GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Engine 🢒 Engine Mechanical - 1.6L (L91) 🢒 Engine Replacement

Removal Procedure

    Object Number: 1291944 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine. Crank the engine for 10 seconds after stalling to rid the fuel system of fuel pressure.
  3. Drain the engine oil.
  4. Remove the battery and the battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical.

    5. Object Number: 1371870 Size: SH
  5. Discharge the air conditioning (A/C) system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  6. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  7. Remove the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement in Engine Cooling.
  8. Disconnect the upper radiator hose from the thermostat housing.
  9. If the vehicle is equipped with a power steering pump, perform the following procedures:
    10. 9.1. Disconnect the power steering return hose from the power steering pump.
    9.2. Remove the union nut from the power steering pressure hose.
    9.3. Disconnect the power steering pressure hose from the power steering pump.

    Object Number: 1272762 Size: SH
  10. Disconnect the intake air temperature (IAT) sensor connector.
  11. Disconnect the breather tube from the valve cover.
  12. Disconnect the air intake tube from the throttle body.
  13. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 1.6L (L91).

    14. Object Number: 1371851 Size: SH
  14. Remove the bolts from the spark plug cover.
  15. Remove the spark plug cover.

    16. Object Number: 1371861 Size: SH
  16. Disconnect the connector from the idle air control (IAC) valve.
  17. Disconnect the connector from the throttle position sensor (TPS).
  18. Disconnect the connector from the A/C pressure (ACP) transducer, if equipped.
  19. Disconnect the camshaft position (CMP) sensor.
  20. Disconnect the throttle cable from the throttle body and from the intake manifold bracket.

    21. Object Number: 1371862 Size: SH
  21. Disconnect the connector from the manifold absolute pressure (MAP) sensor.

    22. Object Number: 1371923 Size: SH
  22. Disconnect the ignition wires from the spark plugs.

    23. Object Number: 1371863 Size: SH
  23. Disconnect the surge tank coolant hose at the throttle body.
  24. Disconnect the fuel injector connectors.

    25. Object Number: 1371866 Size: SH
  25. Disconnect the connector from the exhaust gas recirculation (EGR) valve.
  26. Disconnect the electrical connector at the electronic ignition (EI) system ignition coil
  27. Disconnect the oxygen sensor connector.
  28. Disconnect the connector from the crankshaft position sensor (CPS).

    29. Object Number: 1371864 Size: SH
  29. Disconnect all of the necessary vacuum lines. Disconnect the brake booster vacuum hose at the intake manifold.
  30. Disconnect the fuel feed line at the fuel rail.

    31. Object Number: 1241697 Size: SH
  31. Remove the bolts from the battery tray support.
  32. Remove the battery tray support.

    33. Object Number: 1241850 Size: SH
  33. Disconnect the lower radiator hose from the coolant pipe.

    34. Object Number: 1371928 Size: SH
  34. Remove the bolt from the A/C compressor pipe and hose assembly, if equipped.
  35. Remove the A/C compressor pipe and hose assembly from the compressor.
  36. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  37. Remove the front splash shield and the engine undercover.
  38. Disconnect the A/T oil cooler inlet/outlet pipe, if equipped. Refer to Transmission Cooler Pipes and Hoses Replacement in Automatic Transmission - Aisin (81-40LE).
  39. Disconnect the A/T shift control cable, if equipped. Refer to Floor Shift Control Cable Replacement in Automatic Transmission - Aisin (81-40LE).
  40. Disconnect all of the A/T electrical connectors, if equipped.
  41. Disconnect the electrical connector at the A/C compressor coil, if equipped.
  42. Disconnect the connector from the rear heat oxygen sensor (HO2S).

    43. Object Number: 1371910 Size: SH
  43. Remove the lower flange nuts from the exhaust manifold studs. Retain the gasket.
  44. Remove the bolts at the bracket.

    45. Object Number: 1371911 Size: SH
  45. Remove the nuts that secure the front muffler pipe. Retain the gasket.
  46. Remove the front exhaust pipe as a unit.

    47. Object Number: 1242020 Size: SH
  47. Remove the nut and bolt from the damping block connection.
  48. Remove bolts from the rear mounting bracket. Remove the bracket.
  49. Remove the A/T drive axle, if equipped. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement in Front Drive Axle.

    50. Object Number: 1371908 Size: SH
  50. Disconnect the electrical connector at the oil pressure switch.

    51. Object Number: 1241861 Size: SH
  51. Remove the battery harness connector nut from the generator.
  52. Disconnect the connector from the generator voltage regulator.

    53. Object Number: 1371867 Size: SH
  53. Disconnect the electrical connector from the evaporative (EVAP) emission canister purge solenoid.

    54. Object Number: 1371868 Size: SH
  54. Remove the bolts from the intake manifold support bracket.
  55. Remove the intake manifold support bracket.
  56. Disconnect the connector from the engine coolant temperature (ECT) sensor.
  57. Remove the lower starter mounting bolt.
  58. Remove the starter solenoid nuts in order to disconnect the electrical cable.
  59. Remove the lower engine wire harness.

    60. Object Number: 1245846 Size: SH
  60. Remove the rubber from the oil pan.
  61. Remove the torque converter service cover and the bolts.

    62. Object Number: 1371846 Size: SH
  62. Install the engine lifting device.

    63. Object Number: 1371917 Size: SH
  63. Remove the retaining bolts from the engine mount bracket.
  64. Remove the bracket from the engine block.

    65. Object Number: 1245844 Size: SH
  65. Remove the 3 bolts from the upper transaxle mounting bracket.

    66. Important: Verify that the engine and transaxle assembly is not attached to the vehicle.

  66. Lift up the vehicle slowly to separate the engine and transaxle assembly from the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  67. Separate the engine block from the transaxle.
  68. Remove the engine.

Installation Procedure

    Object Number: 1371917 Size: SH
  1. Install the engine and transaxle assembly into the engine compartment.
  2. Install the right engine mount bracket to the engine block.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the mounting bolts to the bracket.

    4. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).

  4. Install the bracket to the engine mount with 2 retaining bolts.

    5. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).


    Object Number: 1245844 Size: SH
  5. Install the upper transaxle mounting bracket with 3 bolts.

    6. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).


    Object Number: 1245846 Size: SH
  6. Install the service cover to the transaxle torque converter with bolts.

    7. Tighten
    Tighten the bolts to 65 N·m (48 lb ft).

  7. Install the rubber to the oil pan.
  8. Position the starter electrical wire on the solenoid terminal.
  9. Install the starter solenoid nuts.

    10. Tighten
    Tighten the nuts to 15 N·m (11 lb ft).

  10. Install the lower mounting bolts to the starter.

    11. Tighten
    Tighten the bolt to 43 N·m (32 lb ft).

  11. Connect the ECT sensor connector.

    12. Object Number: 1371868 Size: SH
  12. Install the intake manifold support bracket.
    13. 12.1. Install the upper bracket bolts to the intake manifold.

    Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

    12.2. Install the lower bracket bolts to the engine block.

    Tighten
    Tighten the bolts to 40 N·m (30 lb ft).


    Object Number: 1371867 Size: SH
  13. Connect the electrical connector to the EVAP canister purge solenoid.

    14. Object Number: 1241861 Size: SH
  14. Connect the voltage regulator connector to the generator.
  15. Install the battery harness connector to the generator using a nut.

    16. Tighten
    Tighten the nut to 15 N·m (11 lb ft).


    Object Number: 1371908 Size: SH
  16. Connect the electrical connector to the oil pressure switch.

    17. Object Number: 1242023 Size: SH
  17. Install the A/T drive axle. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement in Front Drive Axle.
  18. Install the rear mounting bracket and the bracket bolts.

    19. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).

  19. Install the damping block connection bolt and nut.

    20. Tighten
    Tighten the bolt and the nut to 80 N·m (59 lb ft).


    Object Number: 1371911 Size: SH
  20. Install the front exhaust pipe and the gasket.
  21. Install the nuts to the front exhaust pipe.

    22. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).


    Object Number: 1371910 Size: SH
  22. Install the exhaust front pipe and gasket to the catalytic converter. Secure with the retaining nuts.

    23. Tighten
    Tighten the nuts to 40 N·m (30 lb ft).

  23. Secure the exhaust front pipe to the bracket with a bolt.

    24. Tighten
    Tighten the bolt to 40 N·m (30 lb ft).

  24. Connect the rear HO2S connector.
  25. Connect the A/C compressor coil connector, if equipped.
  26. If the vehicle is equipped with automatic transmission, perform the following procedures:
    27. 26.1. Connect all of the A/T electrical connectors.
    26.2. Connect the A/T shift control cable. Refer to Floor Shift Control Cable Replacement in Automatic Transmission - Aisin (81-40LE).
    26.3. Connect the A/T oil cooler inlet/outlet pipe. Refer to Transmission Cooler Pipes and Hoses Replacement in Automatic Transmission - Aisin (81-40LE).

    Object Number: 1371928 Size: SH
  27. Install the front splash shield and the engine undercover.
  28. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  29. Install the pipe and hose assembly to the A/C compressor, if equipped. Secure with a retaining bolt.

    30. Tighten
    Tighten the bolt to 33 N·m (24 lb ft).


    Object Number: 1241850 Size: SH
  30. Connect the lower radiator hose to the coolant pipe.

    31. Object Number: 1241697 Size: SH
  31. Install the battery tray support. Secure the support with a bolt.

    32. Object Number: 1371864 Size: SH
  32. Connect the brake booster vacuum hose at the intake manifold. Connect all of the necessary vacuum lines.
  33. Connect the fuel feed line at the fuel rail.

    34. Object Number: 1371866 Size: SH
  34. Connect the CPS connector.
  35. Connect the oxygen sensor connector.
  36. Connect the electrical connector at the EI system ignition coil
  37. Connect the EGR valve connector.

    38. Object Number: 1371863 Size: SH
  38. Connect the fuel injector connectors.
  39. Connect the surge tank coolant hose at the throttle body.

    40. Object Number: 1371923 Size: SH
  40. Connect the ignition wires to the spark plugs.

    41. Object Number: 1371862 Size: SH
  41. Connect the MAP sensor connector.

    42. Object Number: 1371861 Size: SH
  42. Connect the throttle cable to the throttle body and to the intake manifold bracket.
  43. Connect the CMP sensor.
  44. Connect the ACP transducer connector, if equipped.
  45. Connect the TPS connector.
  46. Connect the IAC valve connector.

    47. Object Number: 1371851 Size: SH
  47. Install the spark plug cover. Install the bolts to the spark plug cover.

    48. Tighten
    Tighten the bolts to 3 N·m (27 lb in).

  48. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 1.6L (L91).

    49. Object Number: 1272762 Size: SH
  49. Connect the air intake tube to the throttle body.
  50. Connect the breather tube to the valve cover.
  51. Connect the IAT sensor connector.

    52. Object Number: 1371870 Size: SH
  52. If the vehicle is equipped with a power steering pump, perform the following procedures:
    53. 52.1. Connect the power steering pressure hose to the power steering pump.
    52.2. Install the union nut to the power steering pump.

    Tighten
    Tighten the nut to 28 N·m (21 lb ft).

    52.3. Connect the power steering return hose to the power steering pump.
  53. Connect the upper radiator hose to the thermostat housing.
  54. Install the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement in Engine Cooling.
  55. Install the battery and the battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical.

    56. Object Number: 1291944 Size: SH
  56. Install the fuel pump fuse.
  57. Fill the engine crankcase with engine oil.
  58. Fill the engine coolant system. Refer to Cooling System Draining and Filling in Engine Cooling.
  59. Bleed the power steering system, if equipped. Refer to Power Steering System Bleeding in Power Steering System.
  60. Fill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.