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Home >> Pontiac >> 2001 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 560 (Engine Mechanical - 2.2L) >> Removal And Installation >> In-Vehicle >> Engine Replacement >> Installation
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Engine Replacement: Installation

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. With powertrain supported on jacking table, raise powertrain into position.
    NOTE: If radiator assembly is not properly positioned to cradle, damage could occur.
  2. Raise powertrain assembly into position. Align lower radiator alignment pins with cradle assembly. Be sure all hoses and electrical harnesses are correctly routed and free from the loading path of powertrain assembly.
  3. Raise transaxle into vehicle to align input shaft to the center of clutch. Guide transaxle into position, rotate back and forth to align input shaft splines to clutch disc. (M/T Only)
    Fig 1: Raising Powertrain Assembly Into Position
    G01039302Courtesy of GENERAL MOTORS CORP.
    NOTE: Body-to-cradle bolts are a one time use fastener and should be discarded after removal.
  4. Position cradle guide pins into location and install new cradle-to-body bolts.

    Torque: 

    Frame-to-Body Bolts: 155 N.m (114 ft-lbs) 

  5. Lower vehicle.
  6. Install right-hand (RH) engine mount-to-engine bracket bolts.

    Torque: 

    Engine Mount-to-Engine Bracket Bolts: 50 N.m (37 ft-lbs) 

  7. Install RH engine mount assembly and nuts.

    Torque: 

    Engine Mount-to-Engine Body Nuts: 110 N.m (81 ft-lbs) 

    Fig 2: Installing RH Engine Mount Assembly And Nuts
    G01039303Courtesy of GENERAL MOTORS CORP.
  8. Install left-hand (LH) transaxle mount to transaxle bolts.

    Torque: 

    Left-Hand (LH) transaxle Mount-to-Engine Bracket Bolts: 50 N.m (37 ft-lbs) 

    Fig 3: Installing Left-Hand (LH) Transaxle Mount To Transaxle Bolts
    G01039304Courtesy of GENERAL MOTORS CORP.
  9. Raise vehicle.
  10. Remove wood blocks between cradle and powertrain.
    NOTE: Care should be used to avoid damaging transaxle and bearing races when axles are seated.
  11. Swing axle shafts into position and fully seat axles into transaxle.
  12. Position strut assemblies onto lower control arms.
  13. Install lower control arm nut.

    Torque: 

    Lower Control Arm-to-Knuckle Nut: 10 N.m (89 in-lbs)+150° 

  14. Verify axles are fully seated.
  15. Position stabilizer link into position and install nut.
  16. Install stabilizer nut.

    Torque: 

    Stabilizer Link to Strut: 65 N.m (48 ft-lbs) 

  17. Install tie rod end into strut knuckle assembly.

    Torque: 

    Tie Rod to Knuckle Assembly: 50 N.m (37 ft-lbs) 

    Fig 4: Installing Tie Rod End Into Strut Knuckle Assembly
    G01039305Courtesy of GENERAL MOTORS CORP.
  18. Install steering shaft-to-intermediate shaft.
    Fig 5: Installing Steering Shaft-To-Intermediate Shaft
    G01039306Courtesy of GENERAL MOTORS CORP.
  19. Install steering shaft-to-intermediate shaft bolt.

    Torque: 

    Steering Shaft-to-Rack Bolt: 34 N.m (25 ft-lbs) 

  20. Install propshaft into position. Hand-tighten center bearing nuts - AWD Only.
  21. Install propshaft into position - AWD Only.
  22. Install propshaft-to-PTU bolts - AWD Only.

    Torque: 

    Propshaft-to-PTU Bolts: 25 N.m (19 ft-lbs) 

  23. Install propshaft into rear axle assembly - AWD Only.
  24. Install propshaft to rear module bolts - AWD Only.

    Torque: 

    Propshaft-to-Rear Module Bolts: 50 N.m (37 ft-lbs) 

  25. Tighten propshaft support bearing bolts - AWD Only.

    Torque: 

    Propshaft Support Bearing Bolts: 25 N.m (19 ft-lbs) 

  26. Install propshaft support strap - AWD Only.

    Torque: 

    Propshaft Guard Strap: 25 N.m (19 ft-lbs) 

  27. Connect transaxle lines to transaxle.

    Torque: 

    Transaxle Cooler Lines-to-Transaxle Stud: 20 N.m (15 ft-lbs) (Automatic Only) 

    Torque: 

    Transaxle Cooler Lines-to-Transaxle Nut: 10 N.m (7 ft-lbs) (Automatic Only) 

    Fig 6: Connecting Transaxle Lines To Transaxle
    G01039307Courtesy of GENERAL MOTORS CORP.
  28. Install gasket and down pipe to intermediate pipe assembly.
  29. Hand-tighten nuts.
  30. Install gasket and down pipe to exhaust manifold.

    Torque: 

    Down Pipe-to-Exhaust Manifold Nuts: 30 N.m (22 ft-lbs) 

    Torque: 

    Down Pipe-to-Intermediate Pipe Nuts: 50 N.m (37 ft-lbs) 

  31. Route O2 harness into position at heat shield.
  32. Install A/C compressor to engine block.

    Torque: 

    A/C Compressor-to-Block Bolt: 25 N.m (18 ft-lbs) 

  33. Connect A/C compressor harness to compressor.
  34. Connect A/C pressure transducer to sensor.
    Fig 7: Installing A/C Compressor To Engine Block
    G01039308Courtesy of GENERAL MOTORS CORP.
  35. Install route belt around alternator and A/C compressor.
  36. Install Accessory Drive Belt tool J39914 onto tensioner and unload spring tension from tensioner while positioning belt.
    Fig 8: Installing Accessory Drive Belt Tool
    G01039309Courtesy of GENERAL MOTORS CORP.
  37. Release tensioner and remove tool.
  38. Attach front air deflector to cradle assembly.
  39. Route and install sifter cable into bracket.
  40. Install right engine inner splash shield.
  41. Install right wheel and hand-tighten wheel nuts.
  42. Install left-hand (LH) inner splash shield.
  43. Install left wheel and hand-tighten wheel nuts.
  44. Lower vehicle.

    Torque: 

    Wheel Nuts: 125 N.m (92 ft-lbs) 

  45. Connect shifter cable to transaxle range switch. Adjustment is required (Automatic Only). Refer to REMOVAL & INSTALLATION - A/T (VT25-E) and/or REMOVAL & INSTALLATION - A/T (AF33-5) .
  46. Connect clutch hydraulic line to actuator cylinder by inserting and pushing in C-clip until it stops. (M/T Only)
  47. Connect shift cables into shift cable bracket. (M/T Only)
  48. Connect shift cable ends to transaxle. (M/T Only)
  49. Connect heater hoses to heater core at front of dash.
  50. Connect purge hose at purge solenoid.
  51. Connect fuel transfer line to quick connect to fuel line.
  52. Connect surge hose at bottom of surge tank.
  53. Connect de-gas hose at surge tank.
    Fig 9: Connecting Clutch Hydraulic Line To Actuator Cylinder
    G01039310Courtesy of GENERAL MOTORS CORP.
  54. Connect lower radiator hose at coolant pipe.
  55. Connect upper radiator hose at engine cylinder head.
  56. Cut radiator support straps and remove.
    Fig 10: Connecting Upper Radiator Hose At Engine Cylinder Head
    G01039311Courtesy of GENERAL MOTORS CORP.
  57. Install headlamp assemblies and torque bolts.
  58. Route engine ground under A/C line.
  59. Install engine ground-to-body bolt.

    Torque: 

    Engine Ground-to-Body Bolt: 20 N.m (15 ft-lbs) 

  60. Install under hood fuse block (UHFB) and battery tray.
  61. Install UHFB and battery tray bolts.

    Torque: 

    Battery Tray Bolts: 16 N.m (11 ft-lbs) 

  62. Route engine harnesses into position and install main engine and body harness connectors into UHFB housing.
    Fig 11: Installing Bracket And Bolts
    G01039312Courtesy of GENERAL MOTORS CORP.
  63. Snap connectors into position in UHFB.
  64. Connect both electrical connectors underneath UHFB.

    IMPORTANT:  Make sure engine and body harnesses are properly positioned to avoid damage to harness.

    Fig 12: Installing Underhood Fuse Box
    G01039313Courtesy of GENERAL MOTORS CORP.
  65. Install UHFB while aligning UHFB with connectors.
  66. Snap UHFB into position.
  67. Tighten UHFB connector bolts.

    Torque: 

    UHFB Connector Bolts: 4 N.m (35 in-lbs) 

  68. Install battery and electronic power steering (EPS) feed wire to UHFB stud and tighten nut.

    Torque: 

    Battery Positive-to-UHFB Stud: 10 N.m (89 in-lbs) 

  69. Install UHFB fuse cover into position.
  70. Connect electrical connectors to TCM (if equipped).
  71. Install battery cable and harness attachment clips on side of battery tray/UHFB bracket assembly.
  72. Install battery and cover.
  73. Install brake vacuum hose into booster.
  74. Connect rear O2 sensor connector.
  75. Secure rear O2 sensor to body clips (near air cleaner assembly).
  76. Remove shop towel from throttle body opening.
  77. Position outlet resonator/duct assembly into position.
    Fig 13: Installing Outlet Resonator/Duct Assembly
    G01039314Courtesy of GENERAL MOTORS CORP.
  78. Connect PCV fresh air vent hose assembly.
  79. Tighten clamp at throttle body assembly.
  80. Position outlet resonator/duct assembly up with support bracket and install pushpin.
  81. Tighten clamp at air cleaner assembly.
  82. Connect intake air temperature (IAT) sensor connector.
  83. Connect negative battery cable.

    Torque: 

    Battery Terminal Bolt: 17 N.m (13 ft-lbs) 

    NOTE: All entrapped air must be purged from the powertrain cooling system before final coolant level can be determined. Proper coolant level is critical to avoid engine damage.
  84. Fill coolant system.
  85. Start engine and fill automatic transaxle fluid.
  86. Check for leaks.
  87. If excessive engine idle vibration is noticed, mount adjustment procedure can be performed.
  88. Verify wheel alignment is within specifications.
    Fig 14: Connecting Surge Hose At Bottom Of Surge Tank
    G01039315Courtesy of GENERAL MOTORS CORP.
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