Cobalt 2006-2008, G5 2007

Engine

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the tires in the straight forward position, remove the key from the ignition.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air outlet duct.
  8.  
  9. Secure the cooling module to the upper body structure.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the fuel line from the fuel rail.
  14.  
  15. Drain the cooling system.
  16.  
  17. Remove the radiator inlet hose.
  18.  
  19. Remove the surge tank to cylinder head pipe.
  20.  
  21. Remove the radiator outlet hose.
  22.  
  23. Remove the inlet and outlet heater hoses.
  24.  
  25. Disconnect the following harness connectors:

    TMAP sensor
     
    Electronic Temperature Control (ETC)
     
    Manifold Absolute Pressure (MAP) sensor
     
    Barometric Pressure (BARO) sensor
     
    Crankshaft sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil modules
     
    Oxygen (O 2 ) sensor
     
    Vehicle speed sensor
     
    Engine temperature sensor
     
    Boost solenoid
     
    Back-up lamp switch
     

  26.  
  27. Remove the accessory drive belt.
  28.  
  29. Raise and suitably support the vehicle.
  30.  
  31. Recover the refrigerant.
  32.  
  33. Remove the right front fender liner.
  34.  
  35. Disconnect the electrical connector from the compressor.
  36.  
  37. Remove the compressor hose from the evaporator hose.
  38.  
  39. Remove and discard the seal washer.
  40.  
  41. Remove the lower right radiator mount.
  42.  
  43. Remove the cap from the charge air cooler reservoir.
  44.  
  45. Place a drain pan under the charge air cooler radiator.
  46.  
  47. Reposition the inlet hose clamp at the auxiliary water pump.
  48.  
  49. Remove the inlet hose from the auxiliary water pump and allow the cooling system to drain.
  50.  
  51. Remove the auxiliary intercooler pump.
  52.  
  53. Remove the mounting cover from the charge air cooler pump and position the pump forward.
  54.  
  55. Disconnect the electrical connector from the pressure transducer.
  56.  
  57. Remove the compressor and condenser hose assembly bolt from the compressor.
  58.  
  59. Remove the compressor and condenser hose assembly from the compressor.
  60.  
  61. Remove and discard the sealing washers.
  62.  
  63. Remove the compressor hose from the condenser.
  64.  
  65. Remove and discard the seal washer.
  66.  
  67. Remove the auxiliary intercooler pump bolts and position the pump toward the driver-s side of the vehicle.
  68.  
  69. Remove the compressor mounting bolts.
  70.  
  71. Remove the compressor.
  72.  
  73. Disconnect the starter harness connectors.
  74.  
  75. Disconnect the generator harness connectors.
  76.  
  77. Drain the engine oil.
  78.  
  79. Disconnect the front exhaust pipe from the exhaust manifold.
  80.  
  81. Disconnect the transaxle shift cable from the transaxle.
  82.  
  83. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  84.  
  85. Support the engine with a hydraulic floor jack. Use a piece of wood between the jack and the oil pan.
  86.  
  87. Remove the engine mount to intermediate bracket bolts.
  88.  
  89. Remove the engine mount to mid-rail nuts.
  90.  
  91. Remove the engine mount from the engine compartment.

    Click image to see an enlarged view

    Fig. Underhood electrical center

  92.  
  93. Remove the cover from the underhood electrical center.
  94.  
  95. Remove the underhood positive battery terminal lug.
    WARNING
    Take note of the positioning of the positive battery cables before disconnecting the cables.

  96.  
  97. Disconnect the positive battery cables from the underhood electrical center.
    WARNING
    The underhood electrical center bolts are retained in the electrical center.

  98.  
  99. Loosen all of the underhood electrical bolts.
  100.  
  101. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center.
  102.  
  103. Support the transaxle with a floor jack. Use a piece of wood between the jack and the transaxle.
  104.  
  105. Remove the transaxle mount-to-transaxle bracket bolts.
  106.  
  107. Remove the transaxle mount to mid-rail bolts.
  108.  
  109. Using a floor jack, slowly lower the transaxle enough to remove the transaxle mount from the vehicle.
  110.  
  111. Disconnect the control links from the stabilizer bar.
  112.  
  113. Disconnect the outer tie rod ends from the steering knuckles.
    WARNING
    In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

  114.  
  115. Disconnect the intermediate shaft from the steering gear.
  116.  
  117. Disconnect the lower control arms from the steering knuckles.
  118.  
  119. Disconnect the halfshafts from the steering knuckle.
  120.  
  121. Use a paint pen or magic marker in order to mark the frame to body position.
  122.  
  123. Lower the vehicle to about 3 feet (1 meter) off the ground in order to position the lift table under the frame.
  124.  
  125. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  126.  
  127. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2.  
    3. Partially unscrew the rear frame bolts until 1 1 / 4 inches (38mm) of bolt shank is exposed.
    4.  

  128.  
  129. Slowly lower the table to the floor.
  130.  
  131. Attach the engine lift hoist to the engine lift hooks.
  132.  
  133. Remove the starter.
  134.  
  135. Remove the transaxle to engine bolts.
  136.  
  137. Separate the engine from the transaxle.
  138.  
  139. Remove the clutch pressure plate and disk.
  140.  
  141. Remove the exhaust manifold
  142.  
  143. Remove the exhaust manifold studs
  144.  
  145. Remove the engine mount bracket
  146.  
  147. Remove the fuel rail
  148.  
  149. Remove the thermostat housing and feed pipe
  150.  
  151. Remove the generator
  152.  
  153. Remove the engine from the engine lift.
  154.  

To install:

  1. Attach the engine lift hoist to the engine lift hooks.
  2.  
  3. Install the exhaust manifold
  4.  
  5. Install the fuel rail
  6.  
  7. Install the idler pulley
  8.  
  9. Install the drive belt tensioner
  10.  
  11. Install the thermostat housing and feed pipe. Install the thermostat housing cap bolts and cap. Tighten the bolt to 18 inch lbs. (10 Nm).
  12.  
  13. Install the generator
  14.  
  15. Install the flywheel. Install the flywheel bolts. Tighten the flywheel bolts to 39 ft. lbs. (53 Nm) plus 25°.
  16.  
  17. Install the clutch pressure plate and disk.
    WARNING
    NEW CVC compressor assemblies are shipped with a partial Poly-Alkylene Glycol (PAG) refrigerant oil charge. Use of the incorrect PAG oil can result in compressor failure.

  18.  
  19. Install the compressor and the bolts to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm).
  20.  
  21. Install new sealing washers on the hose fittings.
  22.  
  23. Install the hose assembly to the compressor.
  24.  
  25. Install the assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm).
  26.  
  27. Connect the compressor electrical connector.
  28.  
  29. Install the auxiliary intercooler pump. Tighten the pump bolt to 88 inch lbs. (10 Nm).
  30.  
  31. Install the front fender liner.
  32.  
  33. Align the engine to the transaxle.
    WARNING
    The number 3 bolt location is not used.



    Click image to see an enlarged view

    Fig. Transmission to engine bolts. The number 3 bolt location is not used

  34.  
  35. Secure the engine to the transaxle. Tighten the transaxle to engine bolts to 55 ft. lbs. (75 Nm).
  36.  
  37. Install the starter.
  38.  
  39. Remove the engine lift from the engine.
  40.  
  41. Raise and position the frame and powertrain assembly to the vehicle.
  42.  
  43. Hand start all the frame bolts while aligning the frame to the paint marks.
  44.  
  45. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180°.
  46.  
  47. Remove the lift table.
  48.  
  49. Connect the halfshafts to the steering knuckles.
  50.  
  51. Connect the lower control arm to the steering knuckle.
  52.  
  53. Connect the intermediate steering shaft to the steering gear.
  54.  
  55. Connect the outer tie rod ends to the steering knuckles.
  56.  
  57. Connect the control links to the stabilizer bar.
  58.  
  59. Install the transaxle mount to the mid-rail.
  60.  
  61. Install the transaxle mount to mid-rail bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
  62.  
  63. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
    WARNING
    The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.

  64.  
  65. Hand start the transaxle mount to bracket bolts using the following sequence:
    1. Rear bolt
    2.  
    3. Middle bolt
    4.  
    5. Front bolt
    6.  

  66.  
  67. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  68.  
  69. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket.
  70.  
  71. Place the engine mount onto the mid-rail and hand start the nuts.
  72.  
  73. Tighten the engine mount to mid-rail nuts. Tighten the nuts to 74 ft. lbs. (100 Nm).
    WARNING
    The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes.

  74.  
  75. Hand start the engine mount to intermediate bracket bolts.
    WARNING
    The engine mount bracket bolts must be tightened in a mandatory torque sequence as shown.



    Click image to see an enlarged view

    Fig. Engine mount bracket bolt torque sequence

  76.  
  77. Tighten the engine mount to intermediate bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  78.  
  79. Remove the wood blocks between the powertrain and frame.
  80.  
  81. Connect the transaxle shift cable to the transaxle.
  82.  
  83. Connect the exhaust takedown pipe to the exhaust manifold. Tighten the nuts to 22 ft. lbs. (30 Nm).
  84.  
  85. Connect the generator harness connectors. Tighten the generator terminal nut to 15 ft. lbs. (20 Nm).
  86.  
  87. Connect the starter harness connectors. Tighten the battery terminal nut to 13 ft. lbs. (17 Nm). Tighten the S-terminal nut to 27 inch lbs. (3 Nm).
  88.  
  89. Install the compressor and condenser hose assembly to the compressor.
  90.  
  91. Evacuate and charge the refrigerant system.
  92.  
  93. Install the accessory drive belt.
  94.  
  95. Connect the following harness connectors:

    TMAP sensor
     
    ETC
     
    MAP sensor
     
    Crankshaft sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    BARO sensor
     
    Ignition coil modules
     
    O 2 sensor
     
    Vehicle speed sensor
     
    Engine temperature sensor
     
    Boost solenoid
     

  96.  
  97. Install the inlet heater hose and outlet heater hose.
  98.  
  99. Install the radiator outlet hose.
  100.  
  101. Connect the fuel line to the fuel rail.
  102.  
  103. Install the surge tank to the cylinder head pipe. Tighten the bolt to 89 inch lbs. (10 Nm).
  104.  
  105. Release the cooling module from the upper body structure.
  106.  
  107. Install the air outlet duct.
  108.  
  109. Connect the negative battery cable.
  110.  
  111. Fill the engine with engine oil to the proper level.
  112.  
  113. Fill the cooling system.
  114.  
  115. To fill the intercooler system:
    WARNING
    The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

    1. Install the inlet hose to the auxiliary water pump.
    2.  
    3. Reposition the inlet hose clamp to secure the hose.
    4.  
    5. Lower the vehicle.
    6.  
    7. Remove the right front headlamp assembly.
    8.  
    9. Remove the bleeder screw from the radiator on the passenger top side of the charge air cooler.
      WARNING
      Use a 50/50 mixture of DEX-COOL® antifreeze and clean, drinkable water. It is necessary to maintain the coolant level near the cold fill line on the surge tank to ensure all the air has been purged from the cooling system.

    10.  
    11. Slowly add a mixture of 50/50 DEX-COOL® antifreeze and clean, drinkable water to the cooling system until the coolant level reaches the top of the bleeder screw opening.
    12.  
    13. Install the bleeder screw.
    14.  
    15. Slowly add a mixture of 50/50 DEX-COOL® antifreeze and clean, drinkable water to the cooling system until the coolant level is just visible in the bottom of the charge air cooler reservoir. The coolant level will reach the hot fill line once the system has reached operating temperature.
    16.  
    17. Install the cap to the charge air cooler reservoir.
    18.  
    19. Inspect the cooling system for leaks.
    20.  
    21. Install the right front headlamp assembly.
    22.  
    23. Rinse away any excess coolant from the engine and the engine compartment.
    24.  

  116.  
  117. Road test the vehicle.
  118.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the tires in the straight forward position, remove the key from the ignition.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air inlet duct and resonator.
  8.  
  9. Secure the cooling module to the upper body structure.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the fuel lines from the fuel rail.
  14.  
  15. Drain the cooling system.
  16.  
  17. Remove the radiator inlet hose.
  18.  
  19. Remove the surge tank to cylinder head hose.
  20.  
  21. Remove the radiator outlet hose.
  22.  
  23. Remove the inlet and outlet heater hoses.
  24.  
  25. Disconnect the following harness connectors:

    Idle Air Control (IAC) motor
     
    TPS
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    Oxygen (O 2 ) sensor
     
    Vehicle speed sensor
     
    Engine temperature sensor
     
    Backup lamp switch
     

  26.  
  27. Raise and suitably support the vehicle.
  28.  
  29. Remove the engine accessory drive belt.
  30.  
  31. Remove the front fender liner.
  32.  
  33. Rotate the drive belt tensioner counterclockwise to release the spring tension.
  34.  
  35. Remove the drive belt.
  36.  
  37. Disconnect the electrical connector from the A/C compressor.
  38.  
  39. Remove the A/C compressor bolts and set the compressor aside.
  40.  
  41. Disconnect the starter harness connectors.
  42.  
  43. Disconnect the generator harness connectors.
  44.  
  45. Drain the engine oil.
  46.  
  47. Disconnect the front exhaust pipe from the exhaust manifold.
  48.  
  49. Disconnect the transaxle harness connectors.
  50.  
  51. Disconnect the transaxle shift cable from the transaxle.
  52.  
  53. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  54.  
  55. Support the engine with a hydraulic floor jack. Use a piece of wood between the jack and the oil pan.
  56.  
  57. Remove the engine mount to intermediate bracket bolts.
  58.  
  59. Remove the engine mount to mid-rail nuts.
  60.  
  61. Remove the engine mount from the engine compartment.
  62.  
  63. With an automatic transaxle:
    1. Remove the front transaxle mount thru bolt.
    2.  
    3. Remove the rear transaxle mount thru bolt.
    4.  
    5. Lower the vehicle.
    6.  
    7. Remove the under hood electrical center cover.
    8.  
    9. Disconnect the engine control module harness connector.
    10.  
    11. Disconnect the positive battery cables from the under hood electrical center.
    12.  
    13. Disconnect the surge tank inlet hose from the surge tank.
    14.  
    15. Remove the under hood electrical center tray bracket nuts and bolt.
    16.  
    17. Disconnect the wiring harness retainer from the tray bracket.
    18.  
    19. Lift the electrical center up and swing it back and out of the way.
    20.  
    21. Support the transaxle with a hydraulic floor jack. Use a block of wood between the jack and the transaxle.
    22.  
    23. Remove the transaxle mount to transaxle bolts.
    24.  
    25. Remove the transaxle mount to mid-rail bolts.
    26.  
    27. Using the floor jack, slowly lower the transaxle just enough to remove the transaxle mount from the vehicle.
    28.  

  64.  
  65. With an MU3 manual transaxle:
    1. Remove the cover from the underhood electrical center.
    2.  
    3. Remove the underhood positive battery terminal lug.
      WARNING
      Take note of the positioning of the positive battery cables before disconnecting the cables.

    4.  
    5. Disconnect the positive battery cables from the underhood electrical center.
      WARNING
      The underhood electrical center bolts are retained in the electrical center.

    6.  
    7. Loosen all of the underhood electrical bolts.
    8.  
    9. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center.
    10.  
    11. Support the transaxle with a floor jack. Use a piece of wood between the jack and the transaxle.
    12.  
    13. Remove the transaxle mount-to-transaxle bracket bolts.
    14.  
    15. Remove the transaxle mount to mid-rail bolts.
    16.  
    17. Using a floor jack, slowly lower the transaxle enough to remove the transaxle mount from the vehicle.
    18.  

  66.  
  67. With a Getrag 5-speed manual transaxle:
    1. Remove the underhood electrical center cover.
    2.  
    3. Disconnect the Engine Control Module (ECM) harness connector.
    4.  
    5. Disconnect the positive battery cables from the underhood electrical center.
    6.  
    7. Disconnect the surge tank inlet hose from the surge tank.
    8.  
    9. Remove the underhood electrical center tray bracket nuts and bolt.
    10.  
    11. Disconnect the wiring harness retainer from the tray bracket.
    12.  
    13. Lift the electrical center up and swing it back and out of the way.
    14.  
    15. Support the transaxle with a floor jack. Use a piece of wood between the jack and the transaxle.
    16.  
    17. Remove the transaxle mount to transaxle bolts.
    18.  
    19. Remove the transaxle mount to mid-rail bolts.
    20.  
    21. Using a floor jack, slowly lower the transaxle enough to remove the transaxle mount from the vehicle.
    22.  
    23. Disconnect the control links from the stabilizer bar.
    24.  
    25. Disconnect the outer tie rod ends from the steering knuckles.
      WARNING
      In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

    26.  
    27. Disconnect the intermediate shaft from the steering gear.
    28.  
    29. Disconnect the lower control arms from the steering knuckles.
    30.  
    31. Disconnect the drive axles from the steering knuckle.
    32.  
    33. Use a paint pen or magic marker in order to mark the frame to body position.
    34.  
    35. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
    36.  
    37. Use wood blocks as necessary between the lift table and the frame to support the assembly.
    38.  

  68.  
  69. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2.  
    3. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
    4.  

  70.  
  71. Slowly lower the table to the floor with the cradle and powertrain assembly.
  72.  
  73. Attach the engine lift hoist to the engine lift hooks.
  74.  
  75. Remove the starter.
  76.  
  77. If applicable, remove the torque converter to flywheel bolts.
  78.  
  79. Remove the transaxle to engine bolts.
  80.  
  81. Separate the engine from the transaxle.
  82.  
  83. If applicable, remove the clutch pressure plate and disk.
  84.  
  85. Remove the following components:
  86.  
  87. Remove the exhaust manifold
  88.  
  89. Remove the exhaust manifold studs
  90.  
  91. Remove the engine mount bracket
  92.  
  93. Remove the engine block heater
  94.  
  95. Remove the thermostat housing and feed pipe
  96.  
  97. Remove the generator
  98.  
  99. Remove the engine from the engine lift.
  100.  

To install:

  1. Attach the engine lift hoist to the engine lift hooks.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the intermediate bracket to the engine.
  6.  
  7. Hand tighten the engine mount intermediate bracket bolts in the following locations:

    The long bolts in the forward and front lower holes
     
    The short bolt in the rear upper hole
     

  8.  
  9. Tighten the intermediate bracket bolts to 74 ft. lbs. (100 Nm).
  10.  
  11. Install the fuel rail.
  12.  
  13. Install the engine block heater, if equipped.
  14.  
  15. Install the drive belt tensioner.
  16.  
  17. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    WARNING
    Lubricate the O-ring with soapy water or coolant before installing the O-ring in the water pump.

  18.  
  19. Install the feed pipe that connects the thermostat housing to the water pump.
  20.  
  21. Install the bolt that secures the water pump feed pipe. Tighten the bolt to 88 inch lbs. (10 Nm).
  22.  
  23. Install the generator.
  24.  
  25. Install the flywheel. Tighten the flywheel bolts to 39 ft. lbs. (53 Nm) plus 25°
  26.  
  27. If applicable, install the clutch pressure plate and disk.
  28.  
  29. Align the engine to the transaxle.
    WARNING
    The number 3 bolt location is not used.

  30.  
  31. Secure the engine to the transaxle. Tighten the transaxle to engine bolts to 55 ft. lbs. (75 Nm).
  32.  
  33. If applicable, install the torque converter bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
  34.  
  35. Install the starter.
  36.  
  37. Remove the engine lift from the engine.
  38.  
  39. Raise and position the frame and powertrain assembly to the vehicle.
  40.  
  41. Hand start all the frame bolts while aligning the frame to the paint marks.
  42.  
  43. Tighten the frame bolts. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180°.
  44.  
  45. Remove the lift table.
  46.  
  47. Connect the drive axles to the steering knuckles.
  48.  
  49. Connect the lower control arm to the steering knuckle.
  50.  
  51. Connect the intermediate steering shaft to the steering gear.
  52.  
  53. Connect the outer tie rod ends to the steering knuckles.
  54.  
  55. Connect the control links to the stabilizer bar.
  56.  
  57. With an automatic transaxle:
    1. Install the transaxle mount to the mid-rail.
    2.  
    3. Hand start the transaxle mount to mid-rail bolts. Tighten the bolts to 25 ft. lbs. (34 Nm).
    4.  
    5. Using a hydraulic jack, raise the transaxle until it contacts the transaxle mount.
      WARNING
      The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.

    6.  
    7. Hand start the transaxle mount to transaxle bolts using the following sequence:

      Rear Bolt
       
      Middle Bolt
       
      Front Bolt
       

    8.  
    9. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
    10.  
    11. Reposition the under hood electrical center.
    12.  
    13. Connect the wiring harness retainer to the tray bracket.
    14.  
    15. Install the electrical center nuts  and bolts. Tighten the nut to 89 inch lbs. (10 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
    16.  
    17. Connect the surge tank inlet hose to the surge tank.
    18.  
    19. Install the positive battery cables to the under hood electrical center. Tighten the positive cable nut to 11 ft. lbs. (15 Nm).
    20.  
    21. Connect the engine control module harness connectors.
    22.  
    23. Install the under hood electrical center cover.
    24.  
    25. Raise the vehicle.
    26.  
    27. Hand tighten the front transaxle mount thru bolt
    28.  
    29. Hand tighten the rear transaxle mount thru bolt.
    30.  
    31. Tighten the front transaxle mount thru bolt. Tighten the bolt to 74 ft. lbs. (100 Nm).
    32.  
    33. Tighten the rear transaxle mount thru bolt. Tighten the bolt to 74 ft. lbs. (100 Nm).
    34.  

  58.  
  59. With an MU3 manual transaxle:
    1. Install the transaxle mount to the mid-rail.
    2.  
    3. Install the transaxle mount to mid-rail bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
    4.  
    5. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
      WARNING
      The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.

    6.  
    7. Hand start the transaxle mount to bracket bolts using the following sequence:

      Rear bolt
       
      Middle bolt
       
      Front bolt
       

    8.  
    9. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
    10.  
    11. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket.
    12.  

  60.  
  61. With a Getrag 5-speed:
    1. Install the transaxle mount to the mid-rail.
    2.  
    3. Hand start the transaxle mount to mid-rail bolts. Tighten the bolts to.
    4.  
    5. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
      WARNING
      The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.

    6.  
    7. Hand start the transaxle mount to transaxle bolts using the following sequence:

      Rear bolt
       
      Middle bolt
       
      Front bolt
       

    8.  
    9. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 33 ft. lbs. (45 Nm).
    10.  

  62.  
  63. Reposition the underhood electrical center.
  64.  
  65. Connect the wiring harness to the tray bracket.
  66.  
  67. Install the electrical center nuts and bolt. Tighten the nuts to 89 inch lbs. (10 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
  68.  
  69. Connect the surge tank inlet hose to the surge tank.
  70.  
  71. Install the positive battery cables to the underhood electrical center. Tighten the positive cable nut to 11 ft. lbs. (15 Nm).
  72.  
  73. Connect the engine control module harness connectors.
  74.  
  75. Install the underhood electrical center cover.
  76.  
  77. Place the engine mount onto the mid rail and hand start the nuts.
  78.  
  79. Tighten the engine mount to mid-rail nuts. Tighten the nuts to 74 ft. lbs. (100 Nm).
    WARNING
    The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes.

  80.  
  81. Hand start the engine mount to intermediate bracket bolts.
  82.  
  83. Tighten the engine mount to intermediate bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  84.  
  85. Remove the hydraulic floor jack.
  86.  
  87. Install the air cleaner assembly.
  88.  
  89. Remove the wood blocks between the powertrain and frame.
  90.  
  91. Connect the transaxle shift cable to the transaxle.
  92.  
  93. Connect the transaxle harness connector.
  94.  
  95. Connect the exhaust takedown pipe to the exhaust manifold. Tighten the nuts to 22 ft. lbs. (30 Nm).
  96.  
  97. Connect the generator harness connectors. Tighten the generator terminal nut to 15 ft. lbs. (20 Nm).
  98.  
  99. Connect the starter harness connectors. Tighten the battery terminal nut to 13 ft. lbs. (17 Nm). Tighten the S-terminal nut to 27 inch lbs. (3 Nm).
  100.  
  101. Install the A/C compressor to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm).
  102.  
  103. Install the engine drive belt.
  104.  
  105. Connect the following harness connectors:

    IAC motor
     
    TPS
     
    MAP sensor
     
    Crankshaft sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coil and module assembly
     
    O 2 sensor
     
    Vehicle speed sensor
     
    Engine temperature sensor
     

  106.  
  107. Install the inlet heater hose and outlet heater hose.
  108.  
  109. Install the radiator outlet hose.
  110.  
  111. Connect the fuel line to the fuel rail.
  112.  
  113. Connect the brake booster hose at the brake booster.
  114.  
  115. Release the cooling module from the upper body structure.
  116.  
  117. Install the air inlet duct and resonator.
  118.  
  119. Connect the negative battery cable.
  120.  
  121. Fill the engine with engine oil to the proper level.
  122.  
  123. Fill the cooling system.
  124.  
  125. Road test the vehicle.
  126.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the tires in the straight forward position, remove the key from the ignition.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Relieve fuel system pressure.
  8.  
  9. Disconnect the fuel feed line quick connect fitting from the fuel rail.
  10.  
  11. Disconnect the Evaporative Emission (EVAP) line quick connect fitting from the EVAP purge solenoid.
  12.  
  13. Remove the fuel line clips from the engine brackets.
  14.  
  15. Drain the cooling system.
  16.  
  17. Secure the cooling module to the upper body structure.
  18.  
  19. Remove the accessory drive belt. Refer to Accessory Drive Belts removal and installation.
  20.  
  21. Disconnect the cooling fan electrical connector.
  22.  
  23. Reposition the radiator inlet hose clamp at the engine.
  24.  
  25. Remove the radiator inlet hose from the engine.
  26.  
  27. If the vehicle is equipped with an engine oil cooler, perform the following steps, otherwise proceed to step 19.
  28.  
  29. Reposition the radiator outlet hose clamp at the water outlet.
  30.  
  31. Reposition the radiator outlet hose clamp at the oil cooler.
  32.  
  33. Remove the radiator outlet hose from the water outlet.
  34.  
  35. Remove the radiator outlet hose from the oil cooler. Proceed to step 23.
  36.  
  37. If the vehicle is not equipped with an engine oil cooler, reposition the surge tank outlet hose clamp at the surge tank.
  38.  
  39. Remove the surge tank outlet hose from the surge tank.
  40.  
  41. Reposition the radiator outlet hose clamp at the thermostat cover.
  42.  
  43. Remove the radiator outlet hose from the thermostat cover.
  44.  
  45. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  46.  
  47. Remove the heater inlet and outlet hoses from the thermostat housing.
  48.  
  49. Reposition the brake booster vacuum hose clamp at the intake manifold.
  50.  
  51. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.
  52.  
  53. Disconnect the following electrical connectors:

    Throttle Actuator Control (TAC)
     
    Manifold Absolute Pressure (MAP) sensor
     
    Fuel injector harness
     
    Alternator
     

  54.  
  55. Remove or disconnect the following:

    The engine harness clip from the oil level indicator tube
     
    The engine harness clips from the intake manifold
     
    The ignition coils electrical connectors
     
    The intake and exhaust camshaft position actuator electrical connectors
     
    The engine harness clips from the camshaft cover
     
    The negative battery cable ground nut
     
    The engine harness ground terminal from the stud
     
    The negative battery cable ground terminal from the stud
     

  56.  
  57. Disconnect the following engine harness electrical connectors:

    Oil pressure sensor
     
    Crankshaft Position (CKP) sensor
     
    Knock sensor
     
    The EVAP purge solenoid electrical connector
     

  58.  
  59. Remove the engine harness clip from the purge solenoid bracket.
  60.  
  61. Remove the engine harness ground bolt.
  62.  
  63. Reposition the engine harness ground terminal.
  64.  
  65. Disconnect the engine harness electrical connector from the Air Conditioning (A/C) pressure switch.
  66.  
  67. Disconnect the engine harness electrical connector from A/C compressor.
  68.  
  69. Unbolt and reposition the A/C compressor to one side.
  70.  
  71. Raise and suitably support the vehicle.
  72.  
  73. Drain the engine oil.
  74.  
  75. Remove the transaxle fluid cooler bracket nut.
  76.  
  77. Remove the transaxle fluid cooler lines from the transaxle.
  78.  
  79. Remove the engine harness clip nut from the engine stud.
  80.  
  81. Remove the engine harness clip from the stud.
  82.  
  83. If equipped with an automatic transaxle, disconnect the engine harness electrical connector from the Vehicle Speed Sensor (VSS).
  84.  
  85. Remove the engine harness clip from the speed sensor.
  86.  
  87. Remove the positive battery cable lead nut from the starter solenoid.
  88.  
  89. Remove the positive battery cable terminal from the starter.
  90.  
  91. Remove the engine harness terminal from the starter.
  92.  
  93. Remove the engine harness to starter solenoid "S" terminal nut.
  94.  
  95. Remove the engine harness lead terminals from the starter solenoid.
  96.  
  97. Lower the vehicle.
  98.  
  99. If equipped with an automatic transaxle, disconnect the engine harness from the transaxle.
  100.  
  101. If equipped with an automatic transaxle, perform the following steps:
    1. Disconnect the engine harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
    2.  
    3. Remove the Heated Oxygen Sensor (HO2S) Connector Position Assurance (CPA) retainers.
    4.  
    5. Disconnect the engine harness electrical connectors from the HO2S.
    6.  
    7. Remove the HO2S connector clips from the thermostat housing and engine bracket.
    8.  
    9. Disconnect the engine harness electrical connector from the park neutral position switch.
    10.  

  102.  
  103. If equipped with a manual transaxle:
    1. Disconnect the engine harness electrical connector from the VSS.
    2.  
    3. Disconnect the engine harness electrical connector from the back up lamp switch.
    4.  
    5. Remove the HO2S CPA retainers.
    6.  
    7. Disconnect the engine harness electrical connectors from the HO2S.
    8.  
    9. Remove the HO2S clips from the engine brackets.
    10.  
    11. Gather all engine harness branches and reposition the harness off to the side, out of the way.
    12.  

  104.  
  105. If equipped with an automatic transaxle:
    1. Disconnect the range selector lever cable from the transaxle lever.
    2.  
    3. Remove the range selector lever cable from the transaxle bracket.
    4.  

  106.  
  107. If equipped with a manual transaxle:
    1. Disconnect the range selector and shift lever cables from the transaxle levers.
    2.  
    3. Remove the range selector and shift lever cables from the transaxle bracket.
    4.  

  108.  
  109. Remove the catalytic converter.
  110.  
  111. Lower the vehicle.
  112.  
  113. Insert blocks of wood between the powertrain and the frame, in order to support the powertrain.
  114.  
  115. Remove the engine mount.
  116.  
  117. Remove the transaxle mount to transaxle bolts.
  118.  
  119. Raise the vehicle.
  120.  
  121. Disconnect the control links from the stabilizer bar.
  122.  
  123. Disconnect the outer tie rod ends from the steering knuckles.
  124.  
  125. Disconnect the intermediate shaft from the steering gear.
  126.  
  127. Disconnect the lower control arms from the steering knuckles.
  128.  
  129. Using a paint pen or magic marker, mark the frame to body position.
  130.  
  131. Lower the vehicle to about 3 feet off the ground.
  132.  
  133. Position a engine lift table under the frame.
  134.  
  135. Place wood blocks on top of the lift table between the table and the frame.
  136.  
  137. Lower the vehicle until the frame is resting on the blocks of wood.
  138.  
  139. Slowly loosen/remove the frame bolts using the following sequence:
    1. Loosen/remove the front frame bolts.
    2.  
    3. Loosen/remove the rear frame bolts.
    4.  

  140.  
  141. Slowly raise the vehicle away from the powertrain assembly.
  142.  
  143. Slide the lift table out from under the vehicle.
  144.  
  145. Attach the engine lift hoist to the engine lift hooks.
  146.  
  147. Remove the starter bolts and starter.
  148.  
  149. If equipped with an automatic transaxle:
    1. Remove the torque converter housing access plug.
    2.  
    3. Remove the torque converter bolts.
    4.  

  150.  
  151. Remove the transaxle brace bolts and brace.
  152.  
  153. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.
  154.  
  155. If equipped with an automatic transaxle, remove the transaxle to engine bolts/stud.
  156.  
  157. Separate the engine from the transaxle.
  158.  
  159. If equipped with a manual transaxle, remove the clutch pressure plate and disc.
  160.  
  161. Remove the following components:

    The engine mount bracket
     
    The engine block heater
     
    The alternator
     

  162.  
  163. Using an engine hoist, install the engine onto an engine stand.
  164.  

To install:

  1. Using an engine hoist, remove the engine from the engine stand.
  2.  
  3. Install the following components:

    The engine mount bracket
     
    The engine block heater
     
    The alternator
     

  4.  
  5. If equipped with a manual transaxle, install the clutch pressure plate and disc.
  6.  
  7. Install the engine to the transaxle.
  8.  
  9. If equipped with an automatic transaxle, install the transaxle to engine bolts/stud. Tighten the bolts/stud to 55 ft. lbs. (75 Nm).
  10.  
  11. If equipped with a manual transaxle, install the transaxle to engine bolts/stud. Tighten the bolts/stud to 55 ft. lbs. (75 Nm).
  12.  
  13. Install the transaxle brace and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  14.  
  15. If equipped with an automatic transaxle:
    1. Install the torque converter bolts. Tighten the bolts to 46 ft. lbs. (62 Nm).
    2.  
    3. Install the torque converter housing access plug.
    4.  

  16.  
  17. Install the starter and bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
  18.  
  19. Remove the engine lift hoist from the engine lift hooks.
  20.  
  21. Slide the lift table under the vehicle.
  22.  
  23. Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
  24.  
  25. Tighten/install the frame bolts. Tighten the bolts to 74 ft. lbs. (100 Nm) plus and additional 180°.
  26.  
  27. Raise the vehicle until the lift table can be removed from under the vehicle.
  28.  
  29. Remove the lift table.
  30.  
  31. Install the transaxle fluid cooler lines to the transaxle.
  32.  
  33. Install the transaxle fluid cooler bracket nut. Tighten the nut to 62 inch lbs. (7 Nm).
  34.  
  35. Connect the lower control arms to the steering knuckles.
  36.  
  37. Connect the intermediate shaft to the steering gear.
  38.  
  39. Connect the outer tie rod ends to the steering knuckles.
  40.  
  41. Connect the control links to the stabilizer bar.
  42.  
  43. Lower the vehicle.
  44.  
  45. Install the transaxle mount to transaxle bolts. Tighten the bolts to 33 ft. lbs. (45 Nm).
  46.  
  47. Install the engine mount.
  48.  
  49. Remove the blocks of wood from between the powertrain and the frame.
  50.  
  51. Install the catalytic converter.
  52.  
  53. Lower the vehicle.
    NOTE
    Ensure that the black cable is installed in the top notch of the transaxle bracket and the white cable is installed in the bottom notch of the transaxle bracket.

  54.  
  55. If equipped with a manual transaxle:
    1. Install the range selector and shift lever cables to the transaxle bracket.
    2.  
    3. Connect the range selector and shift lever cables to the transaxle levers.
    4.  

  56.  
  57. If equipped with an automatic transaxle:
    1. Install the range selector lever cable to the transaxle bracket.
    2.  
    3. Connect the range selector lever cable to the transaxle lever.
    4.  

  58.  
  59. Gather all engine harness branches and position the harness over the engine.
  60.  
  61. If equipped with a manual transaxle, perform the following steps:
    1. Install the HO2S clips to the engine brackets.
    2.  
    3. Connect the engine harness electrical connectors to the HO2S.
    4.  
    5. Install the HO2S CPA retainers.
    6.  

  62.  
  63. Connect the engine harness electrical connector to the back up lamp switch.
  64.  
  65. Connect the engine harness electrical connector to the VSS.
  66.  
  67. If equipped with an automatic transaxle, perform the following steps:
    1. Connect the engine harness electrical connector to the park neutral position switch.
    2.  
    3. Install the engine harness clips to the thermostat housing and engine brackets.
    4.  
    5. Connect the engine harness electrical connectors to the HO2S.
    6.  
    7. Install the HO2S CPA retainers.
    8.  

  68.  
  69. Connect the ECT sensor electrical connector.
  70.  
  71. If equipped with an automatic transaxle, connect the engine harness to the transaxle.
  72.  
  73. Raise the vehicle.
  74.  
  75. Install the engine harness lead terminal to the starter solenoid.
  76.  
  77. Install the engine harness to starter solenoid "S" terminal nut. Tighten the nut to 27 inch lbs. (3 Nm).
  78.  
  79. Install the engine harness terminal to the starter.
  80.  
  81. Install the positive battery cable terminal to the starter.
  82.  
  83. Install the positive/negative battery cable lead nut to the starter solenoid. Tighten the nut to 13 ft. lbs. (17 Nm).
  84.  
  85. Install the engine harness clip to the speed sensor.
  86.  
  87. Connect the engine harness electrical connector to the VSS.
  88.  
  89. Install the engine harness clip to the stud.
  90.  
  91. Install the engine harness clip nut to the engine stud. Tighten the nut to 37 ft. lbs. (50 Nm).
  92.  
  93. Lower the vehicle.
  94.  
  95. Reposition and install the A/C compressor. Tighten the bolts to 37 ft. lbs. (50 Nm).
  96.  
  97. Connect the engine harness electrical connector to the A/C compressor.
  98.  
  99. Connect the engine harness electrical connector to the A/C pressure switch.
  100.  
  101. Position the engine harness ground terminal to the engine block.
  102.  
  103. Install the engine harness ground bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  104.  
  105. Connect the EVAP purge solenoid electrical connector.
  106.  
  107. Install the engine harness clip to the EVAP purge solenoid bracket.
  108.  
  109. Connect the following electrical connectors:

    Knock sensor
     
    CKP sensor
     
    Oil pressure sensor
     

  110.  
  111. Install the negative battery cable ground terminal to the stud.
  112.  
  113. Install the engine harness ground terminal to the stud.
  114.  
  115. Install the negative battery cable ground nut. Tighten the nut to 89 inch lbs. (10 Nm).
  116.  
  117. Install the engine harness clips to the camshaft cover.
  118.  
  119. Connect the intake and exhaust camshaft position actuator electrical connectors.
  120.  
  121. Connect the ignition coils electrical connectors.
  122.  
  123. Connect the engine harness clips to the intake manifold.
  124.  
  125. Connect the engine harness clip to the oil level indicator tube.
  126.  
  127. Connect the following electrical connectors:

    TAC
     
    MAP sensor
     
    Fuel injector harness
     
    Alternator
     

  128.  
  129. Install the brake booster vacuum hose to the intake manifold.
  130.  
  131. Position the brake booster vacuum hose clamp at the intake manifold.
  132.  
  133. Install the heater inlet and outlet hoses to the thermostat housing.
  134.  
  135. Position the heater inlet and outlet hose clamps at the thermostat housing.
  136.  
  137. If the vehicle is not equipped with a engine oil cooler, perform the following steps:
    1. Install the surge tank outlet hose to the surge tank.
    2.  
    3. Position the surge tank outlet hose clamp at the surge tank.
    4.  
    5. Install the radiator outlet hose to the thermostat cover.
    6.  
    7. Position the radiator outlet hose clamp at the thermostat cover.
    8.  

  138.  
  139. If the vehicle is equipped with a engine oil cooler, perform the following steps:
    1. Install the radiator outlet hose to the oil cooler.
    2.  
    3. Install the radiator outlet hose to the water outlet.
    4.  
    5. Position the radiator outlet hose clamp at the oil cooler.
    6.  
    7. Position the radiator outlet hose clamp at the water outlet.
    8.  

  140.  
  141. Install the radiator inlet hose to the engine.
  142.  
  143. Position the radiator inlet hose clamp at the engine.
  144.  
  145. Connect the cooling fan electrical connector.
  146.  
  147. Install the accessory drive belt.
  148.  
  149. Remove the cooling module from the upper body structure.
  150.  
  151. Fill the cooling system.
  152.  
  153. Check and fill the transaxle fluid as needed.
  154.  
  155. Connect the EVAP line quick connect fitting to the EVAP purge solenoid.
  156.  
  157. Connect the fuel feed line quick connect fitting to the fuel rail.
  158.  
  159. Install the fuel line clips to the engine brackets.
  160.  
  161. Fill the engine with oil.
  162.  
  163. Connect the negative battery cable.
  164.  
  165. Road test the vehicle.
  166.  

 
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