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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
    2. Fig 1: Locating Intake Air Duct Clamps From MAF Sensor & Throttle Body
    GM763014Courtesy of GENERAL MOTORS CORP.
  2. Loosen the 2 intake air duct clamps (1) from air cleaner housing (2) and the throttle body.
  3. Remove the air cleaner intake duct from the air cleaner housing and throttle body.
  4. Drain the 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.
  5. Remove the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement (LX9) or Radiator Inlet Hose Replacement (LZ9) in Engine Cooling.
  6. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement (LX9) or Radiator Outlet Hose Replacement (LZ9) in Engine Cooling.
  7. Remove the heater outlet and inlet hoses from the engine. Refer to Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement in Heating Ventilation and Air Conditioning.
  8. Remove the vacuum hoses from the upper intake manifold.
  9. Remove the brake booster vacuum hose from the upper intake manifold.
  10. Remove the fuel lines from the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.5L.
  11. Disconnect the following electrical connectors:
    • The knock sensor (KS)
    • The camshaft position (CMP) sensor
    • The crankshaft position (CKP) sensor
    • The heated oxygen sensor (HO2S)
    • The manifold absolute pressure (MAP) sensor
    • The exhaust gas recirculation (EGR) valve
    • The evaporative emission (EVAP) canister purge solenoid
    • The electronic throttle control
    • The ignition coil
    • The body wiring harness-to-engine harness
    • The engine wiring harness from transmission
  12. Remove the engine wiring harness grounds from the transaxle.
  13. Remove the engine mount strut. Refer to Engine Mount Strut Replacement - Left Side  and Engine Mount Strut Replacement - Right Side .
  14. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  15. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  16. Remove rear propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft. (AWD Only)
  17. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
  18. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  19. Remove the lower radiator air baffle assembly. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
  20. Remove the engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
  21. Remove the stabilizer shaft links from 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.
  22. Remove the tie rod ends from the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  23. Remove the lower ball joints from the knuckles. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  24. Remove the A/C compressor bolts and position compressor aside. DO NOT discharge the A/C system. Support the compressor. Refer to Compressor Replacement (LX9) or Compressor Replacement (LZ9) in Heating, Ventilation, and Air Conditioning.
  25. Disconnect the drive axles from the transaxle. Refer to Front Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  26. Secure the drive axles to the steering knuckle/struts.
    27. 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
  27. Remove the intermediate shaft pinch bolt from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
    28. Fig 2: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  28. Lower the vehicle until the frame contacts the transaxle table.
  29. Remove the frame bolts. Refer to Front Frame Replacement in Frame and Underbody.
  30. Raise the vehicle in order to separate the powertrain/frame assembly from the vehicle.
  31. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  32. Remove the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  33. Remove the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T40-E/4T45-E.
    34. Fig 3: Identifying Engine Mount Lower Nuts
    GM96002Courtesy of GENERAL MOTORS CORP.
  34. Remove the engine mount lower nuts.
  35. Remove 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.
  36. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (RPO LX9) or Exhaust Crossover Pipe Replacement (RPO LZ9) in Engine Exhaust.
  37. Install engine hoist to engine.
    38. Fig 4: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  38. Remove the transaxle-to-engine bolts (3, 4, 5, 6) and the studs (1, 2).
  39. Support the transaxle.
  40. Separate and remove the engine from the transaxle/frame.
  41. Install the engine to the engine stand.
  42. Remove the flywheel. Refer to Engine Flywheel Replacement .
  43. Remove the drive belt. Refer to Drive Belt Replacement .
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