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Home >> Pontiac >> 2010 >> Solstice Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.0L - Repair Instructions - On Vehicle) >> Engine Replacement (w/Automatic Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Catalytic Converter & Turbocharger
    GM1827025Courtesy of GENERAL MOTORS CORP.
  1. Install the catalytic converter (3) and gasket (1) to the turbocharger and bracket (4).
    2. CAUTION: Refer to Fastener Caution .
  2. Install the catalytic converter nuts (2) and tighten to 59 N.m (43 lb ft).
    3. Fig 2: View Of Catalytic Converter-To-Catalytic Converter Bracket Bolts
    GM1827024Courtesy of GENERAL MOTORS CORP.
  3. Install the catalytic converter to bracket bolts and tighten to 22 N.m (16 lb ft).
    4. Fig 3: View Of A/C Compressor & Bolts
    GM1592623Courtesy of GENERAL MOTORS CORP.
  4. Install the A/C compressor and bolts. Tighten the bolts in the sequence shown to 22 N.m (16 lb ft).
    5. Fig 4: View Of Flywheel (Automatic Transaxle)
    GM1578311Courtesy of GENERAL MOTORS CORP.
  5. Install a suitable engine lifting devise to the engine.
  6. Remove the engine from the stand.
  7. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
  8. Install the flywheel and bolts. Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059  .
    9. Fig 5: View Of Right Engine Mount
    GM1717067Courtesy of GENERAL MOTORS CORP.
  9. Install the engine to the vehicle.
  10. Install the right engine mount upper nut and tighten to 55 N.m (41 lb ft).
    11. Fig 6: View Of Left Engine Mount
    GM1717064Courtesy of GENERAL MOTORS CORP.
  11. Install the left engine mount upper nut and tighten to 55 N.m (41 lb ft).
  12. If installed, remove the engine lift bracket from the engine.
    13. Fig 7: Locating Bellhousing Bolts
    GM1765917Courtesy of GENERAL MOTORS CORP.
    NOTE: The top 2 bellhousing bolts install through the bellhousing into the engine block. The remaining 7 bolts install through the engine block into the bellhousing.
  13. Install the upper 5 bellhousing bolts (1) and tighten to 50 N.m (37 lb ft).
  14. Raise and support the vehicle.
  15. Install the 4 lower bellhousing bolts (2) and tighten to 50 N.m (37 lb ft).
  16. Install the torque converter to flywheel bolts and tighten to 63 N.m (46 lb ft).
    17. Fig 8: View Of Power Steering Pump & Bracket
    GM1765296Courtesy of GENERAL MOTORS CORP.
  17. Position the power steering pump bracket to the engine and install the bracket bolts and tighten to 58 N.m (43 lb ft).
  18. Lower the vehicle.
    19. Fig 9: View Of A/C Compressor Line
    GM1765251Courtesy of GENERAL MOTORS CORP.
  19. Position the A/C compressor line and install the bolt and tighten to 22 N.m (16 lb ft).
    20. Fig 10: Identifying Turbocharger Coolant Feed Pipe & Bolts
    GM1750401Courtesy of GENERAL MOTORS CORP.
  20. Position the turbocharger coolant feed pipe to the vehicle.
  21. Install the turbocharger coolant feed pipe bracket bolt (3) to the cylinder head and tighten to 10 N.m (89 lb in).
  22. Install the turbocharger coolant feed pipe fitting (2) to the cylinder head and tighten to 35 N.m (26 lb ft).
  23. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger and tighten to 35 N.m (26 lb ft).
    24. Fig 11: Identifying Charge Air Bypass Solenoid Components
    GM1750413Courtesy of GENERAL MOTORS CORP.
  24. Install the charge air bypass valve vacuum solenoid.
  25. Install the charge air bypass valve vacuum hose to the turbocharger coolant feed pipe clips (4).
  26. Position the charge air bypass valve vacuum hose clamp (5) at the turbocharger.
  27. Place the charge air bypass valve solenoid out of the way.
    28. Fig 12: Identifying Engine Harness Clips
    GM1826858Courtesy of GENERAL MOTORS CORP.
  28. Position the branches of the engine harness to the engine.
  29. Install the engine harness clips (3, 4) to the front studs.
    30. Fig 13: Identifying Engine Wiring Harness Ground Terminal
    GM1826860Courtesy of GENERAL MOTORS CORP.
  30. Install the engine wiring harness ground terminal (1) to the cylinder head.
  31. Install the engine wiring harness ground bolt (2) to the cylinder head and tighten to 25 N.m (18 lb ft).
    32. Fig 14: Locating turbocharger wastegate solenoid valve Harness & Connector
    GM1750410Courtesy of GENERAL MOTORS CORP.
  32. Connect the engine wiring harness electrical connector to the boost sensor.
    33. Fig 15: View Of Turbocharger Coolant Feed Pipe Clips & Studs
    GM1750409Courtesy of GENERAL MOTORS CORP.
  33. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe tab.
  34. Install the engine wiring harness clip (3) to the turbocharger coolant feed pipe stud (2).
    35. Fig 16: Identifying Engine Wiring Harness Clips
    GM1825746Courtesy of GENERAL MOTORS CORP.
  35. Connect the engine harness clips (2) to the camshaft cover.
  36. Connect the engine harness clip (1) to the camshaft cover.
    37. Fig 17: Identifying ECT Sensor Engine Wiring Harness Electrical Connector
    GM1826284Courtesy of GENERAL MOTORS CORP.
  37. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
  38. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
  39. Position the engine harness ground terminal (1) and install the engine harness ground terminal bolt (2) and tighten to 25 N.m (18 lb ft).
    40. Fig 18: Identifying CPA Retainer & HO2S Electrical Connector
    GM1592538Courtesy of GENERAL MOTORS CORP.
  40. Connect the engine wiring harness electrical connector (1) to the HO2S (3).
    41. Fig 19: View Of Ignition Coil Electrical Connectors
    GM1825747Courtesy of GENERAL MOTORS CORP.
  41. Connect the engine wiring harness electrical connectors to the ignition coils.
    42. Fig 20: Identifying Engine Wiring Harness Clip
    GM1825748Courtesy of GENERAL MOTORS CORP.
  42. Install the engine harness clip (1) to the camshaft cover.
    43. Fig 21: Identifying Intake & Exhaust CMP Actuator Solenoid Valve Connectors
    GM1825749Courtesy of GENERAL MOTORS CORP.
  43. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator.
  44. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator.
    45. Fig 22: Identifying High Pressure Fuel Pump Connector & Clip
    GM1826282Courtesy of GENERAL MOTORS CORP.
  45. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.
  46. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  47. Install the engine wiring harness clip (3) to the high pressure fuel pump bracket.
    48. Fig 23: Locating Windshield Wiper Motor Electrical Connector & Harness Clip
    GM1826964Courtesy of GENERAL MOTORS CORP.
  48. Connect the engine wiring harness electrical connector (1) to the windshield wiper motor.
  49. Install the engine harness clip (2) to the wiper motor hole.
    50. Fig 24: Identifying Brake Booster Vacuum Sensor Electrical Connector
    GM1826934Courtesy of GENERAL MOTORS CORP.
  50. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum sensor.
    51. Fig 25: View Of Intake Air Pressure & Temperature Sensor Electrical Connector
    GM1826861Courtesy of GENERAL MOTORS CORP.
  51. Connect the engine wiring harness electrical connector (1) to the A/C refrigerant pressure sensor.
    52. Fig 26: Identifying Throttle Actuator & Knock Sensor Electrical Connectors & Harness Clip
    GM1825527Courtesy of GENERAL MOTORS CORP.
  52. Connect the engine wiring harness electrical connector (2) to the knock sensor.
    53. Fig 27: View Of Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM1826857Courtesy of GENERAL MOTORS CORP.
  53. Connect the engine wiring harness electrical connector (1) to the fuel injector jumper electrical connector.
    54. Fig 28: Identifying Generator
    GM1717482Courtesy of GENERAL MOTORS CORP.
  54. Install the positive battery cable terminal (3) to the generator.
  55. Install the generator terminal nut (1) and tighten to 20 N.m (15 lb ft).
  56. Position the positive battery cable terminal boot (2).
  57. Connect the engine wiring harness electrical connector (4) to the A/C compressor.
    58. Fig 29: Identifying Generator Wiring Harness Electrical Connector
    GM1826855Courtesy of GENERAL MOTORS CORP.
  58. Connect the engine wiring harness electrical connector (1) to the generator.
    59. Fig 30: Locating Transmission Oil Cooler Pump Electrical Connector
    GM1826927Courtesy of GENERAL MOTORS CORP.
  59. Connect the engine wiring harness electrical connector (1) to the transmission oil cooler pump.
    60. Fig 31: Identifying Negative Battery Cables & Cable Components
    GM1717479Courtesy of GENERAL MOTORS CORP.
  60. Position the negative/positive battery cable to the engine.
  61. Install the negative battery cable ground terminal (5) to the engine lift bracket.
  62. Install the negative battery cable ground bolt (6) to the front engine lift bracket and tighten to 25 N.m (18 lb ft).
  63. Install NEW tie straps (1) to the engine wiring harness.
    64. Fig 32: Identifying MAF Sensor Electrical Connector
    GM1826859Courtesy of GENERAL MOTORS CORP.
  64. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
  65. Raise the vehicle.
    66. Fig 33: Identifying Brake Booster Auxiliary Pump Connector
    GM1826929Courtesy of GENERAL MOTORS CORP.
  66. Connect the engine wiring harness electrical connector (1) to the brake booster vacuum pump.
  67. Bolt the catalytic converter to the exhaust pipe and tighten to 17 N.m (13 lb ft).
    68. Fig 34: Identifying Engine Oil Pressure & Crankshaft Position Sensor Electrical Connectors
    GM1716603Courtesy of GENERAL MOTORS CORP.
  68. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
  69. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
  70. Lower the vehicle.
    71. Fig 35: Identifying Heater Inlet & Outlet Hoses & Clamps
    GM1826795Courtesy of GENERAL MOTORS CORP.
  71. Install the heater inlet (1) and outlet (2) hoses to the thermostat housing.
  72. Position the heater inlet and outlet hose clamps at the thermostat housing.
    73. Fig 36: Identifying Surge Tank Hose Components
    GM1825533Courtesy of GENERAL MOTORS CORP.
  73. Position the air bleed hose to the engine.
  74. Install the surge tank air bleed hose to the engine.
  75. Install the surge tank air bleed hose clip (3) to the surge tank bracket.
  76. Position the surge tank air bleed hose clamp (1) at the engine.
    77. Fig 37: Identifying Surge Tank Outlet Hose Clamp (At Surge Tank)
    GM1826792Courtesy of GENERAL MOTORS CORP.
  77. Install the surge tank clip (1) to the oil level indicator tube bracket.
  78. Position the surge tank outlet hose clamp (2) at the surge tank.
    79. Fig 38: Identifying Surge Tank Outlet Hose
    GM1826446Courtesy of GENERAL MOTORS CORP.
  79. Install the surge tank outlet hose to the thermostat housing and oil cooler.
  80. Position the surge tank outlet hose clamp (1) at the oil cooler.
  81. Position the surge tank outlet hose clamp (2) at the thermostat housing.
    82. Fig 39: Identifying Radiator Outlet Hose Components
    GM1826444Courtesy of GENERAL MOTORS CORP.
  82. Position the outlet hose to the engine.
  83. Install the radiator outlet hose clip (3) to the bracket.
  84. Install the radiator outlet hose to the thermostat housing and oil cooler.
  85. Position the radiator outlet hose clamp (1) at the oil cooler.
  86. Position the radiator outlet hose clamp (2) at the thermostat housing.
    87. Fig 40: View Of Radiator Inlet Hose
    GM1592523Courtesy of GENERAL MOTORS CORP.
  87. Position the inlet hose to the engine.
  88. Install the radiator inlet hose to the engine.
  89. Position the radiator inlet hose clamp at the engine.
    90. Fig 41: Identifying Charge Air Cooler Pipe & Gasket
    GM1750442Courtesy of GENERAL MOTORS CORP.
  90. Remove the cap or plug from the turbocharger opening.
  91. Install the charge air cooler pipe to the turbocharger.
  92. Install the charge air cooler pipe to turbocharger bolts (1) and tighten to 22 N.m (16 lb ft).
    93. Fig 42: Identifying Turbocharger Heat Shield & Bolts
    GM1750397Courtesy of GENERAL MOTORS CORP.
  93. Install the turbocharger heat shield and bolts (1) and tighten to 10 N.m (89 lb in).
  94. Install the starter. Refer to Starter Replacement .
  95. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) or Air Inlet Grille Panel Replacement (Solstice) .
  96. Install the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement and Charge Air Cooler Outlet Pipe Replacement .
    97. Fig 43: Identifying EVAP & Fuel Feed Pipes
    GM1825535Courtesy of GENERAL MOTORS CORP.
  97. Connect the fuel feed pipe (1) to the fuel line. Refer to Metal Collar Quick Connect Fitting Service .
  98. Connect the EVAP canister purge solenoid tube to the valve (2). Refer to Plastic Collar Quick Connect Fitting Service .
  99. Install the radiator. Refer to Radiator Replacement .
  100. Install the drive belt. Refer to Drive Belt Replacement .
  101. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  102. Install the hood. Refer to Hood Replacement .
  103. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  104. Fill the engine with oil.
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