Engine Replacement. Chevrolet Joy 2008

For 1990-2009 cars

#### Tools Required

EN-47935 (DW110-040) Engine and Transaxle Assembly Support Remover/Installer

### Removal Procedure

Caution: Refer to Breathing R-134a Caution in the Preface section.

1. Discharge the air conditioning (A/C) system, if equipped.
2. Drain the power steering oil, if equipped.
3. Relieve the fuel system pressure. Refer to Fuel System Diagnosis for the 0.8L engine.

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

4. Disconnect the negative battery cable.
5. Remove the air filter, resonator with snorkel assembly (1). Refer to Air Cleaner Element Replacement for the 0.8L engine.
6. Remove the engine ignition system ignition coil, if equipped.
7. Disconnect the radiator lower hose (2) and drain the coolant. Refer to Cooling System Draining and Filling .
8. Disconnect the fuel line inlet hose and the fuel injector wire connectors from the fuel rail (3).
9. Disconnect the throttle cable (4).
10. Disconnect the manifold absolute pressure (MAP) sensor connector (3).
11. Disconnect the canister solenoid connector (3).
12. Disconnect the brake booster vacuum hose (5).
13. Disconnect the MAP sensor vacuum hose (2).
14. Disconnect the evaporative emission (EVAP) canister vacuum hose.
15. Disconnect the intake air temperature (IAT) sensor connector.
16. Remove the distributor. Refer to Distributor Replacement for the 0.8L engine.
17. Disconnect the engine coolant temperature (ECT) sensor connector (2).
18. Disconnect the coolant temperature sensor connector (1).
19. Disconnect the oxygen sensor connector (3).
20. Disconnect the idle air control (IAC) valve connector (4).
21. Disconnect the throttle position (TP) sensor connector (5).
22. Disconnect the camshaft position (CMP) sensor connector and crankshaft position (CKP) sensor connector.
23. Disconnect the heat core inlet hose.
24. Disconnect the throttle body coolant outlet hose.
25. Remove the power steering fluid reservoir (1), if equipped. Refer to Power Steering Fluid Reservoir Replacement .
26. Remove the coolant surge tank (2).
27. Disconnect the coolant fan electrical connector (3).
28. Loosen the coolant fan bolts (2).
29. Take out the coolant fan assembly as shown in the picture (1).
30. Disconnect and remove the radiator upper hose (1).
31. Disconnect and remove the radiator surge tank hose (2).
32. Disconnect and remove the radiator lower hose (3).
33. Loosen the radiator bolts (2).
34. Remove the radiator mounting brackets (1).
35. Take out the radiator as shown in the picture (3).
36. If equipped with the air conditioning (A/C) system and the power steering, disconnect the connectors, the pipes, and the hoses.
37. Disconnect the power steering pressure sensor connector (3).
38. Disconnect the hose from the power steering pump (2).
39. Disconnect the pipe from the power steering pump (1).
40. Disconnect the air conditioning low and high pressure pipes (4).
41. Disconnect the power steering hose.
42. Remove the select and shift cable pin (2).
43. Remove the select and shift washer (3).
44. Disconnect the select and shift cable (4).
45. Remove the E-ring (1).
46. Remove the engine electrical wire bending strap.
47. Loosen the transaxle case ground connection line bolt (2).
48. Disconnect the transaxle case ground connection line (1).
49. Disconnect the backup lamp switch electrical connector (3).
50. Remove the transaxle under cover bolts (2).
51. Remove the transaxle under cover (1).
52. Remove the transaxle oil drain plug and drain oil.
53. Loosen the clutch cable adjusting nut (3).
54. Disconnect the clutch cable from the wire clip (1).
55. Disconnect the clutch cable from the transaxle mount hole (2).
56. Loosen the speedometer cable nut (1).
57. Disconnect the speedometer cable (2).
58. If equipped, disconnect the vehicle speed sensor electrical connector.
59. Loosen the front exhaust pipe nuts (1).
60. Remove the gasket and disconnect the pipe (4).
61. Loosen the nuts (3).
62. Remove the front exhaust pipe (2).
63. Disconnect the oil pressure switch electrical connector (3).
64. Disconnect the generator B+ terminal (1).
65. Disconnect the generator electrical connector (5).
66. Disconnect the starter electrical connector (2).
67. Disconnect the electrical wire strap (4).
68. Disconnect the surge tank coolant return hose (1) and the heater outlet hose (2).
69. Remove both of the front wheels. Refer to Tire and Wheel Removal and Installation .
70. Remove the control arm (1) and the tie rod end (2). Refer to Control Arm Replacement .
71. Remove the left and right front longitudinal member (2) and stabilizer bar (1). Refer to Stabilizer Shaft Replacement .
72. Loosen the caulking nut. Refer to Wheel Hub, Bearing, Knuckle, and Seal Replacement .

Notice: When removing the drive axle, use extreme care not to nick or cut the drive axle oil seal.

73. Remove the wheel side drive axle (1).
74. Insert a driver between the transaxle case and the drive axle joint case (2).
75. Remove the differential side drive axle, as shown (3).
76. Remove the damping bush assembly bolt and nut (1).
77. Remove the engine mount front bracket (2) and the damping bush assembly (3).
78. Remove the right (1) and left (2) crossmember. Refer to Front Suspension Crossmember Replacement .

Important: Before loosening the engine mount intermediate bracket nut, oil pan should be supported by the EN-47935 .

79. Loosen the engine mount intermediate bracket nut (1).
80. Support the oil pan with the EN-47935 .

Loosen the bolt and nut from the engine mount lower bracket (1).

81. Loosen the bolt from the body bracket (2).
82. Remove the engine mount reaction rod (3).
83. Loosen the transaxle mount bolts (1) and remove the mount.
84. Remove the engine and transaxle assembly (1) by slowly lowering the special tool (2).
85. Remove the transaxle from the engine/transaxle assembly. Refer to Transmission Replacement for the Y4M transmission.
86. Remove some parts to be equipped with the engine assembly. Refer to Cylinder Head Disassemble .

### Installation Procedure

1. Install the transaxle to the engine assembly. Refer to Transmission Replacement for the Y4M transmission.
2. Place the engine and transaxle assembly on the EN-47935 making sure that the assembly is properly supported.
3. Install the engine and transaxle assembly in to the vehicle by slowly raising the EN-47935 .

Notice: Refer to Fastener Notice in the Preface section.

4. Install the transaxle mount and bolts (1).

Tighten
Tighten the transaxle mount bolt(s) to 45-55 N·m (33-41 lb ft).

5. Install the engine mount reaction rod (2, 3).

Tighten
Tighten the lower bracket side reaction rod bolt and nut to 68-83 N·m (50-61 lb ft).

6. Install the engine mount intermediate bracket and nuts (1, 2).

Tighten
Tighten the engine mount intermediate bracket upper nut to 60-70 N·m (44-52 lb ft).

7. Install the crossmember and bolts (1, 2).

Tighten
Tighten the crossmember rear side bolts to 17-27 N·m (13-20 lb ft).

8. Install the engine mount front bracket and bolt (1).

Tighten
Tighten the engine block side front bracket bolt to 35-41 N·m (25-30 lb ft).

9. Install the damping front bush assembly and bolts (1, 2, 3).

Tighten

• | Tighten the crossmember side front damping bush bolt to 35-41 N·m (25-30 lb ft).

• | Tighten the crossmember side two front damping bush bolts to 45-55 N·m (33-41 lb ft).

• | Tighten the front damping bush bolt and nut to 68-83 N·m (50-62 lb ft).

Notice: When removing the drive axle, use extreme care not to nick or cut the drive axle oil seal.

10. Install the differential side drive axle.
11. Install the wheel side drive axle.
12. Install the caulking nut.
13. Install the stabilizer bar.

Tighten

• | Tighten the stabilizer bar castellated nut to 40-50 N·m (30-36 lb ft).

• | Tighten the stabilizer bar mounting bolt to 33-53 N·m (24-39 lb ft).

14. Install the left and right front longitudinal member.

Tighten

• | Tighten the front longitudinal member bolt to 10-14 N·m (7-10.5 lb ft).

• | Tighten the front longitudinal member nut to 60-80 N·m (44-59 lb ft).

15. Install the control arm and stud nut (2).

Tighten
Tighten the control arm stud to 50-70 N·m (36-52 lb ft).

16. Install the tie rod end and castellated nut (1).

Tighten
Tighten the tie rod end castellated nut to 35-55 N·m (25-41 lb ft).

17. Install both of the front wheels. Refer to Tire and Wheel Removal and Installation .
18. Connect the surge tank coolant return hose (1) and heater outlet hose (2).
19. Connect the generator B+ terminal (1).
20. Connect the starter electrical connector (2).
21. Connect oil pressure switch electrical connector (3).
22. Connect the electrical wire strap (4).
23. Connect the generator electrical connector (5).
24. Install the front exhaust pipe, gasket, and bolts.

Tighten

• | Tighten the front exhaust pipe nuts (1), exhaust manifold side to 25-35 N·m (18-25 lb ft).

• | Tighten the front exhaust pipe nuts (2), muffler pipe side to 25-35 N·m (18-25 lb ft).

25. Connect the speedometer cable and vehicle speed sensor electrical connector, if equipped.
26. Connect the clutch cable and wire clip (1).
27. Install the transaxle under cover.

Tighten
Tighten the transaxle under-cover bolts (1) to 35-55 N·m (25-41 lb ft).

28. Connect the backup lamp switch electrical connector (3).
29. Connect the transaxle case ground connection line (1) and bolt (2).
30. Install the engine electrical wire-bending strap.
31. Connect the select and shift cable (4).
32. Install the power steering pump pressure pipes and power steering pressure sensor, if equipped.

Tighten

• | Tighten the power steering pump pressure pipe nut (1) to 36-50 N·m (26-36 lb ft).

• | Tighten the power steering pump pressure pipe fitting (2) to 21-35 N·m (15-25 lb ft).

33. Install the air conditioning low and high pressure pipes, if equipped.

Tighten
Tighten the air conditioning low and high pressure pipe bolts (1) to 23 N·m (17 lb ft).

34. Install the radiator (1) and cooling fan (2).

Tighten

• | Tighten the radiator bolt (1, 2) to 4-5 N·m (35-44 lb in).

• | Tighten the cooling fan bolt (3) to 4-5 N·m (35-44 lb in).

35. Install the radiator upper (1), surge tank (2), and lower hose (3).
36. Install the power steering oil tank (1), if equipped.
37. Install the coolant surge tank (2).
38. Connect the coolant temperature sensor connector (1).
39. Connect the ECT sensor connector (2).
40. Connect the oxygen sensor connector (3).
41. Connect the IAC valve connector (4).
42. Connect the TP sensor connector (5).
43. Connect the CMP sensor connector and the CKP sensor connector.
44. Connect the heat core inlet hose.
45. Connect the throttle body coolant outlet hose.
46. Install the distributor. Refer to Distributor Replacement for the 0.8L engine.
47. Install the EVAP canister.
48. Connect the throttle cable (1).
49. Connect the MAP sensor connector (2).
50. Connect the canister solenoid connector (3).
51. Connect the brake booster vacuum hose (4).
52. Connect the MAP sensor vacuum hose (5).
53. Connect the EVAP canister vacuum hose.
54. Connect the IAT sensor connector (6).
55. Connect the fuel line inlet hose and the fuel injector wire connectors on to the fuel rail.
56. Install the air filter, resonator with snorkel assembly. Refer to Air Cleaner Element Replacement for the 0.8L engine.
57. Fill and check the following fluids:

• | Transaxle oil

• | Power steering oil

• | Radiator coolant

58. Connect the negative battery cable.
59. Reset the engine control module (ECM). Refer to Engine Control Module Replacement for the 0.8L engine.
60. Start the engine and check the engine for normal operation.
61. Recharge the air conditioning, if equipped.
62. Verify that all electrical connectors and hoses are properly secured.
63. Check all fluid levels and verify that there are not leaks.