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Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove engine from engine stand.
  2. Install and align the engine to the transaxle/frame.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1, 2).

    Tighten 

    Tighten the bolts (3, 4, 5, 6) and studs (1, 2) to 75 N.m (55 lb ft).

  4. Install engine mount to frame nuts.

    Tighten 

    Tighten nuts to 43 N.m (32 lb ft).

  5. Remove engine hoist from engine.
  6. Install the engine flywheel to torque converter bolts.

    Tighten 

    Tighten bolts to 62 N.m (46 lb ft).

  7. Install starter. Refer to STARTER  in Starter.
  8. Position the transaxle table with the powertrain/frame under the vehicle.
    Fig 1: Installing Engine-To-Transaxle Bolts And Studs
    G01485489Courtesy of GENERAL MOTORS CORP.
  9. Lower the vehicle until the frame contacts the transaxle table.
  10. Install the new frame bolts.
  11. Raise and support the vehicle. Refer to VIBRATION DIAGNOSIS AND CORRECTION in General information.
  12. Remove the transaxle table.
    CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
  13. Install the intermediate shaft pinch bolt to steering gear. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT  in Steering Wheel and Column.
  14. Install the drive axles to the transaxle. Refer to AXLE SHAFT  in Drive Axle.
  15. Install the transaxle cooler lines and bracket to the transaxle. Refer to AUTOMATIC TRANSMISSION OIL COOLER HOSE REPLACEMENT  in Automatic Transaxle - 4T65-E.
  16. Install A/C compressor and bolts.
  17. Install the lower ball joints to the knuckles. Refer to LOWER BALL JOINT REPLACEMENT  in Front Suspension.
  18. Install the tie rod ends to the steering knuckles. Refer to STEERING KNUCKLE REPLACEMENT  in Front Suspension.
  19. Install the stabilizer shaft links to the lower control arms. Refer to STABILIZER SHAFT LINK REPLACEMENT  in Front Suspension.
  20. Install the engine splash shields. Refer to SPLASH SHIELD REPLACEMENT - ENGINE  in Body Front End.
  21. Install lower radiator baffle.
  22. Install the front tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION  in Tires and Wheels.
  23. Install the three-way catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT  in Engine Exhaust.
  24. Install the lower engine wiring harness to engine and transmission.
  25. Install rear propshaft. Refer to PROPELLER SHAFT REPLACEMENT  in Driveline/Axle.
  26. Lower the vehicle.
  27. Install the automatic transaxle range selector cable. Refer to AUTOMATIC TRANSMISSION RANGE SELECTOR CABLE REPLACEMENT  in Automatic Transaxle - 4T65-E.
    Fig 2: Installing Engine Hoist To Engine
    G01485490Courtesy of GENERAL MOTORS CORP.
  28. Install the vacuum brake booster hose.
  29. Install the vacuum hoses to the engine. Refer to VACUUM DIAGRAMS  in Vacuum Diagrams in Engine Performance.
  30. Install the upper engine wiring harness to engine and transmission.
  31. Install the fuel lines at quick connects. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  32. Install the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - LEFT   and ENGINE MOUNT STRUT REPLACEMENT - RIGHT   . 
  33. Connect the heater hoses to the engine. Refer to HEATING, VENTILATION AND AIR CONDITIONING  or HEATING, VENTILATION AND AIR CONDITIONING  and HEATING, VENTILATION AND AIR CONDITIONING  or HEATING, VENTILATION AND AIR CONDITIONING  in HVAC Systems - Manual.
  34. Connect the radiator hoses to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET  and RADIATOR HOSE REPLACEMENT - OUTLET  in Engine Cooling.
    CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  35. Install the NEW accelerator control cable to the engine. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  36. Install the cruise control cable to the engine. Refer to CRUISE CONTROL CABLE REPLACEMENT  in Cruise Control.
  37. Install the throttle body air inlet duct. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
  38. Fill the cooling system with engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM  in Engine Cooling.
  39. Adjust the transaxle fluid level. Refer to the following information:
  40. Fill the engine with oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT   . 
  41. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE  in Battery.
  42. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE  in Self-Diagnostics in Engine Performance.
  43. Inspect for proper fluid levels and possible fluid leaks.
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