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Home › Pontiac › 2002 › Aztek AWD › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine Mechanical (On-Vehicle) › Repair Instructions › Engine Replacement › Installation Procedure

Installation Procedure

  1. Remove engine from engine stand.
  2. Install and align the engine to the transaxle/frame.
    Fig 1: Attaching And Installing Engine To Transaxle/Frame
    G01747469Courtesy of GENERAL MOTORS CORP.
  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 ft. lbs.).

  4. Install engine mount to frame nuts.

    Tighten 

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

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

    Tighten 

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

  7. Install starter.
  8. Position the transaxle table with the powertrain/frame under the vehicle.
    Fig 2: Transaxle Table
    G01747470Courtesy 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.
  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.
  14. Install the drive axles to the transaxle.
  15. Install the transaxle cooler lines and bracket to the transaxle.
  16. Install A/C compressor and bolts.
  17. Install the lower ball joints to the knuckles.
  18. Install the tie rod ends to the steering knuckles.
  19. Install the stabilizer shaft links to the lower control arms.
  20. Install the engine splash shields.
  21. Install lower radiator baffle.
  22. Install the front tires and wheels.
  23. Install the three-way catalytic converter.
  24. Install the lower engine wiring harness to engine and transmission.
  25. Install rear propeller shaft. (AWD Only)
  26. Lower the vehicle.
  27. Install the automatic transaxle range selector cable.
  28. Install the vacuum brake booster hose.
  29. Install the vacuum hoses to the engine
  30. Install the upper engine wiring harness to engine and transmission.
  31. Install the fuel lines at quick connects.
  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.
  34. Connect the radiator hoses to the engine.
    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.
  36. Install the cruise control cable to the engine.
  37. Install the throttle body air inlet duct.
  38. Fill the cooling system with engine coolant.
  39. Adjust the transaxle fluid level.
  40. Fill the engine with oil.
  41. Connect the negative battery cable.
  42. Perform the CKP system variation learn procedure.
  43. Inspect for proper fluid levels and possible fluid leaks.
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