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Engine Installation

WARNING: This page is about a different car, the 2002 Saturn LW300 and 2002 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lower engine into vehicle and guide to mate with dowel pins on transaxle.
    Fig 1: Using Engine Hoist To Install Engine
    G01037334Courtesy of GENERAL MOTORS CORP.
  2. When engine and transaxle are aligned on shuffle pins, install upper bell housing bolts. Do not torque at this time.
  3. Install engine mount bracket onto engine and install bolts.

    Torque: 

    Engine Mount Bracket Bolt: 55 N.m (41 ft-lbs) 

  4. Install right front engine mount and install bolts.

    Torque: 

    Engine Mount-to-Frame Bolt: 55 N.m (41 ft-lbs) 

    Engine Mount-to-Bracket Bolt: 55 N.m (41 ft-lbs) 

  5. Install transaxle nose bracket bolts.

    Torque: 

    Nose Cone Bracket-to-Oil Pan Bolts (Transaxle Nose Bracket Bolts): 40 N.m (30 ft-lbs) 

  6. Remove engine lift hoist.
  7. Attach metal power steering line.
  8. Attach small hose to bottom of power steering reservoir.
  9. Attach power steering reservoir to radiator support.
  10. Install upper radiator hose.
  11. Install lower radiator hose
  12. Attach main coolant reservoir hose to engine.
  13. Raise vehicle.
  14. Install lower engine to transaxle bell housing bolts and torque.

    Torque: 

    Lower Engine-to-Transaxle Bell Housing Bolts: 65 N.m (48 ft-lbs) 

  15. Install torque converter bolts.

    Torque: 

    Torque Converter Bolts: 65 N.m (48 ft-lbs) 

  16. Install starter.
  17. Connect heater hoses at lower cowl.
  18. Install A/C compressor to engine mounting bracket.

    Torque: 

    A/C Compressor Bracket Bolt: 40 N.m (30 ft-lbs) 

  19. Install exhaust down pipes to catalytic converter.
  20. Lower vehicle.
  21. Connect EVAP purge solenoid hose.
  22. Connect fuel lines.
  23. Connect brake booster vacuum hose.
  24. Connect the following electrical connections:
    1. Rear connector on ECM
    2. Transaxle shift control
    3. Transaxle main connector
    4. Transaxle ground
    5. Right front speed sensor
  25. Connect front O2 sensor connector.
  26. Connect right front speed sensor.
  27. Connect EVAP purge solenoid connector.
  28. Torque upper bell housing bolts.

    Torque: 

    Upper Bell Housing Bolts: 65 N.m (48 ft-lbs) 

  29. Install battery tray.
  30. Install fuse block.
    1. Install fuse block mounting bolts.
    2. Route engine harness into block.
    3. Connect lower weather pack connector.
    4. Connect main engine harness under fuse block panel.
    5. Assemble fuse block.
  31. Connect A/C pressure connector.
  32. Connect TCM inline connector near brake master cylinder.
  33. Connect TCM main connector under cowl cover and secure to engine.
  34. Connect positive main feed cable at fuse block.
  35. Connect battery ground cable at wheel housing.
  36. Install battery.
  37. Install intake air cleaner. Refer to "Intake Air Installation" procedure in the Engine Control section of this service manual.
  38. Connect MAF connector.
  39. Add coolant.
  40. Add power steering fluid.
  41. Start engine and check for leaks.
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