Cobalt And G5 2.4L Engine replacing Procedure?

Please Note this,the procedure for Engine removal Covers All U.S. And Canadian Models Of Chevrolet Cobalt & Pontiac G5.

In this chapter the details are provided to replace 2.4L Engine for both
Automatic Transaxle and Manual Transaxle.

The procedure is as follows:-----


2.4L Engine

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable.
3. Relieve fuel system pressure.
4. Disconnect the fuel feed line quick connect fitting from the fuel rail.
5. Disconnect the Evaporative Emission (EVAP) line quick connect fitting from the EVAP purge solenoid.
6. Remove the fuel line clips from the engine brackets.
7. Drain the cooling system.
8. Secure the cooling module to the upper body structure.
9. Remove the accessory drive belt. Refer to Accessory Drive Belts removal and installation.
10. Disconnect the cooling fan electrical connector.
11. Reposition the radiator inlet hose clamp at the engine.
12. Remove the radiator inlet hose from the engine.
13. If the vehicle is equipped with an engine oil cooler, perform the following steps, otherwise proceed to step 19.
14. Reposition the radiator outlet hose clamp at the water outlet.
15. Reposition the radiator outlet hose clamp at the oil cooler.
16. Remove the radiator outlet hose from the water outlet.
17. Remove the radiator outlet hose from the oil cooler. Proceed to step 23.
18. If the vehicle is not equipped with an engine oil cooler, reposition the surge tank outlet hose clamp at the surge tank.
19. Remove the surge tank outlet hose from the surge tank.
20. Reposition the radiator outlet hose clamp at the thermostat cover.
21. Remove the radiator outlet hose from the thermostat cover.
22. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
23. Remove the heater inlet and outlet hoses from the thermostat housing.
24. Reposition the brake booster vacuum hose clamp at the intake manifold.
25. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.
26. Disconnect the following electrical connectors:
    
    
    Throttle Actuator Control (TAC)

    Manifold Absolute Pressure (MAP) sensor

    Fuel injector harness

    Alternator
27. Remove or disconnect the following:
    
    
    The engine harness clip from the oil level indicator tube

    The engine harness clips from the intake manifold

    The ignition coils electrical connectors

    The intake and exhaust camshaft position actuator electrical connectors

    The engine harness clips from the camshaft cover

    The negative battery cable ground nut

    The engine harness ground terminal from the stud

    The negative battery cable ground terminal from the stud
28. Disconnect the following engine harness electrical connectors:
    
    
    Oil pressure sensor

    Crankshaft Position (CKP) sensor

    Knock sensor

    The EVAP purge solenoid electrical connector
29. Remove the engine harness clip from the purge solenoid bracket.
30. Remove the engine harness ground bolt.
31. Reposition the engine harness ground terminal.
32. Disconnect the engine harness electrical connector from the Air Conditioning (A/C) pressure switch.
33. Disconnect the engine harness electrical connector from A/C compressor.
34. Unbolt and reposition the A/C compressor to one side.
35. Raise and suitably support the vehicle.
36. Drain the engine oil.
37. Remove the transaxle fluid cooler bracket nut.
38. Remove the transaxle fluid cooler lines from the transaxle.
39. Remove the engine harness clip nut from the engine stud.
40. Remove the engine harness clip from the stud.
41. If equipped with an automatic transaxle, disconnect the engine harness electrical connector from the Vehicle Speed Sensor (VSS).
42. Remove the engine harness clip from the speed sensor.
43. Remove the positive battery cable lead nut from the starter solenoid.
44. Remove the positive battery cable terminal from the starter.
45. Remove the engine harness terminal from the starter.
46. Remove the engine harness to starter solenoid "S" terminal nut.
47. Remove the engine harness lead terminals from the starter solenoid.
48. Lower the vehicle.
49. If equipped with an automatic transaxle, disconnect the engine harness from the transaxle.
50. If equipped with an automatic transaxle, perform the following steps:
    1. Disconnect the engine harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
    2. Remove the Heated Oxygen Sensor (HO2S) Connector Position Assurance (CPA) retainers.
    3. Disconnect the engine harness electrical connectors from the HO2S.
    4. Remove the HO2S connector clips from the thermostat housing and engine bracket.
    5. Disconnect the engine harness electrical connector from the park neutral position switch.
51. If equipped with a manual transaxle:
    1. Disconnect the engine harness electrical connector from the VSS.
    2. Disconnect the engine harness electrical connector from the back up lamp switch.
    3. Remove the HO2S CPA retainers.
    4. Disconnect the engine harness electrical connectors from the HO2S.
    5. Remove the HO2S clips from the engine brackets.
    6. Gather all engine harness branches and reposition the harness off to the side, out of the way.
52. If equipped with an automatic transaxle:
    1. Disconnect the range selector lever cable from the transaxle lever.
    2. Remove the range selector lever cable from the transaxle bracket.
53. If equipped with a manual transaxle:
    1. Disconnect the range selector and shift lever cables from the transaxle levers.
    2. Remove the range selector and shift lever cables from the transaxle bracket.
54. Remove the catalytic converter.
55. Lower the vehicle.
56. Insert blocks of wood between the powertrain and the frame, in order to support the powertrain.
57. Remove the engine mount.
58. Remove the transaxle mount to transaxle bolts.
59. Raise the vehicle.
60. Disconnect the control links from the stabilizer bar.
61. Disconnect the outer tie rod ends from the steering knuckles.
62. Disconnect the intermediate shaft from the steering gear.
63. Disconnect the lower control arms from the steering knuckles.
64. Using a paint pen or magic marker, mark the frame to body position.
65. Lower the vehicle to about 3 feet off the ground.
66. Position a engine lift table under the frame.
67. Place wood blocks on top of the lift table between the table and the frame.
68. Lower the vehicle until the frame is resting on the blocks of wood.
69. Slowly loosen/remove the frame bolts using the following sequence:
    1. Loosen/remove the front frame bolts.
    2. Loosen/remove the rear frame bolts.
70. Slowly raise the vehicle away from the powertrain assembly.
71. Slide the lift table out from under the vehicle.
72. Attach the engine lift hoist to the engine lift hooks.
73. Remove the starter bolts and starter.
74. If equipped with an automatic transaxle:
    1. Remove the torque converter housing access plug.
    2. Remove the torque converter bolts.
75. Remove the transaxle brace bolts and brace.
76. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.
77. If equipped with an automatic transaxle, remove the transaxle to engine bolts/stud.
78. Separate the engine from the transaxle.
79. If equipped with a manual transaxle, remove the clutch pressure plate and disc.
80. Remove the following components:
    
    
    The engine mount bracket

    The engine block heater

    The alternator
81. Using an engine hoist, install the engine onto an engine stand.

To install:

1. Using an engine hoist, remove the engine from the engine stand.
2. Install the following components:
   
   
   The engine mount bracket

   The engine block heater

   The alternator
3. If equipped with a manual transaxle, install the clutch pressure plate and disc.
4. Install the engine to the transaxle.
5. If equipped with an automatic transaxle, install the transaxle to engine bolts/stud. Tighten the bolts/stud to 55 ft. lbs. (75 Nm).
6. If equipped with a manual transaxle, install the transaxle to engine bolts/stud. Tighten the bolts/stud to 55 ft. lbs. (75 Nm).
7. Install the transaxle brace and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
8. If equipped with an automatic transaxle:
   1. Install the torque converter bolts. Tighten the bolts to 46 ft. lbs. (62 Nm).
   2. Install the torque converter housing access plug.
9. Install the starter and bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
10. Remove the engine lift hoist from the engine lift hooks.
11. Slide the lift table under the vehicle.
12. Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
13. Tighten/install the frame bolts. Tighten the bolts to 74 ft. lbs. (100 Nm) plus and additional 180°.
14. Raise the vehicle until the lift table can be removed from under the vehicle.
15. Remove the lift table.
16. Install the transaxle fluid cooler lines to the transaxle.
17. Install the transaxle fluid cooler bracket nut. Tighten the nut to 62 inch lbs. (7 Nm).
18. Connect the lower control arms to the steering knuckles.
19. Connect the intermediate shaft to the steering gear.
20. Connect the outer tie rod ends to the steering knuckles.
21. Connect the control links to the stabilizer bar.
22. Lower the vehicle.
23. Install the transaxle mount to transaxle bolts. Tighten the bolts to 33 ft. lbs. (45 Nm).
24. Install the engine mount.
25. Remove the blocks of wood from between the powertrain and the frame.
26. Install the catalytic converter.
27. Lower the vehicle.
    
    NOTE

    Ensure that the black cable is installed in the top notch of the transaxle bracket and the white cable is installed in the bottom notch of the transaxle bracket.
28. If equipped with a manual transaxle:
    1. Install the range selector and shift lever cables to the transaxle bracket.
    2. Connect the range selector and shift lever cables to the transaxle levers.
29. If equipped with an automatic transaxle:
    1. Install the range selector lever cable to the transaxle bracket.
    2. Connect the range selector lever cable to the transaxle lever.
30. Gather all engine harness branches and position the harness over the engine.
31. If equipped with a manual transaxle, perform the following steps:
    1. Install the HO2S clips to the engine brackets.
    2. Connect the engine harness electrical connectors to the HO2S.
    3. Install the HO2S CPA retainers.
32. Connect the engine harness electrical connector to the back up lamp switch.
33. Connect the engine harness electrical connector to the VSS.
34. If equipped with an automatic transaxle, perform the following steps:
    1. Connect the engine harness electrical connector to the park neutral position switch.
    2. Install the engine harness clips to the thermostat housing and engine brackets.
    3. Connect the engine harness electrical connectors to the HO2S.
    4. Install the HO2S CPA retainers.
35. Connect the ECT sensor electrical connector.
36. If equipped with an automatic transaxle, connect the engine harness to the transaxle.
37. Raise the vehicle.
38. Install the engine harness lead terminal to the starter solenoid.
39. Install the engine harness to starter solenoid "S" terminal nut. Tighten the nut to 27 inch lbs. (3 Nm).
40. Install the engine harness terminal to the starter.
41. Install the positive battery cable terminal to the starter.
42. Install the positive/negative battery cable lead nut to the starter solenoid. Tighten the nut to 13 ft. lbs. (17 Nm).
43. Install the engine harness clip to the speed sensor.
44. Connect the engine harness electrical connector to the VSS.
45. Install the engine harness clip to the stud.
46. Install the engine harness clip nut to the engine stud. Tighten the nut to 37 ft. lbs. (50 Nm).
47. Lower the vehicle.
48. Reposition and install the A/C compressor. Tighten the bolts to 37 ft. lbs. (50 Nm).
49. Connect the engine harness electrical connector to the A/C compressor.
50. Connect the engine harness electrical connector to the A/C pressure switch.
51. Position the engine harness ground terminal to the engine block.
52. Install the engine harness ground bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
53. Connect the EVAP purge solenoid electrical connector.
54. Install the engine harness clip to the EVAP purge solenoid bracket.
55. Connect the following electrical connectors:
    
    
    Knock sensor

    CKP sensor

    Oil pressure sensor
56. Install the negative battery cable ground terminal to the stud.
57. Install the engine harness ground terminal to the stud.
58. Install the negative battery cable ground nut. Tighten the nut to 89 inch lbs. (10 Nm).
59. Install the engine harness clips to the camshaft cover.
60. Connect the intake and exhaust camshaft position actuator electrical connectors.
61. Connect the ignition coils electrical connectors.
62. Connect the engine harness clips to the intake manifold.
63. Connect the engine harness clip to the oil level indicator tube.
64. Connect the following electrical connectors:
    
    
    TAC

    MAP sensor

    Fuel injector harness

    Alternator
65. Install the brake booster vacuum hose to the intake manifold.
66. Position the brake booster vacuum hose clamp at the intake manifold.
67. Install the heater inlet and outlet hoses to the thermostat housing.
68. Position the heater inlet and outlet hose clamps at the thermostat housing.
69. If the vehicle is not equipped with a engine oil cooler, perform the following steps:
    1. Install the surge tank outlet hose to the surge tank.
    2. Position the surge tank outlet hose clamp at the surge tank.
    3. Install the radiator outlet hose to the thermostat cover.
    4. Position the radiator outlet hose clamp at the thermostat cover.
70. If the vehicle is equipped with a engine oil cooler, perform the following steps:
    1. Install the radiator outlet hose to the oil cooler.
    2. Install the radiator outlet hose to the water outlet.
    3. Position the radiator outlet hose clamp at the oil cooler.
    4. Position the radiator outlet hose clamp at the water outlet.
71. Install the radiator inlet hose to the engine.
72. Position the radiator inlet hose clamp at the engine.
73. Connect the cooling fan electrical connector.
74. Install the accessory drive belt.
75. Remove the cooling module from the upper body structure.
76. Fill the cooling system.
77. Check and fill the transaxle fluid as needed.
78. Connect the EVAP line quick connect fitting to the EVAP purge solenoid.
79. Connect the fuel feed line quick connect fitting to the fuel rail.
80. Install the fuel line clips to the engine brackets.
81. Fill the engine with oil.
82. Connect the negative battery cable.
83. Road test the vehicle.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html