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Removal & Installation: Engine: Installation

WARNING: This page is about a different car, the 2003 Saturn Vue and 2002 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: When fuel lines have been disconnected, NEW plastic retainers must be installed.
NOTE: If the radiator assembly is not properly positioned to the cradle, damage could occur.
  1. With the powertrain supported on the jacking table, raise the powertrain into position. Align the lower radiator alignment pins with the cradle assembly. Ensure all the hoses and the electrical harnesses are correctly routed and free from the loading path of the powertrain assembly.
    NOTE: The cradle-to-body bolts are one-time use fasteners and should be discarded after removal.
  2. Position the cradle guide pins into location and install NEW cradle-to-body bolts. Tighten cradle-to-body bolts to specification. See TORQUE SPECIFICATIONS . Lower the vehicle.
  3. Install right motor mount-to-engine bracket bolts. Tighten right motor mount-to-engine bracket bolts to specification. See TORQUE SPECIFICATIONS . Install left transaxle mount-to-transaxle bolts. Tighten left motor mount-to-transaxle bolts to specification. See TORQUE SPECIFICATIONS . Lower the vehicle. Remove the wood blocks between the cradle and the powertrain.
    CAUTION: Care should be used to avoid damaging the transaxle and bearing races when the axles are seated.
  4. Swing the axle shafts into position and fully seat in the transaxle and bearing. Slight taps may be required on the back of the CV axle housing.
  5. Position the strut assemblies onto the lower control arms. Install the lower control arm nut. Verify the axles are fully seated. Position the stabilizer link into position and install the nut. Install the stabilizer nut. Tighten stabilizer link-to-strut nut to specification. See TORQUE SPECIFICATIONS .
  6. Install tie rod end into the strut knuckle assembly. Tighten tie rod-to-knuckle assembly nut to specification. See TORQUE SPECIFICATIONS .
  7. Secure the brake line-to-cradle assembly. Install the steering shaft-to-intermediate shaft. Install steering shaft-to-intermediate shaft bolt. Tighten steering shaft-to-rack bolt to specification. See TORQUE SPECIFICATIONS .
  8. Install the drive shaft into position. Install and hand-tighten center bearing nuts. Install the drive shaft into position. Install drive shaft-to-PTU bolts. Tighten drive shaft-to-PTU bolts to specification. See TORQUE SPECIFICATIONS . Install the drive shaft into the rear axle assembly. Install drive shaft-to-rear axle bolts. Tighten drive shaft-to-rear axle bolts to specification. See TORQUE SPECIFICATIONS .
  9. Install drive shaft support bearing bolts. Tighten drive shaft support bearing bolts to specification. See TORQUE SPECIFICATIONS . Install drive shaft support strap. Tighten drive shaft support strap to specification. See TORQUE SPECIFICATIONS . Tighten center bearing nuts to specification. See TORQUE SPECIFICATIONS .
  10. Install the shifter cable bracket-to-transaxle. Connect the transaxle cooler lines-to-transaxle and tighten to specification. See TORQUE SPECIFICATIONS .
  11. Install the down pipe-to-intermediate pipe assembly. Hand-tighten the nuts. Install the gasket and down pipe-to-exhaust manifold. Tighten down pipe-to-exhaust manifold nuts to specification. See TORQUE SPECIFICATIONS . Tighten down pipe-to-intermediate pipe nuts to specification. See TORQUE SPECIFICATIONS . Route the Heated Oxygen Sensor (HO2S) harness into position at the heat shield.
  12. Install the A/C hoses-to-compressor. Reconnect A/C hoses, if disconnected. Connect the A/C compressor harness. Connect the A/C pressure transducer. Attach the front air deflector-to-cradle assembly. Install the right inner splash shield.
  13. Install the right wheel and tire assembly. Tighten right wheel nuts to specification. See TORQUE SPECIFICATIONS . Install the left inner splash shield. Install the left wheel. Tighten left wheel nuts to specification. See TORQUE SPECIFICATIONS . Lower the vehicle. Connect the shifter cable to the PRNDL switch. Adjust the PRNDL switch as necessary.
  14. Connect heater hoses to the heater core at the front of the dash. Connect the purge hose at the purge solenoid. Connect the fuel transfer line to the quick connect to the fuel line. Connect the surge hose at the bottom of the surge tank. Connect the de-gas hose at the surge tank. Connect the lower radiator hose at the coolant pipe. Connect the upper radiator hose at the engine cylinder head.
  15. Install the engine ground-to-body bolt. Tighten the engine ground-to-body bolt to specification. See TORQUE SPECIFICATIONS .
  16. Install the Under Hood Fuse Block (UHFB) and battery tray. Install the UHFB and the battery tray bolts and tighten to specification. See TORQUE SPECIFICATIONS . Route the engine harness into position and install the main engine and the body harness connectors into the UHFB housing. Snap all connectors into original position. Tighten the UHFB connector bolts to specification. See TORQUE SPECIFICATIONS . Connect both electrical connectors underneath the UHFB.
    CAUTION: Ensure the engine and body harness are properly positioned to avoid damage to the harness.
  17. Install the UHFB into position while aligning the UHFB with the connectors. Snap the UHFB into position. Tighten the UHFB connector bolts to specification. See TORQUE SPECIFICATIONS . Install the battery and Electronic Power Steering (EPS) feed wire to the UHFB stud and tighten the nut to specification. See TORQUE SPECIFICATIONS . Install the UHFB fuse cover into position.
  18. Connect the electrical connectors to the Transmission Control Module (TCM), if equipped. Install the battery cable and harness attachment clips on the side of the battery tray/UHFB bracket assembly. Install the battery and cover. Install the brake vacuum hose into the booster. Connect the rear Heated Oxygen Sensor (HO2S) connector.
  19. Tighten clamp at air cleaner assembly. Connect the negative battery cable. Tighten the battery terminal bolt to specification. See TORQUE SPECIFICATIONS . Install air cleaner assembly. Fill engine oil to proper level.
    NOTE: All entrapped air must be purged from the powertrain cooling system before the final coolant level can be determined. Proper coolant level is critical to avoid engine damage.
  20. Fill and bleed coolant system. See COOLING SYSTEM BLEEDING . Start the engine and fill the transaxle fluid. Check for leaks.
  21. Fill and bleed power steering system. See POWER STEERING BLEEDING . Recheck fluid level. Check for leaks.
  22. Evacuate and recharge A/C system. See appropriate RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Check A/C-Heater system operation.
  23. Verify the wheel adjustment is within specifications. See appropriate ADJUSTMENT & SPECIFICATIONS article under WHEEL ALIGNMENT in SUSPENSION.
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