LEMON Manuals: Even more car manuals for everyone
Home >> Saturn >> 2006 >> Relay 3.9 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 3.5L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Install the drive belt. Refer to Drive Belt Replacement .
  2. Install the flywheel. Refer to Engine Flywheel Replacement .
  3. Remove the engine from the engine stand.
  4. Install and align the engine to the transaxle/frame.
    5. Fig 1: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the transaxle-to-engine bolts (3, 4, 5, 6) and the studs (1, 2).

    Tighten:  Tighten the bolts (3, 4, 5, 6) and the studs (1, 2) to 75 N.m (55 lb ft).

  6. Remove the engine hoist from the engine.
  7. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (RPO LX9) or Exhaust Crossover Pipe Replacement (RPO LZ9) in Engine Exhaust.
  8. Install the transaxle brace. Refer to Automatic Transmission Brace Replacement (Front Wheel Drive) or Automatic Transmission Brace Replacement (All Wheel Drive) or Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive) in Automatic Transaxle - 4T40-E/4T45-E.
    9. Fig 2: Identifying Engine Mount Lower Nuts
    GM96002Courtesy of GENERAL MOTORS CORP.
  9. Install the engine mount lower nuts.

    Tighten:  Tighten the nuts to 43 N.m (32 lb ft).

  10. Install the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  11. Install the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  12. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  13. Position the transaxle table with the powertrain/frame under the vehicle.
    14. Fig 3: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  14. Lower the vehicle until the frame contacts the transaxle table.
  15. Install the new frame bolts. Refer to Front Frame Replacement in Frame and Underbody.
  16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  17. Remove the transaxle table.
    18. CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage may cause loss of steering control which could result in an accident and possible personal injury
  18. Install the intermediate shaft pinch bolt to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  19. Connect the drive axles to the transaxle. Refer to Front Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  20. Position compressor to the engine and Install the A/C compressor bolts. Refer to Compressor Replacement (LX9) or Compressor Replacement (LZ9) in Heating, Ventilation, and Air Conditioning.
  21. Install the lower ball joints to the knuckles. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  22. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  23. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement (with Rear Twist Axle) or Stabilizer Shaft Link Replacement (with Rear IRS) in Front Suspension.
  24. Install the engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
  25. Install the lower radiator air baffle assembly. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
  26. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  27. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
  28. Install rear propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft. (AWD Only)
  29. Lower the vehicle.
  30. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  31. Install the engine mount strut. Refer to Engine Mount Strut Replacement - Left Side  and Engine Mount Strut Replacement - Right Side .
  32. Connect the following electrical connectors:
    • The KS
    • The CMP sensor
    • The CKP sensor
    • The HO2S
    • The MAP sensor
    • The EGR valve
    • The EVAP canister purge solenoid
    • The electronic throttle control
    • The ignition coil
    • The body wiring harness-to-engine harness
    • The engine wiring harness from transmission
  33. Install the engine wiring harness ground nut to the transaxle stud.

    Tighten:  Tighten the nut to 35 N.m (26 lb ft).

  34. Install the fuel lines to the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.5L.
  35. Install the brake booster vacuum hose to the upper intake manifold.
  36. Install the vacuum hoses to the upper intake manifold.
  37. Install the heater outlet and inlet hoses to the engine. Refer to Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement in Heating Ventilation and Air Conditioning.
  38. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement (LX9) or Radiator Outlet Hose Replacement (LZ9) in Engine Cooling.
  39. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement (LX9) or Radiator Inlet Hose Replacement (LZ9) in Engine Cooling.
    40. Fig 4: Locating Intake Air Duct Clamps From MAF Sensor & Throttle Body
    GM763014Courtesy of GENERAL MOTORS CORP.
  40. Install the air cleaner intake duct to the air cleaner housing (2) and the throttle body.
  41. Tighten the 2 intake air duct clamps (1).

    Tighten:  Tighten the clamps to 2 N.m (18 lb in).

  42. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  43. Fill cooling system. Refer to Cooling System Draining and Filling (Static Fill LX9) or Cooling System Draining and Filling (Static Fill LZ9) or Cooling System Draining and Filling (Vac-N-Fill) in Engine Cooling.
  44. Perform a CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.5L.
  45. Inspect for leaks.
scientia non olet · About LEMON Manuals