GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Optra - Mexico 🢒 Engine 🢒 Engine Mechanical - 1.6L (L91) 🢒 Engine Replacement

Removal Procedure

    Object Number: 1291147 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Remove the hood. Refer to Hood Replacement .
  4. Drain the engine oil.

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

  5. Disconnect the negative battery cable.

    6. Object Number: 1291257 Size: SH
  6. Remove the air cleaner outlet hose from the throttle body and air cleaner housing.
  7. Disconnect the breather tubes from the camshaft cover.
  8. Remove the serpentine accessory drive belt. Refer to Power Steering Pump Belt Replacement .
  9. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation .
  10. Remove the right front wheel well splash shield.

    11. Caution: Refer to Safety Glasses Caution in the Preface section.


    Object Number: 1291222 Size: SH
  11. Drain the engine coolant. Refer to Cooling System Draining and Filling .
  12. Remove the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement and Engine Cooling Fan Replacement .
  13. Disconnect the upper radiator hose from the thermostat housing.
  14. Disconnect the power steering return hose from the power steering pump.
  15. Disconnect the power steering pressure hose from the power steering pump.
  16. Disconnect the electrical connector at the direct ignition system coil and the electronic control module (ECM) ground terminal at the intake manifold and at the starter motor.

    17. Notice: Refer to Oxygen Sensor Notice in the Preface section.


    Object Number: 1291152 Size: SH
  17. Disconnect the oxygen (O2) sensor connector, if equipped.
  18. Disconnect the fuel injector harness connectors.
  19. Disconnect the intake air temperature (IAT) and manifold absolute pressure (MAP) sensor connectors.
  20. Disconnect the throttle position (TP) sensor connector.
  21. Disconnect the generator voltage regulator connector and power lead.
  22. Remove the electrical harness clamp bolt.

    23. Object Number: 1291241 Size: SH
  23. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
  24. Disconnect the fuel feed line at the fuel rail.

    25. Object Number: 1291368 Size: SH
  25. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
  26. Disconnect the surge tank coolant hose at the throttle body.
  27. Disconnect the heater outlet hose at the coolant pipe.
  28. Disconnect the heater inlet hose from the cylinder head.
  29. Disconnect the surge tank coolant hose from the coolant pipe.
  30. Disconnect the lower radiator hose from the coolant pipe. Disconnect the starter solenoid "S" terminal wire. Remove the A/C compressor, if equipped.

    31. Object Number: 1291270 Size: SH
  31. Remove the catalytic converter retaining nuts from the exhaust pipe.
  32. Remove the exhaust pipe.

    33. Object Number: 1291228 Size: SH
  33. Remove the crankshaft pulley bolt.
  34. Remove the crankshaft pulley.
  35. Disconnect the vacuum lines at the charcoal canister purge solenoid.
  36. Disconnect the electrical connector at the charcoal canister purge (CCP) solenoid and at the knock sensor.
  37. Disconnect the electrical connector at the oil pressure switch and at the exhaust gas recirculation (EGR) solenoid.
  38. Disconnect the crankshaft position (CKP) sensor connector.

    39. Object Number: 1291369 Size: SH
  39. Remove the transaxle torque converter bolts, if automatic transaxle equipped.
  40. Remove the stater motor. Refer to Starter Motor Replacement .
  41. Remove the transaxle bell housing bolts.
  42. Support the transaxle with a floor jack.
  43. Install the engine lifting device.

    44. Object Number: 1291231 Size: SH
  44. Disconnect the right engine mount bracket from the engine mount and the engine by removing the attaching bolts and the nuts.
  45. Remove the right engine mount from the engine block. Refer to Engine Mount Replacement .
  46. Separate the engine block from the transaxle.
  47. Remove the engine.

Installation Procedure

    Object Number: 1291231 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 right engine mount to the engine block. Refer to Engine Mount Replacement .
  5. Connect the right engine mount bracket to the engine mount and the engine by installing the attaching bolts and the nuts.

    6. Tighten
    Tighten the engine mount bracket attaching bolts and the nuts to 55 N·m (41 lb ft).


    Object Number: 1291369 Size: SH
  6. Remove the floor jack used for support of the transaxle.
  7. Remove the engine lifting device.
  8. Install the transaxle torque converter bolts, if automatic transaxle equipped.

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

  9. Install the starter motor. Refer to Starter Motor Replacement .

    10. Object Number: 1291228 Size: SH
  10. Connect the vacuum lines at the CCP solenoid.
  11. Connect the electrical connector at the CCP solenoid and at the knock sensor.
  12. Connect the oil pressure switch and the EGR solenoid connectors
  13. Install the crankshaft pulley.
  14. Install the crankshaft pulley bolt.

    15. Tighten
    Tighten the crankshaft pulley bolt to 95 N·m (70 lb ft) and retighten 30 degrees plus 15 degrees.


    Object Number: 1291270 Size: SH
  15. Connect the CKP sensor connector.
  16. Install the exhaust front pipe.
  17. Install the catalytic converter retaining nuts to the exhaust pipe.

    18. Tighten
    Tighten the catalytic converter to exhaust pipe retaining nuts to 35 N·m (26 lb ft).


    Object Number: 1291371 Size: SH
  18. Connect the power steering pressure hose.
  19. Connect the power steering return hose.
  20. Install the A/C compressor, if equipped.

    21. Object Number: 1291241 Size: SH
  21. Install the generator. Refer to Generator Replacement .
  22. Install the serpentine accessory drive belt. Refer to Power Steering Pump Belt Replacement .
  23. Install the right front wheel well splash shield.
  24. Install the right front wheel. Refer to Tire and Wheel Removal and Installation .
  25. Connect the fuel feed line to the fuel rail.

    26. Object Number: 1291378 Size: SH
  26. Connect all of the necessary vacuum lines, including the brake booster vacuum hose.
  27. Connect the O2 sensor connector, if equipped.
  28. Connect the starter solenoid "S" terminal wire and power lead.
  29. Connect the generator voltage regulator connector and power lead.
  30. Connect the ECT sensor connector.
  31. Connect the MAP and IAT sensor connectors.
  32. Connect the TP sensor connector.
  33. Install the electrical wiring harness clamp bolt at the intake manifold support bracket.

    34. Object Number: 1291381 Size: SH
  34. Connect the fuel injector harness connectors.
  35. Connect the electrical connector at the direct ignition system coil and the ECM ground terminal at the intake manifold and at the starter.
  36. Install the air cleaner outlet hose between the throttle body and the air cleaner housing.
  37. Connect the breather tubes to the camshaft cover.
  38. Install the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement and Engine Cooling Fan Replacement .

    39. Object Number: 1291368 Size: SH
  39. Connect the lower radiator hose to the coolant pipe.
  40. Connect the upper radiator hose to the thermostat housing.
  41. Connect the surge tank coolant hose to the radiator.
  42. Connect the heater inlet hose to the cylinder head.
  43. Connect the heater outlet hose to the coolant pipe.
  44. Connect the coolant surge tank hose to the coolant pipe.
  45. Connect the surge tank coolant hose to the throttle body.

    46. Object Number: 1291220 Size: SH
  46. Connect the throttle cable to the throttle body and the intake manifold bracket.
  47. Install the fuel pump fuse.
  48. Connect the negative battery cable.
  49. Refill the engine crankcase with engine oil.
  50. Refill the engine coolant system. Refer to Cooling System Draining and Filling .
  51. Bleed the power steering system. Refer to Power Steering System Bleeding .
  52. Refill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging .
  53. Install the hood. Refer to Hood Replacement .