GM Service Manual Online
For 1990-2009 cars only

Special Tools

    • EN-48244 Engine Assembly Remove/Install Pallet Supporter
    • EN-49156 Engine Assembly Remove/Install Pallet

Removal Procedure


    Object Number: 2049603  Size: SH
  1. Release the fuel pressure. Refer to Fuel Pressure Relief.
  2. Disconnect the fuel pipe from the fuel rail.
  3. Disconnect the EVAP hose from the EVAP canister solenoid valve.
  4. Drain the engine coolant. Refer to Cooling System Draining and Filling.
  5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

  6. Object Number: 2049604  Size: SH
  7. Remove the battery and tray. Refer to Battery Tray Replacement.
  8. Remove the fuse box bolts.

  9. Object Number: 2049605  Size: SH
  10. Discharge the A/C gas system, if equipped. Refer to Refrigerant Recovery and Recharging.
  11. Remove the A/C inlet/outlet pipe bolt (1) from the A/C compressor.

  12. Object Number: 2049606  Size: SH
  13. Drain the power steering oil if equipped. Refer to Power Steering Pump Replacement.
  14. Remove the power steering pump pressure line union nut. Refer to Power Steering Pump Replacement.
  15. Remove the power steering pressure pipe retaining clamp bolt (1) from the intake manifold.
  16. Disconnect the power steering hose from the power steering pump.
  17. Disconnect the following:
  18. • Oil switch wiring connector
    • A/C compressor connector
  19. Disconnect the following:
  20. • Intake air temperature sensor connector
    • A/C pressure sensor (ACP) connector
    • Cam position solenoid valve connector
    • Electric throttle controller (ETC) connector
    • Manifold air pressure (MAP) sensor connector
    • EVAP solenoid valve connector
    • Injector connectors
  21. Disconnect the following
  22. • Ignition coil connector
    • Camshaft position sensor (CPS) connectors (right/left)
    • Coolant temperature sensor connector
    • Oxygen sensor connector
    • Ground bolt
    • Thermostat heater connector

    Object Number: 2049608  Size: SH
  23. Disconnect the following and pull the engine harness aside.
  24. • Crankshaft position (CKP) sensor connector
    • Knock sensor connector
    • Alternator connector
    • Alternator B+ g nut
    • Oil level switch connector, if equipped
    • Starter solenoid B+ tightening nut
    • Ground nut
    • Starter solenoid ground nut

    Object Number: 2049609  Size: SH
  25. Disconnect the coolant hose (1) from water pump.
  26. Disconnect the coolant hose (2) from the thermostat housing.
  27. Disconnect the heater core coolant inlet/outlet hoses (3) from the coolant distributor.
  28. Disconnect the ETC-to-coolant tank hose (4).
  29. Disconnect the brake boost hose (5) from the intake manifold.

  30. Object Number: 2049610  Size: SH
  31. Remove and disconnect the cables and wiring harness related to the automatic transaxle.
  32. Disconnect the auto transaxle fluid cooler inlet/outlet hoses.

  33. Object Number: 2049611  Size: SH
  34. Remove and disconnect the cables and wiring harness related to the manual transaxle.

  35. Object Number: 2049602  Size: SH
  36. Remove the reaction rod (1).
  37. Remove the exhaust front pipe. Refer to Front Pipe Replacement.
  38. Remove the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement

  39. Object Number: 2049613  Size: SH
  40. Install EN-49156 remove/install pallet on to EN-48244 pallet supporter .
  41. Lift the vehicle up using by lifter.
  42. Locate the pallet and supporter under the vehicle engine and transaxle.
  43. Lift the vehicle down until engine assembly fixing on the EN-49156 remove/install pallet .
  44. Remove the engine mount. Refer to Engine Mount Replacement.
  45. Remove the transaxle mount.

  46. Object Number: 2049614  Size: SH
  47. Separate the engine and the transaxle.

Installation Procedure


    Object Number: 2049614  Size: SH
  1. Assemble the engine to the transaxle.

  2. Object Number: 2049613  Size: SH
  3. Place the engine assembly on the pallet EN-49156 remove/install pallet on the EN-48244 pallet supporter
  4. Lift the vehicle up using by lifter.
  5. Locate the engine assembly with the pallet and supporter.
  6. Lift the vehicle down.
  7. Install the engine mount. Refer to Engine Mount Replacement.
  8. Install the transaxle mount.

  9. Object Number: 2049612  Size: SH
  10. Install the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement.
  11. Install the exhaust front pipe. Refer to Front Pipe Replacement.

  12. Object Number: 2049602  Size: SH
  13. Install the reaction rod (1).
  14. Install and connect the cables and wiring harness related to the automatic transaxle.
  15. Connect the auto transaxle fluid cooler inlet/outlet hoses.

  16. Object Number: 2049611  Size: SH
  17. Install and connect the cables and wiring harness related to the manual transaxle.

  18. Object Number: 2049609  Size: SH
  19. Connect the coolant hose (1) to the water pump.
  20. Connect the coolant hose (2) to the thermostat housing.
  21. Connect the heater core coolant inlet/outlet hoses (3) to the coolant distributor.
  22. Connect the ETC-to-coolant tank hose (4).
  23. Connect the brake boost hose (5) to the intake manifold.
  24. Caution: Refer to Fastener Caution in the Preface section.

  25. Position the engine harness and connect the following connectors.
  26. • Crankshaft position (CKP) sensor connector
    • Knock sensor connector
    • Alternator connector
    • Alternator B+ nut
    • Oil level switch connector, if equipped
    • Starter solenoid B+ nut
    • Ground tightening nut
    • Starter solenoid ground nut

    Tighten

       • 

    Tighten the alternator B+ nut to 15 N·m (11 lb ft).

       • 

    Tighten the starter solenoid B+ nut to 10.5 N·m (7.7 lb ft).

       • 

    Tighten the ground nut to 12 N·m (8.8 lb ft).

       • 

    Tighten the starter solenoid ground nut to 38 N·m (28 lb ft).

  27. Connect the following:
  28. • Ignition coil connector
    • Camshaft position sensor (CPS) connectors (right/left)
    • Coolant temperature sensor connector
    • Oxygen sensor connector
    • Ground bolt

    Tighten
    Tighten the ground bolt to 12 N·m (8.8 lb  ft).

    • Thermostat heater connector
  29. Connect the following:
  30. • Oil switch wiring connector
    • A/C compressor connector

    Object Number: 2049606  Size: SH
  31. Install the power steering pump pressure line union nut.
  32. Install the power steering pressure pipe retaining clamp bolt (1) to the intake manifold.
  33. Connect the power steering hose to the power steering pump.

  34. Object Number: 2049605  Size: SH
  35. Install the A/C inlet/outlet pipe bolt (1) from the A/C compressor if equipped.
  36. Charge the A/C gas system. Refer to Refrigerant Recovery and Recharging.
  37. Install the fuse box tightening bolts.
  38. Install the battery and tray. Refer to Battery Tray Replacement.

  39. Object Number: 2049603  Size: SH
  40. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  41. Connect the fuel pipe to the fuel rail.
  42. Connect the EVAP hose to the EVAP canister solenoid valve.