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Home >> Saturn >> 2010 >> Sky Red Line, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.4L - Repair Instructions - On Vehicle) >> Engine Replacement (W/Manual Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Catalytic Converter, Gasket & Nuts
    GM1592527Courtesy of GENERAL MOTORS CORP.
  1. Install the catalytic converter gasket (2) and converter to the engine.
    2. CAUTION: Refer to Fastener Caution .
  2. Install the catalytic converter nuts (1).

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

    3. Fig 2: View Of Catalytic Converter Bracket & Bolt
    GM1592529Courtesy of GENERAL MOTORS CORP.
  3. Install the catalytic converter to bracket bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    4. Fig 3: Identifying A/C Compressor & Bolts
    GM1592623Courtesy of GENERAL MOTORS CORP.
  4. Install the A/C compressor and bolts.

    Tighten:  Tighten the bolts in the sequence shown to 22 N.m (16 lb ft).

    5. Fig 4: View Of Flywheel & Bolt (Manual Transmission)
    GM1591936Courtesy 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:  Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059  .

  9. Install the clutch pressure plate and disc. Refer to Clutch Pressure and Driven Plate Replacement .
    10. Fig 5: View Of Right Engine Mount Upper Nut
    GM1592519Courtesy of GENERAL MOTORS CORP.
  10. Install the engine to the vehicle.
  11. Install the right engine mount upper nut.

    Tighten:  Tighten the nut to 50 N.m (37 lb ft).

    12. Fig 6: View Of Left Engine Mount
    GM1592518Courtesy of GENERAL MOTORS CORP.
  12. Install the left engine mount upper nut.

    Tighten:  Tighten the nut to 50 N.m (37 lb ft).

  13. Remove the J 42451-1  from the engine.
  14. Raise and support the vehicle.
    15. Fig 7: View Of Power Steering Pump, Bracket & Bolts
    GM1765296Courtesy of GENERAL MOTORS CORP.
  15. Position the power steering pump and bracket to the engine and install the bracket bolts.

    Tighten:  Tighten the bolts to 58 N.m (43 lb ft).

  16. Lower the vehicle.
    17. Fig 8: Identifying A/C Compressor & Bolts
    GM1592623Courtesy of GENERAL MOTORS CORP.
  17. Position the A/C compressor line and install the bolt.

    Tighten:  Tighten the bolt to 22 N.m (16 lb ft).

    18. Fig 9: View Of Intake Manifold Cover Bracket & Bolts
    GM1694522Courtesy of GENERAL MOTORS CORP.
  18. Install the intake manifold cover bracket and bolts.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  19. Position the branches of the engine harness to the engine.
    20. Fig 10: Identifying Engine Harness Bracket
    GM1591665Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine harness clip (2) to the bracket.
  21. Install the engine harness bracket (1) to the intake manifold cover stud.
  22. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
    23. Fig 11: Locating EVAP Canister Purge Valve Electrical Connector & Harness Clips
    GM1591661Courtesy of GENERAL MOTORS CORP.
  23. Connect the engine harness clips (3, 4) to the camshaft cover.
  24. Connect the engine harness clip (2) to the EVAP canister purge solenoid valve bracket.
  25. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
    26. Fig 12: View Of CMP Sensor & ECT Sensor Electrical Connectors
    GM1591858Courtesy of GENERAL MOTORS CORP.
  26. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
  27. Position the engine wiring harness ground terminal (2) and install the bolt (1).

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  28. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
    29. Fig 13: View Of Intake CMP Sensor Electrical Connector
    GM1591857Courtesy of GENERAL MOTORS CORP.
  29. Connect the engine wiring harness electrical connector to the intake CMP sensor.
    30. Fig 14: Identifying CPA Retainer & HO2S Electrical Connector
    GM1592538Courtesy of GENERAL MOTORS CORP.
  30. Connect the HO2S electrical connector clip (4) to the strut.
  31. Connect the engine harness clips (1) to the junction block bracket.
  32. Connect the engine wiring harness electrical connector (2) to the rear HO2S.
  33. Connect the engine wiring harness electrical connector (1) to the front HO2S.
  34. Install the CPA retainers to the HO2S electrical connectors.
    35. Fig 15: View Of Ignition Coil Electrical Connectors
    GM1591652Courtesy of GENERAL MOTORS CORP.
  35. Connect the engine wiring harness electrical connectors to the ignition coils.
    36. Fig 16: Identifying Cam Cover Engine Harness Clip
    GM1591657Courtesy of GENERAL MOTORS CORP.
  36. Install the engine harness clip (1) to the camshaft cover.
    37. Fig 17: Identifying Camshaft Position Actuator Solenoid Valve Electrical Connectors
    GM1591651Courtesy of GENERAL MOTORS CORP.
  37. Connect the engine wiring harness electrical connector (2) to the exhaust CMP actuator.
  38. Connect the engine wiring harness electrical connector (1) to the intake CMP actuator.
    39. Fig 18: View Of Engine Harness Clip To Surge Tank Air Bleed Hose
    GM1590557Courtesy of GENERAL MOTORS CORP.
  39. Install the engine harness clip to the surge tank air bleed hose.
    40. Fig 19: Identifying Windshield Wiper Motor Electrical Connector
    GM1590536Courtesy of GENERAL MOTORS CORP.
  40. Connect the engine wiring harness electrical connector to the windshield wiper motor.
  41. Install the engine harness clip to the wiper motor hole.
    42. Fig 20: Locating A/C Refrigerant Pressure Sensor Electrical Connector
    GM1590533Courtesy of GENERAL MOTORS CORP.
  42. Connect the engine wiring harness electrical connector to the A/C refrigerant pressure sensor.
    43. Fig 21: Identifying Engine Harness Electrical Connectors
    GM1590505Courtesy of GENERAL MOTORS CORP.
  43. Position the negative/positive battery cable.
  44. Connect the engine wiring harness electrical connector (6) to the A/C compressor.
  45. Install the positive battery cable terminal to the generator (5).
  46. Install the generator terminal nut (2).

    Tighten:  Tighten the nut to 20 N.m (15 lb ft).

  47. Position the positive battery cable terminal boot (4).
  48. Connect the engine wiring harness electrical connector (1) to the generator.
    49. Fig 22: View Of Negative Battery Cable Ground Bolt
    GM1591855Courtesy of GENERAL MOTORS CORP.
  49. Position the engine harness ground terminal behind the negative battery cable terminal and position against the cylinder head.
  50. Install the negative battery cable ground terminal bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  51. Install NEW tie straps to the engine harness.
  52. Install the positive battery cable clip to the bracket.
  53. Raise and support the vehicle.
    54. Fig 23: Identifying CKP & Oil Pressure Sensor Electrical Connectors
    GM1589842Courtesy of GENERAL MOTORS CORP.
  54. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
  55. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
  56. Lower the vehicle.
    57. Fig 24: Identifying Heater Inlet & Outlet Hoses
    GM1592522Courtesy of GENERAL MOTORS CORP.
  57. Install the heater inlet (2) and outlet (1) hoses to the thermostat housing.
  58. Position the heater inlet and outlet hose clamps at the thermostat housing.
    59. Fig 25: Identifying Air Bleed Hose & Clamp
    GM1590504Courtesy of GENERAL MOTORS CORP.
  59. Position the air bleed hose (2).
  60. Install the surge tank air bleed hose (1) to the engine.
  61. Position the surge tank air bleed hose clamp at the engine.
    62. Fig 26: Identifying Radiator Outlet Hose Clip
    GM1714037Courtesy of GENERAL MOTORS CORP.
  62. If the vehicle is not equipped with a engine oil cooler perform the following steps, otherwise proceed to step 66.
  63. Install the radiator outlet hose to the thermostat housing.
  64. Reposition the radiator outlet hose clamp at the thermostat housing.
  65. Install the radiator outlet hose clip (1) to the outlet hose bracket. Proceed to step 71.
    66. Fig 27: View Of Radiator Surge Tank
    GM1590499Courtesy of GENERAL MOTORS CORP.
  66. If the vehicle is equipped with a engine oil cooler, install the surge tank outlet hose.
  67. Install the surge tank clip to the oil level indicator tube bracket.
  68. Position the surge tank outlet hose clamp at the surge tank.
    69. Fig 28: View Of Surge Tank Outlet Hose
    GM1591818Courtesy of GENERAL MOTORS CORP.
  69. Install the surge tank outlet hose to the thermostat housing and oil cooler.
  70. Position the surge tank outlet hose clamps at the thermostat housing and oil cooler.
    71. Fig 29: View Of Radiator Outlet Hose
    GM1591816Courtesy of GENERAL MOTORS CORP.
  71. Position the outlet hose.
  72. Install the radiator outlet hose to the thermostat housing and oil cooler.
  73. Position the radiator outlet hose clamps at the thermostat housing and oil cooler.
    74. Fig 30: View Of Radiator Inlet Hose
    GM1592523Courtesy of GENERAL MOTORS CORP.
  74. Install the radiator inlet hose.
  75. Position the radiator inlet hose clamp at the engine.
  76. Install the transmission. Refer to Transmission Replacement (With ZOK) .
  77. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) or Air Inlet Grille Panel Replacement (Solstice) .
    78. Fig 31: View Of Fuel Feed Pipe & EVAP Quick Connect Fitting
    GM1592525Courtesy of GENERAL MOTORS CORP.
  78. Connect the fuel feed pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  79. Connect the EVAP canister purge solenoid tube to the valve (1). Refer to Plastic Collar Quick Connect Fitting Service .
  80. Install the radiator. Refer to Radiator Replacement .
  81. Install the drive belt. Refer to Drive Belt Replacement (With A/C)  or Drive Belt Replacement (Without A/C) .
  82. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  83. Install the hood. Refer to Hood Replacement .
  84. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  85. Fill the engine oil.
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