Installation

Engine Replacement

Special Tools
* J-2619-O1 - Slide Hammer
* J-24319-B - Steering Linkage and Tie Rod Puller
* J-29794 - Axle Shaft Remover Extension
* J-33008-A - Axle Shaft Puller
* J-37096 - Flywheel Holder
* J-38185 (SA-9111E) - Hose Clamp Pliers
* J-39580 - Engine Support Table
* J-41820 - Ball Joint Separator
* J-42640 - Steering Column Anti-Rotation Pin
* J-45059 - Angle Meter

Installation Procedure




1. Install an engine hoist to the engine.
2. Remove the engine from the engine stand.
3. Position the flywheel to the crankshaft.
4. Install the flywheel bolts finger tight.
5. Use the J-37096 - Holder in order to hold the flywheel.

Caution: Refer to Fastener Caution Fastener Caution.

6. Tighten the flywheel bolts and tighten to 70 Nm (52 lb ft).




7. Install the engine to the transaxle and the frame.
8. Install the transaxle bolts and studs and tighten to 75 Nm (55 lb ft).
9. Remove the support from the transaxle.
10. Remove the engine hoist from the engine.
11. Install the power steering pressure and return lines to the power steering pump. Refer to Power Steering Gear Inlet Pipe/Hose Replacement Power Steering Gear Inlet Pipe/Hose Replacement.
12. Connect the power steering line retainer at the generator bracket.




13. Place the engine wiring harness on top of the engine and position the harness branches.
14. Install the engine harness clip to the oil pan.




15. Connect the engine harness electrical connector to the oil level sensor.




16. Install the engine harness clips (1) to the transaxle studs.




17. Install the engine harness clamp bolt (1) to the transaxle and tighten to 20 Nm (15 lb ft).




18. Install the engine harness clip (1) to the stud on the transaxle.




19. Connect the engine harness electrical connector (1) to the VSS.




20. Connect the engine harness electrical connector to the transaxle.




21. Connect the engine harness electrical connector (1) to the knock sensor.
22. Connect the engine harness electrical connector (2) to the oil pressure sensor.




23. Connect the engine harness electrical connector (1) to the CKP sensor.




24. Install the engine harness clip (1) to the strut bracket.




25. Connect the engine harness electrical connector (4) to the HO2S.
26. Connect the engine harness electrical connector (3) to the generator.
27. Install the engine harness lead (2) to the generator.
28. Install the generator terminal nut (1) and tighten to 30 Nm (22 lb ft).




29. Connect the engine harness electrical connector (3) to the fuel injector harness electrical connector.
30. Install the CPA retainer (2).
31. Connect the engine harness electrical connector (1) to the intake manifold tuning valve.




32. Install the engine harness clip (1) to the bracket.




33. Install the engine harness bracket (2) to the stud.
34. Install the engine harness bracket nut (1).




35. Connect the engine harness electrical connector to the camshaft actuator magnet.
36. Install the engine harness bolt and tighten to 20 Nm (15 lb ft).




37. Install the engine harness clip to the engine.




38. Install the engine harness clip (1) to the ignition coil bracket.




39. Install the engine harness clip (1) to the ignition coil bracket.




40. Connect the engine harness electrical connector (2) to the ignition coil.
41. Connect the engine harness electrical connector (1) to the MAP sensor.




42. Connect the engine harness electrical connector (2) to the throttle actuator.
43. Connect the engine harness electrical connector (1) to the EVAP purge solenoid.




44. Install the exhaust crossover pipe (2) and nuts (1). Tighten the nuts to 25 Nm (18 lb ft).




45. Install the exhaust crossover pipe shield (2) and bolts (1). Tighten the bolts to 10 Nm (89 lb in).




46. Install the transaxle brace and bolts. Tighten the bolts to 43 Nm (32 lb ft).




47. Install the engine harness clips (1) to the transaxle brace.




48. Install the engine harness clips (1) to the transaxle brace.




49. Install the engine mount to frame nuts and tighten to 47 Nm (35 lb ft).




50. Install the torque converter bolts.
51. Use the J-37096 - Holder in order to hold the flywheel.
52. Tighten the torque converter bolts and tighten to 63 Nm (47 lb ft).




53. Install the torque converter covers (2, 4).
54. Install the torque converter cover bolts (1, 3) and tighten to 10 Nm (89 lb in).




55. Install the starter motor and bolts. Tighten the bolts to 40 Nm (30 lb ft).




56. Install the transaxle brace and bolts. Tighten the bolts to 43 Nm (32 lb ft).




57. Install the negative battery cable to the transaxle stud.
58. Install the engine harness grounds to the studs.
59. Install the engine harness ground nuts (1, 2) to the transaxle studs. Tighten the nuts to 25 Nm (18 lb ft).




60. If necessary perform the following steps, connect the engine harness electrical connector (3) to the starter.
61. Install the engine battery positive wire terminal (2) to the stud.
62. Install the engine battery positive wire nut (1) and tighten to 20 Nm (15 lb ft).




63. Lower the vehicle over the powertrain/frame assembly.
64. Position the frame rear straps (1, 4).
65. Install the frame rear strap bolts (2, 3) and tighten to 50 Nm (37 lb ft).




66. Install the front and rear frame bolts (1, 2).

* Tighten the front bolts to 130 Nm (96 lb ft).
* Tighten the rear bolts to 240 Nm (177 lb ft).




67. Raise the vehicle off of the J-39580 - Table.
68. Remove the J-39580 - Table from under the frame.




69. Connect the intermediate steering shaft to the power steering gear.
70. Install the intermediate steering shaft pinch bolt and tighten to 48 Nm (35 lb ft).
71. Position the intermediate steering shaft seal onto the steering gear.




72. Unsecure the wheel drive shafts from the steering knuckle/struts.
73. Install the wheel drive shafts to the transaxle.
74. Verify that the wheel drive shaft is properly engaged to the transaxle by grasping the inner tripot housing and pulling outward. Do not pull on the wheel drive shaft bar. The wheel drive shaft will remain firmly in place when properly engaged.





Note: Align the ball joint cotter pin hole parallel to the knuckle in order to ease the cotter pin installation.

75. Install the ball joints to the knuckles.
76. Install the ball joint castle nuts.

Note: DO NOT loosen the castle nut in order to align the nut to the cotter pin hole.

77. If necessary, tighten the castle nut in order to align the nut slot (1) to the cotter pin hole (2) as shown.




78. Tighten the lower ball joint castle nuts (1) to 55 Nm (40 lb ft).
79. Install NEW lower ball joint cotter pins (2) to the ball joints.





Note: Ensure that the cotter pin ends do NOT contact the ABS wheel speed sensor, the ABS sensor connector, or the drive axle.

80. Bend the ends of the cotter pin as shown in either example.




81. Install the outer tie rod (2) to the steering knuckle (1).





Note: This is a prevailing torque type fastener. You may reuse this fastener ONLY under the following conditions:

* The fastener and its counterpart are clean and free from rust.
* The fastener develops 2 Nm (18 lb in) of torque/drag against its counterpart prior to fastener seating.

If the fastener does not meet these criteria, REPLACE the fastener.

82. Install the tie rod end nuts (1) at the steering knuckles. Tighten the nuts to 30 Nm (22 lb ft) plus an additional 120 degrees using the J-45059 - Angle Meter.




83. Install the stabilizer shaft links (2) to the stabilizer shaft. (left side shown, right side similar).
84. Install the stabilizer shaft link lower nuts (3) and tighten to 23 Nm (17 lb ft).




85. Install the engine harness clips (1, 2) to the heat shield.
86. Connect the battery cable retainers at the core support.
87. Install the engine splash shield. Refer to Engine Splash Shield Replacement Service and Repair.
88. Install the catalytic converter. Refer to Catalytic Converter Replacement Service and Repair.




89. Position and install the A/C compressor onto the stud.
90. Install the A/C compressor front bolt and nut and tighten to 50 Nm (37 lb ft).




91. Install the A/C compressor rear bolt and tighten to 50 Nm (37 lb ft).
92. Connect the engine harness electrical connectors to the A/C compressor.
93. Install the drive belt. Refer to Drive Belt Replacement Service and Repair.




94. Connect the engine harness electrical connectors (1) to the left and right wheel speed sensors. (right side shown, left side similar).




95. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation Service and Repair.
96. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Right Side Engine Mount Strut Replacement - Right Side and Engine Mount Strut Bracket Replacement - Left Side Engine Mount Strut Bracket Replacement - Left Side.
97. Connect the fuel feed (1) and EVAP (2) line quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.




98. Install the brake booster vacuum hose to the upper intake manifold fitting.




99. Connect the heater inlet (2) and outlet (1) hose quick connect fittings to the inlet and outlet pipes.




100. Install the radiator outlet hose to the thermostat housing.
101. Using the J-38185 (SA9111E) - Pliers , release the radiator outlet hose clamp.




102. Install the radiator inlet hose to the coolant crossover.
103. Using the J-38185 (SA9111E) - Pliers , release the radiator inlet hose clamp.




104. Remove the engine harness wiring branch from on top of the engine.
105. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor.
106. Tighten the air cleaner outlet duct clamps at the throttle body and the MAF/IAT sensor to 2 Nm (18 lb in).
107. Connect the PCV fresh air tube quick connect fitting to the air cleaner outlet duct. Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.
108. Connect the engine harness electrical connector to the MAF/IAT sensor.




109. Install the engine harness connector to the junction block retainer.
110. Install the underhood junction block. Refer to Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement.




111. Install the engine harness clip (1) to the A/C line.




112. Install the engine harness clip (1) to the A/C line.




113. Connect the engine harness electrical connector (6) to the ABS module.
114. Connect the engine harness electrical connector (5) to the I/P harness electrical connector (4).
115. Connect the engine harness electrical connector (3) to the I/P harness electrical connector (2).
116. Connect the engine harness electrical connector (1) to the TCM.




117. Install the ECM to the air cleaner cover.
118. Install the air cleaner cover.
119. Tighten the air cleaner cover bolts to 4 Nm (35 lb in).




120. Install the junction block cover.
121. Install the left side diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement (Chevrolet) Front End Sheet Metal Diagonal Brace Replacement (Chevrolet)Front End Sheet Metal Diagonal Brace Replacement (Pontiac) Front End Sheet Metal Diagonal Brace Replacement (Pontiac).
122. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement Service and Repair.




123. Install the coolant recovery reservoir hose (2) to the crossover.
124. Position the coolant recovery reservoir hose clamp (1) at the coolant crossover.




125. Remove the J-42640 - Pin from the underside of the steering column.
126. Install the lower radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors Radiator Air Baffle Assemblies and Deflectors.
127. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
128. Connect the positive battery cable.
129. Connect the positive battery cable at the junction box.
130. Connect the auxiliary ground cable on the inner fender.
131. Connect the electrical connector to the sensor on the negative battery cable.
132. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill LZ9) Cooling System Draining and Filling (Static Fill LZ9).
133. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.
134. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn Testing and Inspection.




135. Align the cover to the studs on the engine, push down on the cover above the stud in order to engage the cover to the studs.
136. Install the engine oil fill cap.
137. Start the engine listen for unusual noises.
138. Inspect the engine for leaks.