Engine Replacement

Engine Replacement

Removal Procedure
1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable.
3. Remove the air cleaner assembly.





4. Secure the cooling module to the upper body structure.
5. Remove the battery and battery tray.
6. Disconnect the transmission shifter cable.
7. Disconnect the wiring harness from the underhood junction block.
8. Evacuate the A/C system.
9. Drain the cooling system.
10. Remove the powertrain control module (PCM).
11. Remove the A/C low pressure tube at the front lift bracket.
12. Disconnect the generator positive cable.
13. Disconnect the A/C high pressure switch harness.
14. Remove the A/C tube from the A/C compressor.
15. Disconnect the A/C line from the condenser to compressor.
16. Disconnect the coolant reservoir hose from the engine to reservoir.





17. Disconnect the radiator inlet and outlet hoses from the engine.





18. Remove the inlet and outlet heater hoses (1, 2).
19. Remove the starter positive cable.
20. Relieve the fuel pressure.
21. Disconnect the fuel feed line.
22. Disconnect the fuel EVAP line.
23. Raise and support the vehicle. Refer to Vehicle Lifting.
24. Remove the lower transaxle-to-engine bolts.
25. Remove the PTU.
26. Remove the torque convertor inspection cover.
27. Remove the torque convertor to flywheel bolts.
28. Remove the front wheels.
29. Remove the left wheelhouse liner.
30. Disconnect the transmission cooler lines from the transmission and bracket.
31. Remove the left and right tie rod ends from the steering knuckles.
32. Remove the left and right stabilizer bar links.
33. Disconnect the left and right lower ball joints.
34. Remove the left and right axle shaft nuts.





35. For AWD, remove the propeller shaft completely from the vehicle.

36. Important: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

Disconnect the intermediate shaft from the steering gear.
37. Remove the front exhaust pipe.
38. Remove the 3 front fender pushpins to allow the front fender to flex.
39. Use a paint pen or magic marker to mark the frame to the body position.
40. Support the engine in the cradle with wood blocks.
41. Disconnect the front engine mount from the body.

42. Important: During the powertrain removal, support the vehicle body by placing a jack at the rear of the vehicle.

Position the engine support table under the powertrain assembly.
43. With the table positioned, fully raise the table to contact with the powertrain assembly.
44. Remove the cradle bolts.
45. Slowly lower the table to the floor.





46. Remove the starter.
47. Remove the following components:
1 Remove the A/C compressor.
2 Remove the generator.
3 Remove the front covers.
4 Remove the rocker covers.
5 Remove the catalytic converters.
6 Remove the timing belt.
7 Remove the cylinder heads.
48. Remove the front engine mount from the engine.
49. Remove the right engine mount.
50. Separate the engine from the transmission.

Installation Procedure
1. Align the engine to the transmission.





2. Notice: Refer to Fastener Notice in Service Precautions.

Apply sealant Saturn P/N 21485277 (GM P/N 12345382) or equivalent, to the two upper transmission-to-engine bolts only, and install the transmission-to-engine mounting bolts.
Tighten the bolts to 64 Nm (47 ft. lbs.).
3. Install the right engine mount.
4. Install the front engine mount to the engine.
5. Install the following components:
1 Install the cylinder heads.
2 Install the timing belt.
3 Install the catalytic converters.
4 Install the rocker covers.
5 Install the front covers.
6 Install the generator.
7 Install the A/C compressor.





6. Install the starter.
7. Install the powertrain assembly to the vehicle.
8. Install the cradle bolts.
9. Remove the engine support table.
10. Install the front engine mount bolts to the body.
11. Remove the wood blocks from the cradle.
12. Install the lower transaxle-to-engine bolts.
Tighten the bolts to 64 Nm (47 ft. lbs.).
13. Install the PTU.
14. Install the torque convertor- to- flywheel bolts.
Tighten the bolts to 12 Nm (9 ft. lbs.).
15. Install the torque convertor inspection cover.
Tighten the bolts to 12 Nm (9 ft. lbs.).
16. Install the 3 front fender pushpins
17. Install the front exhaust pipe.
18. Connect the intermediate shaft from the steering gear.
19. Install the propeller shaft.
20. Install the left and right axle shaft nuts.
21. Connect the left and right lower ball joints.
22. Install the left and right stabilizer bar links.
23. Install the left and right tie rod ends to the steering knuckles.
24. Connect the transmission cooler lines to the transmission and bracket.
25. Install the left wheelhouse liner.
26. Install the front tires.
27. Lower the vehicle.





28. Install the fuel EVAP line.
29. Connect the fuel feed line.
30. Install the starter positive cable.
Tighten the starter cable to 10 Nm (89 inch lbs.).
31. Install the inlet and outlet heater hoses.
32. Connect the inlet and outlet radiator hoses to the engine.
33. Install the A/C tube to the A/C compressor.
34. Connect the coolant reservoir hose from the engine to reservoir.
35. Connect the A/C line from the condenser to compressor.
36. Connect the A/C high pressure switch harness.
37. Connect the generator positive cable and nut.
Tighten the nut to 12 Nm (106 inch lbs.).
38. Install the A/C lower pressure tube at the front lift bracket.
39. Install the PCM.





40. Connect the radiator inlet and outlet hoses to the engine.
41. Fill the vehicle with coolant.
42. Connect the wiring harness to the underhood junction block.
43. Connect the transmission shifter cable.





44. Remove the cooling module support.
45. Install the battery tray and battery.
46. Install the air cleaner assembly.
47. Install the air outlet duct assembly.
48. Connect the negative battery cable.