiator hoses
     
    Coolant surge tank
     
    Accessory drive belt
     
    A/C line to the accumulator
     
    Cruise control module
     
    Engine wiring harness
     
    Accelerator and cruise control cables
     
    Brake booster vacuum line
     
    Air cleaner assembly
     
    Both battery cables
     

  6.  
  7. Refill the crankcase and cooling system.
  8.  
  9. Evacuate and recharge the A/C system.
  10.  
  11. Install the hood.
  12.  
  13. Start engine and check for leaks.
  14.  
  15. Install the fuel injector sight shield.
  16.  

Manual Transaxle
2.2L Engine
  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. Remove or disconnect the following:

    Both battery cables
     
    Throttle body air inlet duct
     
    Upper radiator hose
     
    Vacuum hose from the power brake booster
     
    Idle Air Control (IAC) valve electrical connector
     
    Alternator electrical connectors
     
    Throttle Position (TPS) sensor electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    EVAP emission solenoid electrical connection
     
    Fuel injector electrical connectors
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Engine Coolant Temperature (ECT) sender electrical connector
     
    Oxygen (O 2 S) sensor electrical connector
     
    Engine grounds electrical connection
     
    Accessory drive belt
     
    Shift control cable
     
    Coolant surge tank
     
    Vacuum line near the master cylinder
     

  8.  
  9. Install an engine support fixture.

    Lower radiator hose
     
    Wheels
     
    Wheel well splash shields
     
    Exhaust pipe from the manifold
     
    Engine mount strut
     
    Wheel Speed Sensor (WSS) electrical connection
     
    Ball joints from the steering knuckles
     
    Tie rod ends from the steering knuckles
     
    Brake lines from the suspension support
     
    Air conditioning compressor. DO NOT disconnect the lines.
     
    Ignition Control Module (ICM) electrical connector
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Cooling fan electrical connector
     
    Starter electrical connector
     
    Oil pressure sensor electrical connector
     
    Power steering lines from the rack and pinion
     
    Intermediate shaft
     
    Accelerator and cruise control cables
     
    Rack and pinion bolts
     
    Suspension support extension brace
     
    Stabilizer bar
     
    Suspension support
     
    Heater hoses
     
    Halfshafts from the transmission
     
    Fuel lines
     
    Transmission mount
     
    Engine mount

    Click image to see an enlarged view

    Fig. Exploded view of the upper engine mount-2001 2.2L engine

     

  10.  
  11. Remove the engine support fixture.
  12.  
  13. Remove or disconnect the following:

    Engine and transmission assembly from the vehicle
     
    Engine from the transmission

    Click image to see an enlarged view

    Fig. Exploded view of the lower engine mount and strut-2002 2.2L engine

     

  14.  

To install:

  1. Install or connect the following:

    Transaxle to the engine. Torque the bolts to 55 ft. lbs. (75 Nm).
     
    Engine and transmission assembly to the vehicle
     
    Engine support fixture
     
    Engine mount. Torque the bolts to 49 ft. lbs. (66 Nm).
     
    Transmission mount. Torque the bolts to 49 ft. lbs. (66 Nm).
     
    Halfshafts
     
    Heater hoses
     
    Fuel lines
     
    Suspension support. Torque the bolts to 71 ft. lbs. (110 Nm) plus an additional 90 degree turn.
     
    Stabilizer bar. Torque the bolts to 49 ft. lbs. (66 Nm).
     
    Suspension support extension brace. Torque the bolts to 53 ft. lbs. (72 Nm).
     
    Rack and pinion bolts. Torque the bolts to 89 ft. lbs. (120 Nm).
     
    Accelerator and cruise control cables
     
    Intermediate shaft. Torque the pinch bolt to 30 ft. lbs. (41 Nm).
     
    Power steering lines
     
    Ignition module electrical connector
     
    VSS electrical connector
     
    Cooling fan electrical connector
     
    Starter electrical connector
     
    Oil pressure sensor electrical connector
     
    A/C compressor. Torque the front bolts to 33 ft. lbs. (45 Nm) and the rear bolt to 48 ft. lbs. (65 Nm).
     
    Brake lines to the suspension support
     
    Tie rod ends to the steering knuckles. Torque the nuts to 7 ft. lbs. (10 Nm) plus an additional 120 degree turn.
     
    Ball joints to the steering knuckles. Torque the nuts to 46 ft. lbs. (62 Nm).
     
    WSS electrical connector
     
    Engine mount strut. Torque the bolts to 74 ft. lbs. (100 Nm) plus an additional turn of 90 degrees.
     
    Exhaust pipe to the manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Wheel well splash shields
     
    Wheels
     
    Lower radiator hose
     

  2.  
  3. Remove the engine support fixture.
  4.  
  5. Install or connect the following:

    Coolant surge tank. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Shift control cable
     
    Accessory drive belt
     
    O 2 S electrical connector
     
    ECT sender electrical connector
     
    EGR valve electrical connector
     
    Fuel injector electrical connectors
     
    MAP sensor electrical connector
     
    TPS sensor electrical connector
     
    Alternator electrical connector
     
    IAC electrical connector
     
    Brake booster vacuum hose
     
    Upper radiator hose
     
    Throttle body air inlet duct
     
    Both battery cables
     

  6.  
  7. Refill the cooling system.
  8.  
  9. Start the engine and check for proper operation.

    Click image to see an enlarged view

    Fig. Exploded view of the crankshaft and related components-2002 2.2L engine

  10.  
  11. Before servicing the vehicle, refer to the precautions section.
  12.  
  13. Drain the cooling system.
  14.  
  15. Drain the engine oil.
  16.  
  17. Remove the hood.
  18.  
  19. Disconnect the negative battery cable.
  20.  
  21. Remove the air inlet duct and resonator
  22.  
  23. Disconnect the accelerator and cruise control cable.
  24.  
  25. Disconnect the hose from the brake booster.
  26.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the hood.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the air inlet duct and resonator
  12.  
  13. Disconnect the accelerator and cruise control cable.
  14.  
  15. Disconnect the hose from the brake booster.
  16.  
  17. Remove the power steering pump bolts and move the pump aside.
  18.  
  19. Disconnect the fuel lines.
  20.  
  21. Disconnect the transmission shift control cables.
  22.  
  23. Disconnect the clutch actuator cylinder from the transmission.
  24.  
  25. Remove the radiator inlet hose.
  26.  
  27. Disconnect the hose from the surge tank to the cylinder head.
  28.  
  29. Disconnect the outlet hose from the surge tank to the radiator.
  30.  
  31. Remove the bolt attaching the cooling system fill hose to the intake manifold.
  32.  
  33. Remove the radiator outlet hose.
  34.  
  35. Disconnect the heater hoses.
  36.  
  37. Disconnect the following electrical connectors:

    Idle Air Control (IAC) motor
     
    Throttle Position (TPS) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft position (CKP) sensor
     
    Camshaft (CMP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    Oxygen (O 2 S) sensor
     
    Vehicle Speed (VSS) Sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Back-up lamp switch
     

  38.  
  39. Disconnect the electrical harness from the engine and set the harness aside.
  40.  
  41. Remove the front suspension crossmember .
  42.  
  43. Remove the front wheel drive shafts.
  44.  
  45. Remove the accessory drive belt.
  46.  
  47. Remove the A/C compressor bolts and set the compressor aside.
  48.  
  49. Disconnect the alternator electrical connectors.
  50.  
  51. Disconnect the starter electrical connectors.
  52.  
  53. Disconnect the front exhaust pipe from the manifold.
  54.  
  55. Use a block of wood to support the front of the engine at the front of the oil pan.
  56.  
  57. Lower the vehicle onto an engine support table.
  58.  
  59. Remove the bolts which attach the bracket to the engine mount.
  60.  
  61. Remove the bolts which attach the transmission mount to the frame.
  62.  
  63. Raise the vehicle away from the engine and transmission assembly.
  64.  
  65. Install engine lift bracket J 4251 to the right rear of the cylinder head.
  66.  
  67. Install an engine hoist to the engine.
  68.  
  69. Remove the transmission bellhousing bolts.
  70.  
  71. Separate the engine and the transmission.
  72.  

To install:

  1. Install the engine lift bracket to the right rear of the cylinder head.
  2.  
  3. Attach an engine hoist to the engine.
  4.  
  5. Attach the engine to the transmission. Torque the bolts to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the engine and transmission assembly to an engine support table. Use a block of wood under the front of the engine to support the engine.
  8.  
  9. Remove the engine hoist.
  10.  
  11. Remove the engine support fixture.
  12.  
  13. Position the engine support table under the vehicle. Lower the vehicle while aligning the engine and transmission mounts to the vehicle.
  14.  
  15. Install the bolts which secure the transmission mount to the frame. Torque the bolts to 55 ft. lbs. (75 Nm).
  16.  
  17. Install the engine mount. Torque the engine mount-to-body nuts to 49 ft. lbs. (66 Nm) and the engine mount-to-bracket bolts to 96 ft. lbs. (130 Nm) plus an additional 45 degrees
  18.  
  19. Connect the front exhaust pipe to the manifold.
  20.  
  21. Connect the alternator electrical connectors.
  22.  
  23. Connect the starter electrical connectors.
  24.  
  25. Install the A/C compressor to the engine.
  26.  
  27. Install the engine drive belt.
  28.  
  29. Install the front wheel drive shafts.
  30.  
  31. Install the front suspension cross member.
  32.  
  33. Connect the following electrical connectors:

    IAC motor
     
    TPS
     
    MAP sensor
     
    CKP sensor
     
    CMP sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    O 2 sensor
     
    VSS
     
    ECT
     

  34.  
  35. Install the radiator inlet hose.
  36.  
  37. Connect the hose from the surge tank to the cylinder head.
  38.  
  39. Connect the outlet hose from the surge tank to the radiator.
  40.  
  41. Install the bolt attaching the cooling system fill hose to the intake manifold.
  42.  
  43. Install the radiator outlet hose.
  44.  
  45. Install the heater hoses.
  46.  
  47. Connect the transmission shift control cables.
  48.  
  49. Connect the clutch actuator cylinder to the transmission.
  50.  
  51. Install the power steering pump and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  52.  
  53. Connect the accelerator and cruise control cable.
  54.  
  55. Connect the brake booster hose at the brake booster.
  56.  
  57. Connect fuel lines.
  58.  
  59. Install the air inlet duct and resonator.
  60.  
  61. Fill the engine with oil.
  62.  
  63. Connect the negative battery cable .
  64.  
  65. Fill the cooling system.
  66.  
  67. Install the hood.
  68.  

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Discharge and recover the air conditioning refrigerant.
  4.  
  5. Properly drain the cooling system and engine oil.
  6.  
  7. Relieve the fuel system pressure.

    Click image to see an enlarged view

    Fig. Exploded view of the upper engine mount-2.4L engine

  8.  
  9. Remove or disconnect the following:

    Both battery cables
     
    Clutch pushrod from the pedal assembly
     
    Heater hose at the thermostat housing
     
    Upper radiator hose
     
    Air cleaner assembly
     
    Coolant fan
     
    Refrigerant hose assembly at the compressor
     
    Both vacuum hoses from the front of the engine
     
    Alternator electrical connector
     
    Air conditioning compressor electrical connector
     
    Fuel injector harness
     
    Idle Air Control (IAC) electrical connector
     
    Throttle Position (TPS) sensor electrical connector
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Intake Air Temperature (IAT) sensor electrical connector
     
    Evaporative Emissions (EVAP) canister purge solenoid electrical connector
     
    Negative battery cable from the transaxle
     
    Electronic ignition module electrical connector
     
    Engine Coolant Temperature (ECT) sensors electrical connectors
     
    Oil pressure sensor/switch electrical connector
     
    Oxygen (O 2 S) sensor electrical connector
     
    Crankshaft Position (CKP) sensor electrical connector
     
    Back-up lamp switch electrical connector
     
    Power brake vacuum hose from the throttle body
     
    Throttle cable and bracket
     
    Power steering pump and move it aside with the lines attached
     
    Fuel lines
     
    Shift cables
     
    Clutch actuator line
     
    Exhaust manifold and heat shield
     
    Lower radiator hose
     

  10.  
  11. Install an engine support fixture.
  12.  
  13. Remove or disconnect the following:

    Coolant recovery/surge tank, move it aside with the hoses attached
     
    Engine strut mount
     
    Front wheels
     
    Right splash shield
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Knock Sensor (KS) electrical connector
     
    Starter solenoid electrical connector
     
    Both front Anti-lock Brake System (ABS) wheel speed sensor electrical connectors
     
    Engine mount strut
     
    Transmission mount
     
    Ball joints from the steering knuckles
     
    Suspension supports, crossmember and stabilizer shaft as an assembly
     
    Heater outlet hose from the radiator outlet pipe
     
    Halfshaft from the transmission and intermediate shaft
     
    Flywheel housing cover
     

  14.  
  15. Position a suitable support below the engine, then carefully lower the vehicle onto the support.
  16.  
  17. Raise the vehicle slowly off the engine/transaxle assembly.
    NOTE
    It may be necessary to move the engine/transaxle assembly rearward to clear the intake manifold.

  18.  
  19. Remove the engine from the transaxle.

    Click image to see an enlarged view

    Fig. Exploded view of the lower engine mount and strut-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the balance shafts and related components-2.4L engine

  20.  

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 mounting bolts to 55 ft. lbs. (75 Nm).
     
    Engine/transaxle assembly under the vehicle, then lower the vehicle over the assembly
     
    Engine support fixture, making sure to adjust it to the previous setting
     
    Halfshafts to the transaxle
     
    Heater outlet hose to the radiator outlet pipe
     
    Suspension supports, crossmember and stabilizer shaft assembly. Torque the bolts to 53 ft. lbs. (72 Nm).
     
    Ball joints to the steering knuckles. Torque the nuts to 44 ft. lbs. (60 Nm) plus an additional turn of 180 degrees.
     
    Engine mount assembly. Torque the bolts to 46 ft. lbs. (62 Nm).
     
    Transmission mount. Torque the bolts to 66 ft. lbs. (90 Nm).
     
    Both front ABS wheel speed sensor electrical connectors
     
    Starter solenoid electrical connector
     
    KS electrical connector
     
    VSS electrical connector
     
    Right splash shield
     
    Front wheels
     

  2.  
  3. Carefully raise the vehicle off the support.
  4.  
  5. Install or connect the following:

    Engine strut mount. Torque the bolts to 74 ft. lbs. (100 Nm).
     
    Coolant recovery/surge tank
     
    Lower radiator hose
     
    Exhaust manifold. Torque the nuts to 31 ft. lbs. (42 Nm).
     
    Exhaust manifold heat shield. Torque the bolts to 19 ft. lbs. (26 Nm).
     
    Clutch actuator line
     
    Shift cables
     
    Fuel lines
     
    Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Throttle cable and bracket
     
    Vacuum hoses to the intake manifold and the brake booster
     
    Back-up lamp switch electrical connector
     
    CKP sensor electrical connector
     
    O 2 S electrical connector
     
    Oil pressure sensor/switch electrical connector
     
    ECT sensors electrical connectors
     
    Electronic ignition module electrical connector
     
    Negative battery cable to the transaxle
     
    EVAP canister purge solenoid electrical connector
     
    IAT sensor electrical connector
     
    MAP sensor electrical connector
     
    TPS sensor electrical connector
     
    IAC sensor electrical connector
     
    Fuel injector harness
     
    Air conditioning compressor electrical connector
     
    Alternator electrical connector
     
    Refrigerant hose assembly to the compressor
     
    Coolant fan
     
    Air cleaner assembly
     
    Upper radiator hose
     
    Heater hose at the thermostat housing
     
    Clutch pushrod to the pedal assembly
     
    Both battery cables
     

  6.  
  7. Refill the transaxle and the crankcase.
  8.  
  9. Evacuate and recharge the air conditioning system.
  10.  
  11. Refill the cooling system.
  12.  
  13. Start the engine and check for leaks.
  14.