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Home >> Chevrolet >> 2005 >> Optra5 Base, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 1.6L (L91) >> Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Engine Mount Bracket Attaching Bolts/Nuts
    GM1291231Courtesy of GENERAL MOTORS CORP.
  1. Install the engine into the engine compartment.
  2. Align the engine alignment pins to the transaxle.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the transaxle bell housing bolts.

    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.

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

    6. Fig 2: View Of Starter Motor And Bolts
    GM1291369Courtesy of GENERAL MOTORS CORP.
  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.

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

  9. Install the starter motor. Refer to Starter Motor Replacement (1.4L/1.6L) or Starter Motor Replacement (1.8L/2.0L) .
    10. Fig 3: Identifying Crankshaft Pulley And Bolt
    GM1291228Courtesy of GENERAL MOTORS CORP.
  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.

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

    15. Fig 4: View Of Exhaust Pipe Catalytic Converter Retaining Nuts
    GM1291270Courtesy of GENERAL MOTORS CORP.
  15. Connect the CKP sensor connector.
  16. Install the exhaust front pipe.
  17. Install the catalytic converter retaining nuts to the exhaust pipe.

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

    18. Fig 5: Identifying Power Steering Pressure Hose
    GM1291371Courtesy of GENERAL MOTORS CORP.
  18. Connect the power steering pressure hose.
  19. Connect the power steering return hose.
  20. Install the A/C compressor, if equipped.
    21. Fig 6: View Of Brake Booster Vacuum Hose
    GM1291241Courtesy of GENERAL MOTORS CORP.
  21. Install the generator. Refer to Generator Replacement (1.6L) or Generator Replacement (1.8L/2.0L) .
  22. Install the serpentine accessory drive belt. Refer to Power Steering Pump Drive 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 in Tires and Wheels.
  25. Connect the fuel feed line to the fuel rail.
    26. Fig 7: View Of Electrical Harness Clamp And Bolt
    GM1291378Courtesy of GENERAL MOTORS CORP.
  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. Fig 8: View Of Air Cleaner Outlet Hose
    GM1291381Courtesy of GENERAL MOTORS CORP.
  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 Cooling Fan Replacement - Electric in Engine Cooling.
    39. Fig 9: Identifying Surge Tank Coolant Hose
    GM1291368Courtesy of GENERAL MOTORS CORP.
  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. Fig 10: Identifying Throttle Cable And Coolant Hoses
    GM1291220Courtesy of GENERAL MOTORS CORP.
  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 Draining and Filling Cooling System in Engine Cooling.
  51. Bleed the power steering system. Refer to Bleeding the Power Steering System in Power Steering System.
  52. Refill the A/C refrigerant system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  53. Install the hood. Refer to Hood Replacement in Body Front End.
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