Solstice 2006-2008, Sky 2007-2008

Engine

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Removal & Installation



2.0L (LNF) Engine
  1. Remove the hood.
  2.  
  3. Recover the Air Conditioning (A/C) system.
  4.  
  5. Remove the drive belt.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the radiator.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the Evaporative Emission (EVAP) canister purge solenoid tube from the valve.
  14.  
  15. Disconnect the fuel feed pipe from the fuel rail.
  16.  
  17. Remove the transmission.
  18.  
  19. For Manual transmission. After the transmission is removed, reinstall the bolt from the differential case bracket assembly to body, in order to remove the support from under the rear drive module.
  20.  
  21. Remove the turbocharger heat shield bolts and shield.
  22.  
  23. Remove the charge air cooler pipe to turbocharger bolts.
  24.  
  25. Remove the charge air cooler pipe and gasket from the turbocharger.
  26.  
  27. Cap or plug the turbocharger opening.
  28.  
  29. Reposition the radiator inlet hose clamp at the engine.
  30.  
  31. Remove the radiator inlet hose from the engine.
  32.  
  33. Reposition the radiator inlet hose out of the way.
  34.  
  35. Reposition the radiator outlet hose clamp at the thermostat housing.
  36.  
  37. Reposition the radiator outlet hose clamp at the oil cooler.
  38.  
  39. Remove the radiator outlet hose from the thermostat housing and oil cooler.
  40.  
  41. Remove the radiator outlet hose clip from the bracket.
  42.  
  43. Reposition the radiator outlet hose out of the way.
  44.  
  45. Reposition the surge tank outlet hose clamp at the thermostat housing.
  46.  
  47. Reposition the surge tank outlet hose clamp at the oil cooler.
  48.  
  49. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
  50.  
  51. Reposition the surge tank outlet hose clamp at the surge tank.
  52.  
  53. Remove the surge tank outlet hose from the surge tank.
  54.  
  55. Remove the surge tank clip from the oil level indicator tube bracket.
  56.  
  57. Remove the surge tank outlet hose from the vehicle.
  58.  
  59. Reposition the surge tank air bleed hose clamp at the engine.
  60.  
  61. Remove the surge tank air bleed hose clip from the surge tank bracket.
  62.  
  63. Remove the surge tank air bleed hose from the engine.
  64.  
  65. Reposition the air bleed hose out of the way.
  66.  
  67. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  68.  
  69. Remove the heater inlet and outlet hoses from the thermostat housing.
  70.  
  71. Raise and suitably support the vehicle.
  72.  
  73. Drain the engine oil.
  74.  
  75. Disconnect the engine wiring harness electrical connector from the Crankshaft Position (CKP) sensor.
  76.  
  77. Disconnect the engine wiring harness electrical connector from the oil pressure sensor.
  78.  
  79. Disconnect the engine wiring harness electrical connector from the brake booster vacuum pump.
  80.  
  81. Remove the positive battery cable lead nut at the starter.
  82.  
  83. Remove the positive battery cable lead from the starter.
  84.  
  85. Remove the engine wiring harness clip from the oil level indicator tube bracket.
  86.  
  87. Remove the engine wiring harness terminal no. from the starter.
  88.  
  89. Remove the engine wiring harness terminal no. nut from the starter.
  90.  
  91. Remove the engine wiring harness terminal no. from the starter.
  92.  
  93. Remove the engine wiring harness clip from the oil level indicator tube.
  94.  
  95. Lower the vehicle.
  96.  
  97. Disconnect the engine wiring harness electrical connector from the Mass Air Flow (MAF) sensor.
  98.  
  99. Cut the engine harness tie straps.
  100.  
  101. Remove the negative battery cable ground bolt from the front engine lift bracket.
  102.  
  103. Remove the negative battery cable ground terminal no. from the engine lift bracket.
  104.  
  105. Reposition the negative/positive battery cable out of the way.
  106.  
  107. Disconnect the engine wiring harness electrical connector from the transmission oil cooler pump.
  108.  
  109. Disconnect the engine wiring harness electrical connector from the knock sensor.
  110.  
  111. Remove the engine wiring harness clip from the oil level indicator tube bracket.
  112.  
  113. Disconnect the engine wiring harness electrical connector from the generator.
  114.  
  115. Reposition the positive battery cable terminal no. boot.
  116.  
  117. Remove the generator terminal no. nut.
  118.  
  119. Remove the positive battery cable terminal no. from the generator.
  120.  
  121. Disconnect the engine wiring harness electrical connector from the A/C compressor.
  122.  
  123. Disconnect the engine wiring harness electrical connector from the fuel injector jumper electrical connector.
  124.  
  125. Disconnect the engine wiring harness electrical connector from the throttle actuator.
  126.  
  127. Disconnect the engine wiring harness electrical connector from the knock sensor.
  128.  
  129. Remove the engine wiring harness clip from the intake manifold brace.
  130.  
  131. Disconnect the engine wiring harness electrical connector from the EVAP canister purge solenoid valve.
  132.  
  133. Disconnect the engine wiring harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  134.  
  135. Disconnect the engine wiring harness electrical connector from the A/C refrigerant pressure sensor.
  136.  
  137. Disconnect the engine wiring harness electrical connector from the brake booster vacuum sensor.
  138.  
  139. Disconnect the engine wiring harness electrical connector from the windshield wiper motor.
  140.  
  141. Remove the engine harness clip from the wiper motor hole.
  142.  
  143. Disconnect the engine wiring harness electrical connector from the intake Camshaft Position (CMP) sensor.
  144.  
  145. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
  146.  
  147. Remove the engine wiring harness clip from the high pressure fuel pump bracket.
  148.  
  149. Disconnect the engine wiring harness electrical connector from the intake CMP actuator.
  150.  
  151. Disconnect the engine wiring harness electrical connector from the exhaust CMP actuator.
  152.  
  153. Remove the engine harness clip from the camshaft cover.
  154.  
  155. Disconnect the engine wiring harness electrical connectors from the ignition coils.
  156.  
  157. Disconnect the engine wiring harness electrical connector from the Heated Oxygen Sensor (HO2S) (3).
  158.  
  159. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
  160.  
  161. Remove the engine harness ground terminal no. bolt and reposition the engine harness ground terminal.
  162.  
  163. Disconnect the engine wiring harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
  164.  
  165. Disconnect the engine harness clips from the camshaft cover.
  166.  
  167. Disconnect the engine harness clip from the camshaft cover.
  168.  
  169. Remove the engine wiring harness clip from the turbocharger coolant feed pipe stud.
  170.  
  171. Remove the engine wiring harness clip from the turbocharger coolant feed pipe tab.
  172.  
  173. Disconnect the engine wiring harness electrical connector from the boost sensor.
  174.  
  175. Remove the engine wiring harness ground bolt from the cylinder head.
  176.  
  177. Remove the engine wiring harness ground terminal no. from the cylinder head.
  178.  
  179. Remove the engine harness clips from the front studs.
  180.  
  181. Gather all branches of the engine harness and lay off to the side.
  182.  
  183. Reposition the vacuum hose clamp at the turbocharger.
  184.  
  185. Remove the vacuum hose from the turbocharger.
  186.  
  187. Remove the vacuum hose from the turbocharger coolant feed pipe clips.
  188.  
  189. Reposition the vacuum hose out of the way.
  190.  
  191. Remove the turbocharger coolant feed pipe bolt at the turbocharger.
  192.  
  193. Remove the turbocharger coolant feed pipe fitting from the cylinder head.
  194.  
  195. Remove the turbocharger coolant feed pipe bracket bolt from the cylinder head.
  196.  
  197. Remove the turbocharger coolant feed pipe bracket from the vehicle.
  198.  
  199. Remove the A/C compressor line bolt and reposition the line off to the side.
  200.  
  201. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
  202.  
  203. Lower the vehicle.
  204.  
  205. Remove the left engine mount upper nut.
  206.  
  207. Remove the right engine mount upper nut.
  208.  
  209. Install engine support adapter to the engine, if necessary
  210.  
  211. Install a suitable engine lifting devise to the engine.
  212.  
  213. Remove the engine from the vehicle.
    WARNING
    It may be necessary to remove the chamfer (bevel) from the edge of an 18 mm socket in order to get full engagement on the thin headed flywheel bolts.

  214.  
  215. For manual transmission remove the clutch pressure plate and disc.
  216.  
  217. Remove the flywheel bolts and flywheel.
  218.  
  219. Install the engine to an engine stand.
  220.  
  221. Remove the A/C compressor bolts and compressor.
  222.  
  223. Remove the catalytic converter to bracket bolts.
  224.  
  225. Remove the catalytic converter nuts.
  226.  
  227. Remove the catalytic converter and gasket from the turbocharger and bracket.
  228.  

To install:

  1. Install the catalytic converter and gasket to the turbocharger and bracket.
  2.  
  3. Install the catalytic converter nuts and tighten to 43 ft. lbs. (59 Nm).
  4.  
  5. Install the catalytic converter to bracket bolts and tighten to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the A/C compressor and bolts and tighten in sequence to 16 ft. lbs. (22 Nm).

    Click image to see an enlarged view

    Fig. A/C bolt tightening sequence

  8.  
  9. Install a suitable engine lifting devise to the engine.
  10.  
  11. Remove the engine from the stand.
  12.  
  13. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
  14.  
  15. Install the flywheel and bolts and tighten to 39 ft. lbs. (53 Nm), plus an additional 25 degrees.
  16.  
  17. For manual transmission, install the clutch pressure plate and disc. Tighten mounting bolts in a star sequence to 22 ft. lbs. (30 Nm).
  18.  
  19. Install the engine to the vehicle.
  20.  
  21. Install the right and left engine mount upper nuts and tighten to 37 ft. lbs. (50 Nm).
  22.  
  23. Remove engine lifting devise from the engine.
  24.  
  25. Raise and support the vehicle.
  26.  
  27. Position the power steering pump and bracket to the engine and install the bracket bolts.
  28.  
  29. Tighten the power steering pump bracket bolts to 43 ft. lbs. (58 Nm).
  30.  
  31. Lower the vehicle.
  32.  
  33. Position the A/C compressor line and install the bolt and tighten to 16 ft. lbs. (22 Nm).
  34.  
  35. Position the turbocharger coolant feed pipe to the vehicle.
  36.  
  37. Install the turbocharger coolant feed pipe bracket bolt to the cylinder head. Tighten the bolt to 89 inch. lbs. (10 Nm).
  38.  
  39. Install the turbocharger coolant feed pipe fitting to the cylinder head. Tighten the fittings to 26 ft. lbs. (35 Nm).
  40.  
  41. Install the turbocharger coolant feed pipe bolt at the turbocharger. Tighten the bolt to 26 ft. lbs. (35 Nm).
  42.  
  43. Position the vacuum hose to the turbocharger.
  44.  
  45. Install the vacuum hose to the turbocharger.
  46.  
  47. Position the vacuum hose clamp at the turbocharger.
  48.  
  49. Install the vacuum hose to the turbocharger coolant feed pipe clips.
  50.  
  51. Position the branches of the engine harness to the engine.
  52.  
  53. Install the engine harness clips to the front studs.
  54.  
  55. Install the engine wiring harness ground terminal no. to the cylinder head.
  56.  
  57. Install the engine wiring harness ground bolt to the cylinder head and tighten to 18 ft. lbs. (25 Nm).
  58.  
  59. Connect the engine wiring harness electrical connector to the boost sensor.
  60.  
  61. Install the engine wiring harness clip to the turbocharger coolant feed pipe tab.
  62.  
  63. Install the engine wiring harness clip to the turbocharger coolant feed pipe stud.
  64.  
  65. Connect the engine harness clips to the camshaft cover.
  66.  
  67. Connect the engine harness clip to the camshaft cover.
  68.  
  69. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
  70.  
  71. Connect the engine wiring harness electrical connector to the ECT sensor.
  72.  
  73. Position the engine harness ground terminal, install the engine harness ground terminal no. bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  74.  
  75. Connect the engine wiring harness electrical connector to the HO2S.
  76.  
  77. Connect the engine wiring harness electrical connectors to the ignition coils.
  78.  
  79. Install the engine harness clip to the camshaft cover.
  80.  
  81. Connect the engine wiring harness electrical connector to the intake CMP actuator.
  82.  
  83. Connect the engine wiring harness electrical connector to the exhaust CMP actuator.
  84.  
  85. Connect the engine wiring harness electrical connector to the intake CMP sensor.
  86.  
  87. Connect the engine wiring harness electrical connector to the high pressure fuel pump.
  88.  
  89. Install the engine wiring harness clip to the high pressure fuel pump bracket.
  90.  
  91. Connect the engine wiring harness electrical connector to the windshield wiper motor.
  92.  
  93. Install the engine harness clip to the wiper motor hole.
  94.  
  95. Connect the engine wiring harness electrical connector to the brake booster vacuum sensor.
  96.  
  97. Connect the engine wiring harness electrical connector to the A/C refrigerant pressure sensor
  98.  
  99. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid valve.
  100.  
  101. Connect the engine wiring harness electrical connector to the MAP sensor.
  102.  
  103. Connect the engine wiring harness electrical connector to the throttle actuator.
  104.  
  105. Connect the engine wiring harness electrical connector to the knock sensor.
  106.  
  107. Install the engine wiring harness clip to the intake manifold brace.
  108.  
  109. Connect the engine wiring harness electrical connector to the fuel injector jumper electrical connector.
  110.  
  111. Install the positive battery cable terminal no. to the generator.
  112.  
  113. Install the generator terminal no. nut and tighten to 15 ft. lbs. ( 20 Nm).
  114.  
  115. Position the positive battery cable terminal no. boot.
  116.  
  117. Connect the engine wiring harness electrical connector (4) to the A/C compressor
  118.  
  119. Connect the engine wiring harness electrical connector to the generator.
  120.  
  121. Connect the engine wiring harness electrical connector to the knock sensor.
  122.  
  123. Install the engine wiring harness clip to the oil level indicator tube bracket.
  124.  
  125. Connect the engine wiring harness electrical connector to the transmission oil cooler pump.
  126.  
  127. Position the negative/positive battery cable to the engine.
  128.  
  129. Install the negative battery cable ground terminal no. to the engine lift bracket.
  130.  
  131. Install the negative battery cable ground bolt to the front engine lift bracket and tighten to 18 ft. lbs. (25 Nm).
  132.  
  133. Install NEW tie straps to the engine wiring harness.
  134.  
  135. Connect the engine wiring harness electrical connector to the MAF sensor.
  136.  
  137. Raise the vehicle.
  138.  
  139. Install the engine wiring harness terminal no. to the starter.
  140.  
  141. Install the engine wiring harness terminal no. to the starter.
  142.  
  143. Install the engine wiring harness terminal no. nut to the starter and tighten to 27 inch. lbs. (3 Nm).
  144.  
  145. Install the engine wiring harness clip to the oil level indicator tube.
  146.  
  147. Install the positive battery cable lead to the starter.
  148.  
  149. Install the positive battery cable lead nut at the starter and tighten to 89 inch. lbs (10 Nm).
  150.  
  151. Install the engine wiring harness clip to the oil level indicator tube bracket.
  152.  
  153. Connect the engine wiring harness electrical connector to the brake booster vacuum pump.
  154.  
  155. Connect the engine wiring harness electrical connector to the CKP sensor.
  156.  
  157. Connect the engine wiring harness electrical connector to the oil pressure sensor.
  158.  
  159. Install the heater inlet and outlet hoses to the thermostat housing.
  160.  
  161. Position the heater inlet and outlet hose clamps at the thermostat housing.
  162.  
  163. Position the air bleed hose to the engine.
  164.  
  165. Install the surge tank air bleed hose to the engine.
  166.  
  167. Install the surge tank air bleed hose clip to the surge tank bracket.
  168.  
  169. Position the surge tank air bleed hose clamp at the engine.
  170.  
  171. Install the surge tank clip to the oil level indicator tube bracket.
  172.  
  173. Position the surge tank outlet hose clamp at the surge tank.
  174.  
  175. Install the surge tank outlet hose to the thermostat housing and oil cooler.
  176.  
  177. Position the surge tank outlet hose clamp at the oil cooler.
  178.  
  179. Position the surge tank outlet hose clamp at the thermostat housing.
  180.  
  181. Position the outlet hose to the engine.
  182.  
  183. Install the radiator outlet hose clip to the bracket.
  184.  
  185. Install the radiator outlet hose to the thermostat housing and oil cooler.
  186.  
  187. Position the radiator outlet hose clamp at the oil cooler.
  188.  
  189. Position the radiator outlet hose clamp at the thermostat housing.
  190.  
  191. Position the inlet hose to the engine.
  192.  
  193. Install the radiator inlet hose to the engine.
  194.  
  195. Position the radiator inlet hose clamp at the engine.
  196.  
  197. Remove the cap or plug from the turbocharger opening.
  198.  
  199. Install the charge air cooler pipe to the turbocharger.
  200.  
  201. Install the charge air cooler pipe to turbocharger bolts and tighten to 16 ft. lbs. (22 Nm).
  202.  
  203. Install the turbocharger heat shield and bolts. Tighten bolts to 89 inch. lbs. (10 Nm).
  204.  
  205. Install the transmission.
  206.  
  207. Install the air inlet grille panel.
  208.  
  209. Install the charge air cooler inlet and outlet pipes.
  210.  
  211. Connect the fuel feed pipe to the fuel line.
  212.  
  213. Connect the EVAP canister purge solenoid tube to the valve .
  214.  
  215. Install the radiator.
  216.  
  217. Install the drive belt.
  218.  
  219. Vacuum and recharge the A/C system.
  220.  
  221. Install the hood.
  222.  
  223. Connect the negative battery cable.
  224.  
  225. Fill the engine with oil.
  226.  
  227. Fill and bleed cooling system.
  228.  

2.4L (LE5) Engine
  1. Remove the hood.
  2.  
  3. Recover the Air Conditioning (A/C) system.
  4.  
  5. Remove the drive belt.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the radiator.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the Evaporative Emission (EVAP) canister purge solenoid tube from the valve.
  14.  
  15. Disconnect the fuel feed pipe from the fuel rail.
  16.  
  17. Remove the transmission.
  18.  
  19. For manual transmission. After the transmission is removed, reinstall the bolt from the differential case bracket assembly to body, in order to remove the support from under the rear drive module.
  20.  
  21. Remove the starter.
  22.  
  23. Reposition the radiator inlet hose clamp at the engine.
  24.  
  25. Remove the radiator inlet hose.
  26.  
  27. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step (23).
  28.  
  29. Reposition the radiator outlet hose clamps at the thermostat housing and oil cooler
  30.  
  31. Remove the radiator outlet hose from the thermostat housing and oil cooler.
  32.  
  33. Reposition the outlet hose out of the way.
  34.  
  35. Reposition the surge tank outlet hose clamps at the thermostat housing and oil cooler.
  36.  
  37. Remove the surge tank outlet hose from the thermostat housing and oil cooler.
  38.  
  39. Reposition the surge tank outlet hose clamp at the surge tank
  40.  
  41. Remove the surge tank clip from the oil level indicator tube bracket.
  42.  
  43. Remove the surge tank outlet hose. Proceed to step (26).
  44.  
  45. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the thermostat housing.
  46.  
  47. Remove the radiator outlet hose from the thermostat housing.
  48.  
  49. Remove the radiator outlet hose clip from the outlet hose bracket.
  50.  
  51. Reposition the surge tank air bleed hose clamp at the engine.
  52.  
  53. Remove the surge tank air bleed hose from the engine.
  54.  
  55. Reposition the air bleed hose out of the way.
  56.  
  57. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  58.  
  59. Remove the heater inlet and outlet hoses from the thermostat housing.
  60.  
  61. Raise and suitably support the vehicle.
  62.  
  63. Drain the engine oil.
  64.  
  65. Disconnect the engine wiring harness electrical connector from the Crankshaft Position (CKP) sensor.
  66.  
  67. Disconnect the engine wiring harness electrical connector  from the oil pressure sensor.
  68.  
  69. Lower the vehicle.
  70.  
  71. Remove the positive battery cable clip from the bracket.
  72.  
  73. Cut the engine harness tie straps.
  74.  
  75. Remove the negative battery cable ground bolt.
  76.  
  77. Remove the negative battery cable ground terminal no. and engine harness ground terminal no. from the cylinder head.
  78.  
  79. Disconnect the engine wiring harness electrical connector  from the generator.
  80.  
  81. Reposition the positive battery cable terminal no. boot.
  82.  
  83. Remove the generator terminal no. nut.
  84.  
  85. Remove the positive battery cable terminal no. from the generator.
  86.  
  87. Disconnect the engine wiring harness electrical connector from the A/C compressor.
  88.  
  89. Reposition the negative/positive battery cable.
  90.  
  91. Disconnect the engine wiring harness electrical connector from the A/C refrigerant pressure sensor.
  92.  
  93. Disconnect the engine wiring harness electrical connector from the windshield wiper motor.
  94.  
  95. Remove the engine harness clip from the wiper motor hole.
  96.  
  97. Remove the engine harness clip from the surge tank air bleed hose.
  98.  
  99. Disconnect the engine wiring harness electrical connector from the intake Camshaft Position (CMP) actuator.
  100.  
  101. Disconnect the engine wiring harness electrical connector from the exhaust CMP actuator.
  102.  
  103. Remove the engine harness clip from the camshaft cover.
  104.  
  105. Disconnect the engine wiring harness electrical connectors from the ignition coils.
  106.  
  107. Remove the Connector Position Assurance (CPA) retainers from the heated oxygen sensor (HO2S) electrical connectors.
  108.  
  109. Disconnect the engine wiring harness electrical connector from the front HO2S.
  110.  
  111. Disconnect the engine wiring harness electrical connector from the rear HO2S.
  112.  
  113. Disconnect the engine harness clips from the junction block bracket.
  114.  
  115. Disconnect the HO2S electrical connector clip from the strut.
  116.  
  117. Disconnect the engine wiring harness electrical connector from the intake CMP sensor.
  118.  
  119. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
  120.  
  121. Remove the engine harness ground terminal no. bolt and reposition the engine harness ground terminal.
  122.  
  123. Disconnect the engine wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
  124.  
  125. Disconnect the engine wiring harness electrical connector from the EVAP canister purge solenoid.
  126.  
  127. Disconnect the engine harness clip from the EVAP canister purge solenoid valve bracket.
  128.  
  129. Disconnect the engine harness clips from the camshaft cover.
  130.  
  131. Remove the EVAP canister purge solenoid valve.
  132.  
  133. Remove the engine harness bracket from the intake manifold cover stud.
  134.  
  135. Disconnect the engine harness clip from the bracket
  136.  
  137. Remove the intake manifold cover bracket bolts and bracket.
  138.  
  139. Gather all branches of the engine harness and lay off to the side.
  140.  
  141. Remove the A/C compressor line bolt and reposition the line off to the side.
  142.  
  143. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
  144.  
  145. Lower the vehicle.
  146.  
  147. Remove the left engine mount upper nut.
  148.  
  149. Remove the right engine mount upper nut.
  150.  
  151. Install a suitable engine lifting devise to the engine.
  152.  
  153. Remove the engine from the vehicle.
    WARNING
    It may be necessary to remove the chamfer (bevel) from the edge of an 18 mm socket in order to get full engagement on the thin headed flywheel bolts.

  154.  
  155. For manual transmission remove the clutch pressure plate and disc.
  156.  
  157. Remove the flywheel bolts and flywheel.
  158.  
  159. Install the engine to an engine stand.
  160.  
  161. Remove the A/C compressor bolt and compressor.
  162.  
  163. Remove the catalytic converter to bracket bolt.
  164.  
  165. Remove the catalytic converter nuts.
  166.  
  167. Remove the catalytic converter gasket and converter from the engine.
  168.  

To install:

  1. Install the catalytic converter gasket and converter to the engine.
  2.  
  3. Install the catalytic converter nuts and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the catalytic converter to bracket bolt and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the A/C compressor and bolts.
  8.  
  9. Tighten the bolts in sequence to 16 ft. lbs. (22 Nm).

    Click image to see an enlarged view

    Fig. A/C bolt tightening sequence

  10.  
  11. Install a suitable engine lifting devise to the engine.
  12.  
  13. Remove the engine from the stand.
  14.  
  15. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
  16.  
  17. Install the flywheel and bolts and tighten to 39 ft. lbs. (53 Nm), plus an additional 25 degrees.
  18.  
  19. For manual transmission, install the clutch pressure plate and disc. Tighten mounting bolts in a star sequence to 22 ft. lbs. (30 Nm).
  20.  
  21. Install the engine to the vehicle.
  22.  
  23. Install the right and left engine mount upper nuts and tighten to 37 ft. lbs. (50 Nm).
  24.  
  25. Remove engine lifting devise from the engine.
  26.  
  27. Raise and support the vehicle.
  28.  
  29. Position the power steering pump and bracket to the engine and install the bracket bolts.
  30.  
  31. Tighten the power steering pump bracket bolts to 43 ft. lbs. (58 Nm).
  32.  
  33. Lower the vehicle.
  34.  
  35. Position the A/C compressor line and install the bolt .
  36.  
  37. Tighten A/C compressor line mounting bolt to 16 ft. lbs. (22 Nm).
  38.  
  39. Install the transmission and tighten mounting bolts to 37 ft. lbs. (50 Nm).
  40.  
  41. Lower the vehicle.
  42.  
  43. Install the intake manifold cover bracket and tighten mounting bolts to 18 ft. lbs. (20 Nm).
  44.  
  45. Position the branches of the engine harness to the engine.
  46.  
  47. Connect the engine harness clip to the bracket.
  48.  
  49. Install the engine harness bracket to the intake manifold cover stud.
  50.  
  51. Install the EVAP canister purge solenoid valve.
  52.  
  53. Connect the engine harness clips to the camshaft cover.
  54.  
  55. Connect the engine harness clip to the EVAP canister purge solenoid valve bracket.
  56.  
  57. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid.
  58.  
  59. Connect the engine wiring harness electrical connector to the ECT sensor.
  60.  
  61. Position the engine wiring harness ground terminal no. and install the bolt. Tighten to 89 inch. lbs. (10 Nm).
  62.  
  63. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
  64.  
  65. Connect the engine wiring harness electrical connector to the intake CMP sensor.
  66.  
  67. Connect the HO2S electrical connector clip to the strut.
  68.  
  69. Connect the engine harness clips to the junction block bracket.
  70.  
  71. Connect the engine wiring harness electrical connector to the rear HO2S.
  72.  
  73. Connect the engine wiring harness electrical connector to the front HO2S.
  74.  
  75. Install the CPA retainers to the HO2S electrical connectors
  76.  
  77. Connect the engine wiring harness electrical connectors to the ignition coils.
  78.  
  79. Install the engine harness clip to the camshaft cover.
  80.  
  81. Connect the engine wiring harness electrical connector to the exhaust CMP actuator.
  82.  
  83. Connect the engine wiring harness electrical connector to the intake CMP actuator
  84.  
  85. Install the engine harness clip to the surge tank air bleed hose.
  86.  
  87. Connect the engine wiring harness electrical connector to the windshield wiper motor.
  88.  
  89. Install the engine harness clip to the wiper motor hole.
  90.  
  91. Connect the engine wiring harness electrical connector to the A/C refrigerant pressure sensor.
  92.  
  93. Position the negative/positive battery cable.
  94.  
  95. Connect the engine wiring harness electrical connector to the A/C compressor.
  96.  
  97. Install the positive battery cable terminal no. to the generator.
  98.  
  99. Install the generator terminal no. nut and tighten to 15 ft. lbs. (20 Nm).
  100.  
  101. Position the positive battery cable terminal no. boot (4).
  102.  
  103. Connect the engine wiring harness electrical connector (1) to the generator.
  104.  
  105. Position the engine harness ground terminal no. behind the negative battery cable terminal no. and position against the cylinder head.
  106.  
  107. Install the negative battery cable ground terminal no. bolt and tighten to 89 inch. lbs. (10 Nm).
  108.  
  109. Install new tie straps to the engine harness.
  110.  
  111. Install the positive battery cable clip to the bracket.
  112.  
  113. Raise and support the vehicle.
  114.  
  115. Connect the engine wiring harness electrical connector to the oil pressure sensor.
  116.  
  117. Connect the engine wiring harness electrical connector to the CKP sensor.
  118.  
  119. Install the heater inlet and outlet hoses to the thermostat housing.
  120.  
  121. Position the heater inlet and outlet hose clamps at the thermostat housing.
  122.  
  123. Position the air bleed hose.
  124.  
  125. Install the surge tank air bleed hose to the engine.
  126.  
  127. Position the surge tank air bleed hose clamp at the engine.
  128.  
  129. If the vehicle is not equipped with a engine oil cooler perform the following steps, otherwise proceed to step 66.
  130.  
  131. Install the radiator outlet hose to the thermostat housing.
  132.  
  133. Reposition the radiator outlet hose clamp at the thermostat housing.
  134.  
  135. Install the radiator outlet hose clip to the outlet hose bracket. Proceed to step 71.
  136.  
  137. If the vehicle is equipped with a engine oil cooler, install the surge tank outlet hose.
  138.  
  139. Install the surge tank clip to the oil level indicator tube bracket.
  140.  
  141. Position the surge tank outlet hose clamp at the surge tank.
  142.  
  143. Install the surge tank outlet hose to the thermostat housing and oil cooler.
  144.  
  145. Position the surge tank outlet hose clamps at the thermostat housing and oil cooler.
  146.  
  147. Position the outlet hose.
  148.  
  149. Install the radiator outlet hose to the thermostat housing and oil cooler.
  150.  
  151. Position the radiator outlet hose clamps at the thermostat housing and oil cooler.
  152.  
  153. Install the radiator inlet hose.
  154.  
  155. Position the radiator inlet hose clamp at the engine.
  156.  
  157. Install the starter.
  158.  
  159. Install the air inlet grille panel.
  160.  
  161. Connect the fuel feed pipe to the fuel rail.
  162.  
  163. Connect the EVAP canister purge solenoid tube to the valve.
  164.  
  165. Install the radiator.
  166.  
  167. Install the drive belt.
  168.  
  169. Vacuum and recharge the A/C system.
  170.  
  171. Install the hood.
  172.  
  173. Fill the engine oil.
  174.  
  175. Fill and bleed cooling system.
  176.  

 
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