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Friday, October 14, 2011

How to remove Chevrolet 2.2L Engine ?


Engine


REMOVAL & INSTALLATION




2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the tires in the straight forward position, remove the key from the ignition.
  3. Disconnect the negative battery cable.
  4. Remove the air inlet duct and resonator.
  5. Secure the cooling module to the upper body structure.
  6. Relieve the fuel system pressure.
  7. Disconnect the fuel lines from the fuel rail.
  8. Drain the cooling system.
  9. Remove the radiator inlet hose.
  10. Remove the surge tank to cylinder head hose.
  11. Remove the radiator outlet hose.
  12. Remove the inlet and outlet heater hoses.
  13. Disconnect the following harness connectors:

    Idle Air Control (IAC) motor
    TPS
    Manifold Absolute Pressure (MAP) sensor
    Crankshaft sensor
    Oil pressure sensor
    Purge solenoid
    Ignition coil and module assembly
    Oxygen (O 2 ) sensor
    Vehicle speed sensor
    Engine temperature sensor
    Backup lamp switch
  14. Raise and suitably support the vehicle.
  15. Remove the engine accessory drive belt.
  16. Remove the front fender liner.
  17. Rotate the drive belt tensioner counterclockwise to release the spring tension.
  18. Remove the drive belt.
  19. Disconnect the electrical connector from the A/C compressor.
  20. Remove the A/C compressor bolts and set the compressor aside.
  21. Disconnect the starter harness connectors.
  22. Disconnect the generator harness connectors.
  23. Drain the engine oil.
  24. Disconnect the front exhaust pipe from the exhaust manifold.
  25. Disconnect the transaxle harness connectors.
  26. Disconnect the transaxle shift cable from the transaxle.
  27. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  28. Support the engine with a hydraulic floor jack. Use a piece of wood between the jack and the oil pan.
  29. Remove the engine mount to intermediate bracket bolts.
  30. Remove the engine mount to mid-rail nuts.
  31. Remove the engine mount from the engine compartment.
  32. With an automatic transaxle:
    1. Remove the front transaxle mount thru bolt.
    2. Remove the rear transaxle mount thru bolt.
    3. Lower the vehicle.
    4. Remove the under hood electrical center cover.
    5. Disconnect the engine control module harness connector.
    6. Disconnect the positive battery cables from the under hood electrical center.
    7. Disconnect the surge tank inlet hose from the surge tank.
    8. Remove the under hood electrical center tray bracket nuts and bolt.
    9. Disconnect the wiring harness retainer from the tray bracket.
    10. Lift the electrical center up and swing it back and out of the way.
    11. Support the transaxle with a hydraulic floor jack. Use a block of wood between the jack and the transaxle.
    12. Remove the transaxle mount to transaxle bolts.
    13. Remove the transaxle mount to mid-rail bolts.
    14. Using the floor jack, slowly lower the transaxle just enough to remove the transaxle mount from the vehicle.
  33. With an MU3 manual transaxle:
    1. Remove the cover from the underhood electrical center.
    2. Remove the underhood positive battery terminal lug.
      WARNING
      Take note of the positioning of the positive battery cables before disconnecting the cables.
    3. Disconnect the positive battery cables from the underhood electrical center.
      WARNING
      The underhood electrical center bolts are retained in the electrical center.
    4. Loosen all of the underhood electrical bolts.
    5. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center.
    6. Support the transaxle with a floor jack. Use a piece of wood between the jack and the transaxle.
    7. Remove the transaxle mount-to-transaxle bracket bolts.
    8. Remove the transaxle mount to mid-rail bolts.
    9. Using a floor jack, slowly lower the transaxle enough to remove the transaxle mount from the vehicle.
  34. With a Getrag 5-speed manual transaxle:
    1. Remove the underhood electrical center cover.
    2. Disconnect the Engine Control Module (ECM) harness connector.
    3. Disconnect the positive battery cables from the underhood electrical center.
    4. Disconnect the surge tank inlet hose from the surge tank.
    5. Remove the underhood electrical center tray bracket nuts and bolt.
    6. Disconnect the wiring harness retainer from the tray bracket.
    7. Lift the electrical center up and swing it back and out of the way.
    8. Support the transaxle with a floor jack. Use a piece of wood between the jack and the transaxle.
    9. Remove the transaxle mount to transaxle bolts.
    10. Remove the transaxle mount to mid-rail bolts.
    11. Using a floor jack, slowly lower the transaxle enough to remove the transaxle mount from the vehicle.
    12. Disconnect the control links from the stabilizer bar.
    13. Disconnect the outer tie rod ends from the steering knuckles.
      WARNING
      In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.
    14. Disconnect the intermediate shaft from the steering gear.
    15. Disconnect the lower control arms from the steering knuckles.
    16. Disconnect the drive axles from the steering knuckle.
    17. Use a paint pen or magic marker in order to mark the frame to body position.
    18. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
    19. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  35. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
  36. Slowly lower the table to the floor with the cradle and powertrain assembly.
  37. Attach the engine lift hoist to the engine lift hooks.
  38. Remove the starter.
  39. If applicable, remove the torque converter to flywheel bolts.
  40. Remove the transaxle to engine bolts.
  41. Separate the engine from the transaxle.
  42. If applicable, remove the clutch pressure plate and disk.
  43. Remove the following components:
  44. Remove the exhaust manifold
  45. Remove the exhaust manifold studs
  46. Remove the engine mount bracket
  47. Remove the engine block heater
  48. Remove the thermostat housing and feed pipe
  49. Remove the generator
  50. Remove the engine from the engine lift.
To install:
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the exhaust manifold.
  3. Install the intermediate bracket to the engine.
  4. Hand tighten the engine mount intermediate bracket bolts in the following locations:

    The long bolts in the forward and front lower holes
    The short bolt in the rear upper hole
  5. Tighten the intermediate bracket bolts to 74 ft. lbs. (100 Nm).
  6. Install the fuel rail.
  7. Install the engine block heater, if equipped.
  8. Install the drive belt tensioner.
  9. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    WARNING
    Lubricate the O-ring with soapy water or coolant before installing the O-ring in the water pump.
  10. Install the feed pipe that connects the thermostat housing to the water pump.
  11. Install the bolt that secures the water pump feed pipe. Tighten the bolt to 88 inch lbs. (10 Nm).
  12. Install the generator.
  13. Install the flywheel. Tighten the flywheel bolts to 39 ft. lbs. (53 Nm) plus 25°
  14. If applicable, install the clutch pressure plate and disk.
  15. Align the engine to the transaxle.
    WARNING
    The number 3 bolt location is not used.
  16. Secure the engine to the transaxle. Tighten the transaxle to engine bolts to 55 ft. lbs. (75 Nm).
  17. If applicable, install the torque converter bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
  18. Install the starter.
  19. Remove the engine lift from the engine.
  20. Raise and position the frame and powertrain assembly to the vehicle.
  21. Hand start all the frame bolts while aligning the frame to the paint marks.
  22. Tighten the frame bolts. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180°.
  23. Remove the lift table.
  24. Connect the drive axles to the steering knuckles.
  25. Connect the lower control arm to the steering knuckle.
  26. Connect the intermediate steering shaft to the steering gear.
  27. Connect the outer tie rod ends to the steering knuckles.
  28. Connect the control links to the stabilizer bar.
  29. With an automatic transaxle:
    1. Install the transaxle mount to the mid-rail.
    2. Hand start the transaxle mount to mid-rail bolts. Tighten the bolts to 25 ft. lbs. (34 Nm).
    3. Using a hydraulic jack, raise the transaxle until it contacts the transaxle mount.
      WARNING
      The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.
    4. Hand start the transaxle mount to transaxle bolts using the following sequence:

      Rear Bolt
      Middle Bolt
      Front Bolt
    5. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
    6. Reposition the under hood electrical center.
    7. Connect the wiring harness retainer to the tray bracket.
    8. Install the electrical center nuts  and bolts. Tighten the nut to 89 inch lbs. (10 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
    9. Connect the surge tank inlet hose to the surge tank.
    10. Install the positive battery cables to the under hood electrical center. Tighten the positive cable nut to 11 ft. lbs. (15 Nm).
    11. Connect the engine control module harness connectors.
    12. Install the under hood electrical center cover.
    13. Raise the vehicle.
    14. Hand tighten the front transaxle mount thru bolt
    15. Hand tighten the rear transaxle mount thru bolt.
    16. Tighten the front transaxle mount thru bolt. Tighten the bolt to 74 ft. lbs. (100 Nm).
    17. Tighten the rear transaxle mount thru bolt. Tighten the bolt to 74 ft. lbs. (100 Nm).
  30. With an MU3 manual transaxle:
    1. Install the transaxle mount to the mid-rail.
    2. Install the transaxle mount to mid-rail bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
    3. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
      WARNING
      The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.
    4. Hand start the transaxle mount to bracket bolts using the following sequence:

      Rear bolt
      Middle bolt
      Front bolt
    5. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
    6. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket.
  31. With a Getrag 5-speed:
    1. Install the transaxle mount to the mid-rail.
    2. Hand start the transaxle mount to mid-rail bolts. Tighten the bolts to.
    3. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
      WARNING
      The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.
    4. Hand start the transaxle mount to transaxle bolts using the following sequence:

      Rear bolt
      Middle bolt
      Front bolt
    5. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 33 ft. lbs. (45 Nm).
  32. Reposition the underhood electrical center.
  33. Connect the wiring harness to the tray bracket.
  34. Install the electrical center nuts and bolt. Tighten the nuts to 89 inch lbs. (10 Nm). Tighten the bolt to 18 ft. lbs. (25 Nm).
  35. Connect the surge tank inlet hose to the surge tank.
  36. Install the positive battery cables to the underhood electrical center. Tighten the positive cable nut to 11 ft. lbs. (15 Nm).
  37. Connect the engine control module harness connectors.
  38. Install the underhood electrical center cover.
  39. Place the engine mount onto the mid rail and hand start the nuts.
  40. Tighten the engine mount to mid-rail nuts. Tighten the nuts to 74 ft. lbs. (100 Nm).
    WARNING
    The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes.
  41. Hand start the engine mount to intermediate bracket bolts.
  42. Tighten the engine mount to intermediate bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  43. Remove the hydraulic floor jack.
  44. Install the air cleaner assembly.
  45. Remove the wood blocks between the powertrain and frame.
  46. Connect the transaxle shift cable to the transaxle.
  47. Connect the transaxle harness connector.
  48. Connect the exhaust takedown pipe to the exhaust manifold. Tighten the nuts to 22 ft. lbs. (30 Nm).
  49. Connect the generator harness connectors. Tighten the generator terminal nut to 15 ft. lbs. (20 Nm).
  50. Connect the starter harness connectors. Tighten the battery terminal nut to 13 ft. lbs. (17 Nm). Tighten the S-terminal nut to 27 inch lbs. (3 Nm).
  51. Install the A/C compressor to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm).
  52. Install the engine drive belt.
  53. Connect the following harness connectors:

    IAC motor
    TPS
    MAP sensor
    Crankshaft sensor
    Oil pressure sensor
    Purge solenoid
    Ignition coil and module assembly
    O 2 sensor
    Vehicle speed sensor
    Engine temperature sensor
  54. Install the inlet heater hose and outlet heater hose.
  55. Install the radiator outlet hose.
  56. Connect the fuel line to the fuel rail.
  57. Connect the brake booster hose at the brake booster.
  58. Release the cooling module from the upper body structure.
  59. Install the air inlet duct and resonator.
  60. Connect the negative battery cable.
  61. Fill the engine with engine oil to the proper level.
  62. Fill the cooling system.
  63. Road test the vehicle.

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