Engine Installation

- Tool Required - J 28467-A Universal Support Fixture, or equivalent.

1. Remove engine from engine stand and support with engine hoist.
2. Rear end plate to engine; secure with two bolts. Tighten rear end plate bolts to 5.6 Nm (49 inch lbs.).
3. Apply GM P/N 12345493 or equivalent, to the flex plate bolt threads.
4. Rear spacer, flex plate and front spacer to crankshaft, aligning marks made during removal; secure with six bolts (automatic transaxle equipped vehicles). Tighten flex plate bolts to 64 Nm (47 ft. lbs.).
5. Flywheel to crankshaft, aligning marks made during removal; secure with six bolts (manual transaxle equipped vehicles). Tighten flywheel bolts to 78 Nm (58 ft. lbs.).
6. Engine to transaxle.
a. Four engine-to-transaxle bolts. Tighten engine-to-transaxle bolts to 67 Nm (49 ft. lbs.).
b. Flex plate-to-torque converter bolts. See Transmission and Drivetrain.
c. Lower engine reinforcement brace; secure with five bolts. Tighten lower engine reinforcement brace bolts to 64 Nm (47 ft. lbs.).
7. Starter motor to transaxle case; secure with two bolts. Tighten starter motor bolts to 39 Nm (29 ft. lbs.).
8. Starter motor positive (+) terminal nut, positive (+) battery cable and electrical connector to starter motor. Tighten starter motor positive (+) terminal nut to 5 Nm (44 inch lbs.).
9. Engine with transaxle to vehicle, ensuring clearance on all sides.
10. Support engine with J 28467-A and Remove engine hoist.
11. Engine mount.
12. Left transaxle mount. See Transmission and Drivetrain.
13. Raise and suitably support vehicle.
14. Front and rear transaxle mounts. See Transmission and Drivetrain.
15. Drive axles (left and right) from transaxle. For engine or transaxle removal, it is not necessary to Remove drive axle from steering knuckle.
16. Front exhaust pipe.
a. Front exhaust pipe to vehicle; secure with two nuts at front exhaust pipe-to-Three Way Catalytic Converter (TWC) mating flange. Tighten front exhaust pipe-to-exhaust manifold nuts to 62 Nm (46 ft. lbs.).
b. Electrical connector to oxygen sensor (02S1) at front exhaust pipe.
c. Two bolts to front exhaust pipe-to-TWC mating flange. Tighten front exhaust pipe-to-TWC mating flange bolts to 43 Nm (32 ft. lbs.).
d. Front exhaust pipe support to front exhaust pipe; secure with two bolts. Tighten front exhaust pipe support bolts to 19 Nm (14 ft. lbs.).
17. Power steering pump (if equipped); secure with two bolts. Tighten power steering pump bolts to 39 Nm (29 ft. lbs.).
18. Power steering drive belt (if equipped).
19. Lower vehicle.
20. A/C compressor (if equipped); secure with four bolts. Tighten A/C compressor bolts to 25 Nm (18 ft. lbs.).
21. A/C drive belt (if equipped). see Heating and Air Conditioning.
22. A/C compressor electrical connector (if equipped).
23. Insert wiring harness through bulkhead into the passenger compartment and install grommet to bulkhead.
24. Two wiring harness and two Engine Control Module (ECM) electrical connectors.
25. Cruise control module into place; secure with two bolts. Tighten cruise control module bolts to 5 Nm (44 inch lbs.).
26. Left-side floor carpet bracket; secure with one bolt. Tighten left-side floor carpet bracket bolt to 5 Nm (44 inch lbs.).
27. Radio. See Accessories and Optional Equipment.
28. Knee bolster, glove box assembly, center console to bezel, rear center console and center console to vehicle. See Instrument Panel, Gauges and Warning Indicators.
29. Left and right-side sill plates.
30. Shift select and shift control cables to transaxle (manual transaxle equipped vehicles).
31. Shift select cable to transaxle (automatic transaxle equipped vehicles). See Transmission and Drivetrain.
32. Clutch release cylinder (manual transaxle equipped vehicles).
33. Fuel return hose to Fuel Pressure Regulator (FPR)..
34. Fuel feed pipe to fuel rail and intake manifold.
35. Engine coolant control valve outlet hose to thermostat housing; secure with hose clamp.
36. Engine coolant control valve inlet hose to thermostat; secure with hose clamp.
37. EVAP canister to mounting bracket. Tighten EVAP mounting bracket bolt to 10 Nm (89 inch lbs.).
38. Hose to EVAP canister.
39. Fuse and relay box to vehicle, connecting four electrical connectors; secure with two bolts. Tighten fuse and relay box bolts to 10 Nm (89 inch lbs.).
40. The following electrical connectors:
- Engine ground wires to intake manifold, right and left fenders.
- A/C triple pressure switch (if equipped).
- Data Link Connector (DLC).
- Manifold Absolute Pressure (MAP) sensor.
- Air Conditioning Solenoid Vacuum (A/C SV) valve.
41. The following hoses:
- Air hose to air pipe.
- Vacuum hose to the A/C SV valve (if equipped).
- Brake booster vacuum hose.
- MAP vacuum hose to gas filter.
42. Cruise control actuator and bracket.
a. Cruise control actuator bracket to vehicle; secure with three bolts. Tighten cruise control actuator bracket bolts to 25 Nm (18 ft. lbs.).
b. Cruise control actuator; secure with three bolts. Tighten cruise control actuator bolts to 25 Nm (18 ft. lbs.).
c. Accelerator cable to the cruise control actuator.
d. Clip cruise control actuator cover into place.
43. Windshield washer reservoir to vehicle, connecting electrical connector; secure with one bolt (standard brake equipped vehicles).
44. Coolant reservoir support bracket to vehicle; secure with two bolts. Tighten coolant reservoir support bracket bolts to 15 Nm (11 ft. lbs.).
45. Air cleaner (ACL)
a. ACL lower case; secure with three bolts. Tighten ACL lower case bolts to 10 Nm (89 inch lbs.).
b. Two wire harness retaining clips to lower case.
c. ACL filter, cover and hose; secure with four clips and hose clamp bolt. Tighten ACL hose clamp bolt to 5 Nm (44 inch lbs.).
d. Intake Air Temperature (IAT) sensor to ACL cover.
46. Radiator with cooling fan assembly. See Cooling System.
47. Throttle cable to bracket (automatic transaxle equipped vehicles).
48. Accelerator cable to throttle lever.
49. Refill transaxle oil (manual transaxle equipped vehicles) or transaxle fluid (automatic transaxle equipped vehicles). See Transmission and Drivetrain.
50. Two splash shields; secure with twelve bolts. Tighten splash shield bolts to 10 Nm (89 inch lbs.).
51. Oil drain plug arid gasket. Tighten oil drain plug to 44 Nm (33 ft. lbs.).
52. Negative (-) and positive (+) battery cables.
53. Hood assembly. See Body and Frame.
54. Refill oil.
55. Refill engine coolant. See Cooling System.
56. Inspect upon completion of installation, check coolant system for coolant leaks. After completing that inspection, start engine and check exhaust system for leaks and check oil pressure.