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Installation Procedure

WARNING: This page is about a different car, the 2002 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
  1. Attach the engine lifting device. Remove the engine from the engine stand.
  2. Install the engine flywheel. Refer to Engine Flywheel Replacement  .
  3. Position the engine in the vehicle and align the engine with the transaxle.
    CAUTION: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the upper transaxle mounting bolts.

    Tighten 

    Tighten bolts to 90 N.m (66 lb ft).

  5. Install the engine mount bracket and the engine mount. Refer to Engine Mount Replacement  .
  6. Remove the engine lifting device.
  7. Install the power steering pump to the engine front cover.
  8. Connect the upper and the lower radiator hoses. Refer to RADIATOR HOSE REPLACEMENT - INLET and RADIATOR HOSE REPLACEMENT - OUTLET in Engine Cooling.
  9. Raise vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  10. Install the 2 bolts that mount the outer transaxle to the engine. Refer to TRANSAXLE in Automatic Transaxle 4T40-E/4T45-E.
  11. Install the brace between the transaxle and the engine. Refer to TRANSAXLE in Automatic Transaxle 4T40-E/4T45-E.
  12. Install the right front fender liner. Refer to FRONT FENDER LINER REPLACEMENT in Body Front End.
  13. Install the flywheel to torque converter bolts.
  14. Install the A/C compressor. Refer to COMPRESSOR in HVAC Systems- Manual.
  15. Install the starter. Refer to STARTER in Engine Electrical.
  16. Install flywheel inspection cover.
  17. Install the catalytic converter to the rear exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  18. Install a new oil filter.
  19. Install the lower engine wiring harness and the retainers.
  20. Lower the vehicle.
  21. Install the heater hoses to the engine at the quick-connects.
  22. Install the fuel lines at the quick-connects.
  23. Install the upper engine wiring harness and the retainers.
  24. Connect the vacuum hoses.
    25. Fig 1: Locating Hoses
    G01810998Courtesy of GENERAL MOTORS CORP.
  25. Connect the cruise control cable to the throttle body.
  26. Connect the throttle control cable.
  27. Install and connect the cruise control module.
  28. Install the drive belt. Refer to Drive Belt Replacement  .
  29. Connect the surge tank hoses.
  30. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.
  31. Install the air cleaner assembly.
  32. Fill the engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  33. Fill the crankcase to the appropriate level. Use the recommended oil. Refer to Engine Oil and Oil Filter Replacement  .
  34. Start the engine. Inspect the engine for leaks.
  35. Stop the engine. Inspect the fluid levels.
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