GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Optra 🢒 Preface 🢒 Cautions and Notices 🢒 Engine Replacement

Removal Procedure

    Object Number: 1289766 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 .
  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: 1289763 Size: SH
  7. Discharge the air conditioning (A/C) system, if equipped. Refer to Refrigerant Recovery and Recharging .
  8. Disconnect the intake air temperature (IAT) 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 .
  12. Remove the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement .
  13. Remove the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement .

    14. Object Number: 1291067 Size: SH
  14. Drain the engine coolant. Refer to Cooling System Draining and Filling .
  15. Remove the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement .
  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: 1666911 Size: SH
  20. Disconnect the oxygen sensor connector, if equipped.
  21. Disconnect the electronic throttle control (ETC) connector (1).
  22. Disconnect the idle air control (IAC) valve connector and the manifold absolute pressure (MAP) sensor connector.
  23. Disconnect the throttle position (TP) sensor connector.
  24. Disconnect the coolant temperature sensor (CTS) connector.
  25. Disconnect the alternator voltage regulator connector and the power lead.

    26. Object Number: 1669858 Size: SH
  26. Disconnect all of the vacuum lines including the brake booster vacuum hose.
  27. Disconnect the fuel return line at the fuel pressure regulator.
  28. Disconnect the fuel feed line at the fuel rail.
  29. Remove the fuel rail and the injector channel cover. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  30. Disconnect the coolant hose at the throttle body.
  31. Disconnect the heater outlet hose at the coolant pipe.
  32. Disconnect the coolant bypass hose from the cylinder head.
  33. Disconnect the surge tank coolant hose from the coolant pipe.
  34. Disconnect the lower radiator hose from the coolant pipe.
  35. Disconnect the starter solenoid S terminal wire and the power lead.
  36. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .

    37. Object Number: 1289778 Size: SH
  37. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
  38. Remove the exhaust pipe retaining nuts from the catalytic converter or the connecting pipe.
  39. Remove the exhaust flex pipe.

    40. Object Number: 1252119 Size: SH
  40. Remove the crankshaft pulley bolts.
  41. Remove the crankshaft pulley.
  42. Disconnect the vacuum lines at the charcoal canister purge (CCP) and the exhaust gas recirculation (EGR) solenoid.
  43. Disconnect the electrical connector at the CCP and the EGR solenoid.
  44. Disconnect the electrical connector at the oil pressure switch.
  45. Disconnect the crankshaft position and the knock sensor connectors.

    46. Object Number: 1491157 Size: SH
  46. Remove the lower reaction rod bracket bolts.
  47. Remove the lower reaction rod bracket.
  48. Remove the lower reaction rod mount bolt.
  49. Remove the lower reaction rod mount.
  50. Support the transmission with a floor jack.
  51. Install the engine lifting device.

    52. Object Number: 1252173 Size: SH
  52. Remove the transaxle torque converter bolts, if automatic transaxle equipped.
  53. Remove the transaxle bell housing bolts and the oil pan flange bolts.

    54. Object Number: 1289770 Size: SH
  54. Disconnect the right engine mount bracket from the engine mount and the engine by removing the retaining bolts.
  55. Remove the right engine mount bracket from the engine block and the frame mount.

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

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

Installation Procedure

    Object Number: 1289821 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: 1289770 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 55 N·m (41 lb ft).


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

    10. Tighten
    Tighten the transaxle torque converter bolts to 60 N·m (44 lb ft).


    Object Number: 1491157 Size: SH
  10. Install the lower reaction rod mount.
  11. Install the lower reaction rod mount bolt.

    12. Tighten
    Tighten the reaction rod mount bolt to 55 N·m (41 lb ft).

  12. Install the lower reaction rod bracket.
  13. Install the lower reaction rod bracket bolts.

    14. Tighten
    Tighten the reaction rod bracket bolts to 69 N·m (49 lb ft).


    Object Number: 1252119 Size: SH
  14. Connect the vacuum lines at the charcoal canister purge solenoid.
  15. Connect the electrical connector at the CCP and the EGR solenoid.
  16. Connect the oil pressure switch connector.
  17. Install the crankshaft pulley.
  18. Install the crankshaft pulley bolts.

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

  19. Connect the crankshaft position and knock sensor connectors.

    20. Object Number: 1289778 Size: SH
  20. Install the exhaust flex pipe.
  21. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.

    22. Tighten
    Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N·m (26 lb ft).

  22. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.

    23. Tighten
    Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 N·m (26 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 .

    26. Object Number: 1669858 Size: SH
  26. Install the power steering drive belt. Refer to Power Steering Pump Belt Replacement .
  27. Install the right front wheel well splash shield. Refer to Wheelhouse Splash Shield Replacement .
  28. Install the right front wheel. Refer to Tire and Wheel Removal and Installation .
  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 .

    32. Object Number: 1666911 Size: SH
  32. Connect all the previously disconnected vacuum lines, including the brake booster vacuum hose.
  33. Connect the oxygen sensor connector.
  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 (1).
  38. Connect the TP sensor connector.
  39. Connect the IAC valve connector.
  40. Connect the MAP sensor connector.
  41. Connect the knock sensor connector.

    42. Object Number: 1289768 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 intake air temperature (IAT) sensor connector.
  47. Install the cooling system and the engine cooling fans. Refer to Radiator Replacement .

    48. Object Number: 1291076 Size: SH
  48. Connect the lower radiator hose to the coolant pipe.
  49. Connect the upper radiator hose to the thermostat housing.
  50. Connect the heater inlet hose to the cylinder head.
  51. Connect the heater outlet hose to the coolant pipe.
  52. Connect the coolant surge tank hose to the coolant pipe.
  53. Connect the coolant hose to the throttle body.
  54. Install the fuel pump fuse.
  55. Connect the negative battery cable.
  56. Refill the engine crankcase with engine oil.
  57. Refill the engine coolant system. Refer to Cooling System Draining and Filling .
  58. Fill and bleed the power steering system. Refer to Power Steering System Bleeding .
  59. Refill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging .
  60. Install the hood. Refer to Hood Replacement .