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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1634 (Engine Mechanical - 3.5L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Align the engine to the transmission.
    2. Fig 1: View Of Transmission-To-Engine Mounting Bolts
    GM1424759Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  2. Apply sealant to the two upper transmission-to-engine bolts only, and install the transmission-to-engine mounting bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.

    Tighten the bolts to 64 N.m (47 lb ft).

  3. Install the right engine mount. Refer to Engine Mount Replacement .
  4. Install the front transmission mount to the engine. Refer to Transmission Front Mount Replacement .
  5. Install the following components:
    1. Install the cylinder heads. Refer to Cylinder Head Replacement - Left Side  and Cylinder Head Replacement - Right Side .
    2. Install the timing chain. Refer to Camshaft Timing Chain and Sprocket Replacement .
    3. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) and Catalytic Converter Replacement - Right Side (LZ4) .
    4. Install the rocker covers. Refer to Valve Rocker Arm Cover Replacement - Left Side  and Valve Rocker Arm Cover Replacement - Right Side .
    5. Install the front covers. Refer to Engine Front Cover Replacement .
    6. Install the generator. Refer to Generator Replacement (LZ4) .
    7. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4) .
  6. Install the starter. Refer to Starter Replacement (LZ4) .
  7. Install the powertrain assembly to the vehicle.
  8. Install the cradle bolts. Refer to Frame Replacement (6T70 Transmission) .
  9. Remove the engine support table.
  10. Install the front transmission mount bolts to the body. Refer to Transmission Front Mount Replacement .
  11. Remove the wood blocks from the cradle.
  12. Install the lower transaxle-to-engine bolts and tighten to 75 N.m (55 lb ft).
  13. Install the transfer case. Refer to Transfer Case Assembly Replacement (LZ4) .
  14. Install the torque convertor-to-flywheel bolts and tighten to 62 N.m (46 lb ft).
  15. Install the torque convertor inspection cover and tighten the bolts to 12 N.m (106 lb in).
  16. Install the 3 front fender pushpins.
  17. Install the front exhaust pipe. Refer to Catalytic Converter Replacement - Left Side (LZ4) .
  18. Connect the steering shaft coupling from the steering gear. Refer to Steering Shaft Coupling Replacement .
  19. Install the propeller shaft. Refer to Propeller Shaft Replacement .
  20. Install the left and right axle shaft nuts. Refer to Front Wheel Drive Shaft Replacement .
  21. Connect the left and right lower ball joints. Refer to Lower Control Arm Ball Joint Replacement .
  22. Install the left and right stabilizer bar links. Refer to Stabilizer Shaft Link Replacement .
  23. Install the left and right tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement .
  24. Connect the transmission cooler lines to the transmission and bracket. Refer to Transmission Mount Bracket Replacement - Rear .
  25. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
  26. Install the front tires. Refer to Tire and Wheel Removal and Installation .
  27. Lower the vehicle.
    28. Fig 2: View Of Fuel EVAP Line
    GM1226396Courtesy of GENERAL MOTORS CORP.
  28. Install the fuel EVAP line.
  29. Connect the fuel feed line. Refer to Fuel Line Replacement - Chassis .
  30. Install the starter positive cable and tighten to 10 N.m (89 lb in).
    31. Fig 3: Heater Outlet Hose
    GM1875900Courtesy of GENERAL MOTORS CORP.
  31. Install the heater outlet hose (1).
  32. Install the A/C tube to the A/C compressor. Refer to Air Conditioning Compressor Hose Replacement (LZ4) .
  33. Connect the coolant reservoir hose from the engine to reservoir.
  34. Connect the A/C line from the condenser to compressor.
  35. Connect the A/C high pressure switch harness.
  36. Connect the generator positive cable and nut and tighten to 12 N.m (106 lb in).
  37. Install the A/C lower pressure tube at the front lift bracket. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LE5, LZ4, LY7) .
  38. Install the ECM. Refer to Engine Control Module Replacement .
    39. Fig 4: View Of Radiator Inlet & Outlet Hoses From The Engine
    GM1252513Courtesy of GENERAL MOTORS CORP.
  39. Connect the radiator inlet and outlet hoses to the engine.
  40. Fill the vehicle with coolant. Refer to Cooling System Draining and Filling (Static Fill Without HP5) or Cooling System Draining and Filling (GE 47716 Fill Without HP5) .
  41. Connect the wiring harness to the underhood junction block.
  42. Connect the transmission shifter cable.
    43. Fig 5: View Of Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  43. Install the battery box and battery. Refer to Battery Box Replacement .
  44. Remove the cooling module support.
  45. Install the air outlet duct assembly. Refer to Air Cleaner Outlet Duct Replacement .
  46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  47. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  48. Perform the throttle learn procedure. Refer to Throttle/Idle Learn .
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