GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Engine 🢒 Engine Mechanical - 2.0L (L34 GMDAT) 🢒 Engine Replacement

Removal Procedure

    Object Number: 1252114 Size: SH

    Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

  1. Remove the fuel pump fuse.
  2. Start the engine and wait until it stalls.
  3. Crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  4. Remove the hood. Refer to Hood Replacement in Body Front End.
  5. Drain the engine oil.

    6. Caution: Refer to Battery Disconnect Caution in the Preface section.

  6. Disconnect the negative battery cable.

    7. Object Number: 1252116 Size: SH
  7. Discharge the air conditioning (A/C) system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  8. Disconnect the manifold air temperature sensor connector.
  9. Remove the air intake tube.
  10. Disconnect the breather tubes from the valve cover.
  11. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  12. Remove the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
  13. Remove the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement in Power Steering System.

    14. Object Number: 1252172 Size: SH
  14. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  15. Remove the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement in Engine Cooling.
  16. Disconnect the upper radiator hose from the thermostat housing.
  17. Disconnect the power steering return hose from the power steering pump. Collect the oil in a suitable container.
  18. Disconnect the power steering pressure hose from the power steering pump. Collect the oil in a suitable container.
  19. Disconnect the electrical connector at the ignition coil and the engine control module (ECM) ground terminal.

    20. Object Number: 1252117 Size: SH
  20. Disconnect the oxygen sensor connector, if equipped.
  21. Disconnect the idle air control (IAC) valve connector and the manifold absolute pressure (MAP) sensor connector.
  22. Disconnect the throttle position (TP) sensor connector.
  23. Disconnect the engine coolant temperature (ECT) sensor connector.
  24. Disconnect the coolant temperature sensor (CTS) connector.
  25. Disconnect the alternator voltage regulator connector and the power lead.
  26. Disconnect the camshaft position (CMP) sensor connector.

    27. Object Number: 1252126 Size: SH
  27. Disconnect all of the vacuum lines including the brake booster vacuum hose.
  28. Disconnect the fuel return line at the fuel pressure regulator.
  29. Disconnect the fuel feed line at the fuel rail.
  30. Remove the fuel rail and the injector channel cover. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L.

    31. Object Number: 1252161 Size: SH
  31. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
  32. Disconnect the coolant hose at the throttle body.
  33. Disconnect the heater outlet hose at the coolant pipe.
  34. Disconnect the coolant bypass hose from the cylinder head.
  35. Disconnect the surge tank coolant hose from the coolant pipe.
  36. Disconnect the lower radiator hose from the coolant pipe.
  37. Disconnect the starter solenoid S terminal wire and the power lead.
  38. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.

    39. Object Number: 1252123 Size: SH
  39. Remove the front exhaust pipe retaining nuts from the catalytic converter.
  40. Remove the exhaust flex pipe.

    41. Object Number: 1252141 Size: SH
  41. Remove the nuts that secure the front exhaust pipe to the third muffler.
  42. Remove the rubber hangers that attach the connecting pipe to the vehicle.

    43. Object Number: 1252142 Size: SH
  43. Remove the connecting pipe mounting bracket nuts and the bracket.
  44. Remove the connecting pipe.

    45. Object Number: 1252119 Size: SH
  45. Remove the crankshaft pulley bolts.
  46. Remove the crankshaft pulley.
  47. Disconnect the vacuum lines at the charcoal canister purge (CCP) and the exhaust gas recirculation (EGR) solenoid.
  48. Disconnect the electrical connector at the CCP and the EGR solenoid.
  49. Disconnect the electrical connector at the oil pressure switch.
  50. Disconnect the crankshaft position and the knock sensor connectors.
  51. Support the transmission with a floor jack.
  52. Remove the front engine crossmember. Refer to Engine Front Crossmember Replacement in Frame and Underbody.
  53. Install the engine lifting device.

    54. Object Number: 1252173 Size: SH
  54. Remove the transaxle torque converter bolts, if automatic transaxle equipped.
  55. Remove the transaxle bell housing bolts and the oil pan flange bolts.
  56. Remove the rear engine/transaxle mount bracket. Refer to Transmission Disassemble in Manual Transmission - D20 or Transmission Replacement in Automatic Transmission - ZF 4HP 16.
  57. Remove the resonator bolts and the resonator.
  58. Remove the surge tank and the bolts.

    59. Object Number: 1252118 Size: SH
  59. Disconnect the right engine mount bracket from the engine mount and the engine by removing the retaining bolts.

    60. Notice: Refer to Engine Lifting Notice in the Preface section.

  60. Separate the engine block from the transaxle. Remove the engine.

Installation Procedure

    Object Number: 1252143 Size: SH
  1. Install the engine into the engine compartment.
  2. Align the engine alignment pins to the transaxle.

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

  3. Install the transaxle bell housing bolts.

    4. Tighten
    Tighten the transaxle bell housing bolts to 75 N·m (55 lb ft).

  4. Install the oil pan flange-to-transaxle retaining bolts.

    5. Tighten
    Tighten the oil pan flange-to-transaxle bolts to 40 N·m (30 lb ft).


    Object Number: 1252118 Size: SH
  5. Install the right engine mount bracket to the engine block mount and the frame mount.
  6. Install the right engine mount bracket retaining bolts and the nuts.

    7. Tighten
    Tighten the right engine mount bracket retaining bolts and the nut to 60 N·m (44 lb ft).

  7. Install the rear engine/transaxle mount bracket. Refer to Transmission Disassemble in Manual Transmission - D20 or Transmission Replacement in Automatic Transmission - ZF 4HP 16.
  8. Install the front engine crossmember. Refer to Engine Front Crossmember Replacement in Frame and Underbody.

    9. Object Number: 1252173 Size: SH
  9. Remove the floor jack used for support of the transaxle.
  10. Remove the engine lifting device.
  11. Install the transaxle torque converter bolts, if automatic transaxle equipped.

    12. Tighten
    Tighten the transaxle torque converter bolts to 45 N·m (33 lb ft).


    Object Number: 1252119 Size: SH
  12. Connect the vacuum lines at the charcoal canister purge solenoid.
  13. Connect the electrical connectors to the charcoal canister purge solenoid.
  14. Connect the oil pressure switch connector.
  15. Install the crankshaft pulley.
  16. Install the crankshaft pulley bolts.

    17. Tighten
    Tighten the crankshaft pulley bolts to 20 N·m (15 lb ft) using a torque wrench.

  17. Connect the crankshaft position and knock sensor connectors.

    18. Object Number: 1252141 Size: SH
  18. Install the 3rd muffler bolts into the front exhaust pipe flange.
  19. Install the rubber hangers that attach the connecting pipe to the vehicle.
  20. Install the nuts to secure the front exhaust pipe-to-3rd muffler.

    21. Tighten
    Tighten the front exhaust pipe-to-3rd muffler nuts to 30 N·m (22 lb ft).


    Object Number: 1252123 Size: SH
  21. Install the catalytic converter lower flange bolts.

    22. Tighten
    Tighten the catalytic converter-to-connecting pipe nuts to 40 N·m (30 lb ft).


    Object Number: 1252172 Size: SH
  22. Install the exhaust flex pipe retaining nuts to the catalytic converter or the 3rd muffler.

    23. Tighten
    Tighten the exhaust flex pipe retaining nuts to the catalytic converter or the 3rd muffler to 30 N·m (22 lb ft).

  23. Connect the power steering pressure hose.
  24. Connect the power steering return hose.
  25. Install the A/C compressor, if equipped. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation, and Air Conditioning.

    26. Object Number: 1252126 Size: SH
  26. Install the power steering drive belt. Refer to Power Steering Pump Belt Replacement in Power Steering System.
  27. Install the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
  28. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  29. Connect the fuel feed line to the fuel rail.
  30. Connect the fuel return line to the fuel pressure regulator.
  31. Install the fuel rail and the injector channel cover as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L.

    32. Object Number: 1252117 Size: SH
  32. Connect all the previously disconnected vacuum lines, including the brake booster vacuum hose.
  33. Connect the oxygen sensor connector, if equipped.
  34. Connect the starter solenoid S terminal wire and the power lead.
  35. Connect the alternator voltage regulator connector.
  36. Connect the CTS connector.
  37. Connect the ECT sensor connector.
  38. Connect the TP sensor connector.
  39. Connect the IAC valve connector.
  40. Connect the MAP sensor connector.
  41. Connect the CMP sensor connector.

    42. Object Number: 1252116 Size: SH
  42. Connect the electrical connector at the ignition coil and the ECM ground terminal.
  43. Install the air intake tube.
  44. Install the air filter housing and the bolts.

    45. Tighten
    Tighten the air filter housing bolts to 6 N·m (53 lb in).

  45. Connect the breather tubes to the valve cover.
  46. Connect the manifold air temperature sensor connector.
  47. Install the cooling system and the engine cooling fans. Refer to Radiator Replacement in Engine Cooling.
  48. Install the resonator and the retaining bolts.

    49. Tighten
    Tighten the resonator retaining bolts to 3 N·m (27 lb in).


    Object Number: 1252174 Size: SH
  49. Connect the lower radiator hose to the coolant pipe.
  50. Connect the upper radiator hose to the thermostat housing.
  51. Connect the heater inlet hose to the cylinder head.
  52. Connect the heater outlet hose to the coolant pipe.
  53. Connect the coolant surge tank hose to the coolant pipe.
  54. Connect the coolant hose to the throttle body.

    55. Object Number: 1252161 Size: SH
  55. Connect the throttle cable to the throttle body and the intake manifold bracket.
  56. Install the fuel pump fuse.
  57. Connect the negative battery cable.
  58. Refill the engine crankcase with engine oil.
  59. Refill the engine coolant system. Refer to Cooling System Draining and Filling in Engine Cooling.
  60. Fill and bleed the power steering system. Refer to Power Steering System Bleeding in Power Steering System.
  61. Refill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  62. Install the hood. Refer to Hood Replacement in Body Front End.