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Installation Procedure

WARNING: This page is about a different car, the 2003 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front engine mount bracket. Refer to ENGINE MOUNT BRACKET REPLACEMENT - FRONT  .
  2. Carefully position the engine to the supported frame and transaxle assembly, aligning the engine dowels to the transaxle cover.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the bolts attaching the engine to the transaxle.

    Tighten 

    Tighten the engine to transaxle mounting bolts to 75 N.m (55 lb ft).

    Fig 1: Installing Engine To Transaxle Mounting Bolts
    G02554334Courtesy of GENERAL MOTORS CORP.
  4. Install the nut securing the front engine mount to the engine frame.
    Fig 2: Installing Nut Securing Front Engine Mount To Engine Frame
    G02554335Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the front engine mount nut to 70 N.m (52 lb ft).

  5. Place a block of wood between the front of the engine oil pan and the engine frame.
  6. Remove the engine lift chain from the engine lift brackets.
  7. Remove the J 42504  from the cylinder head.
    Fig 3: Removing Engine Lift Bracket From Cylinder Head
    G02554336Courtesy of GENERAL MOTORS CORP.
  8. Install the 4 bolts securing the center transaxle brace to the engine and transaxle.

    Tighten 

    Tighten the center transaxle brace bolts to 50 N.m (37 lb ft).

    Fig 4: Installing Bolts Securing Center Transaxle Brace
    G02554337Courtesy of GENERAL MOTORS CORP.
  9. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.
    Fig 5: Installing Retaining Nuts Securing Vehicle Speed Sensor Heat Shield To Transaxle
    G02554338Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the vehicle speed sensor heat shield nuts to 50 N.m (37 lb ft).

  10. Install the bolts (1, 3) securing the front transaxle brace (2) to the transaxle and right cylinder head.

    Tighten 

    Tighten the front transaxle brace bolts (1, 3) to 50 N.m (37 lb ft).

    Fig 6: Installing Front Transaxle Brace To Transaxle And Right Cylinder Head
    G02554339Courtesy of GENERAL MOTORS CORP.
  11. Position the rear transaxle brace over the studs located at the rear of the right cylinder head.
  12. Loosely install the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
  13. Install the bolt (2) securing the rear transaxle brace (1) to the transaxle.

    Tighten 

    • Tighten the rear transaxle brace bolt (2) to 50 N.m (37 lb ft).
    • Tighten the rear transaxle brace nuts (3) to 50 N.m (37 lb ft).
    Fig 7: Installing Rear Transaxle Brace
    G02554340Courtesy of GENERAL MOTORS CORP.
  14. Position the right engine mount bracket (1) to the engine.
    Fig 8: Locating Right Engine Mount Bracket Components
    G02554341Courtesy of GENERAL MOTORS CORP.
  15. Install the 4 bolts securing the right engine mount bracket (1) to the engine.

    Tighten 

    Tighten the right engine mount bracket bolts to 50 N.m (37 lb ft).

  16. Install the nut (2) securing the power steering pressure hose to the right engine mount bracket (1).

    Tighten 

    Tighten the power steering pressure hose retaining nut to 9 N.m (80 lb in).

  17. Install the power steering pressure hose to the power steering pump.

    Tighten 

    Tighten the power steering hose to power steering pump to 30 N.m (22 lb ft).

    Fig 9: Installing Power Steering Pressure Hose To Power Steering Pump
    G02554342Courtesy of GENERAL MOTORS CORP.
  18. Connect the power steering hose to the power steering pump reservoir.
  19. Install the power steering return hose retaining bolt to the cylinder head.

    Tighten 

    Tighten the power steering return hose retaining bolt to 50 N.m (37 lb ft).

    Fig 10: Installing Power Steering Return Hose To Cylinder Head
    G02554343Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine wiring harness to the engine.
  21. Install the nut (3) securing the coil cassette ground wire to the cylinder head.

    Tighten 

    Tighten the coil cassette ground wire nut to 17 N.m (13 lb ft).

  22. Install the nut securing the intermediate hose to the secondary AIR valve at bank 1.
    Fig 11: Installing Nut Securing Coil Cassette Ground Wire To Cylinder Head
    G02554344Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the intermediate hose to secondary AIR valve nut to 9 N.m (80 lb in).

  23. Connect the intermediate hose to the secondary AIR valve at bank 2.
  24. Install the heater pipes. Refer to HEATER PIPE REPLACEMENT - INLET and HEATER PIPE REPLACEMENT - OUTLET in Heating, Ventilation and Air Conditioning.
  25. Position the engine/transaxle assembly under the vehicle.

    Important:  Ensure clearance is maintained between the engine/transaxle assembly and the following:

    • The A/C accumulator hose
    • The A/C compressor hose
    • The brake pipes
    • The heater hoses
    • The radiator hoses
    • The wheel speed sensor leads
    • The wiring harnesses
  26. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
  27. Install the 6 frame mounting bolts (3) retaining the frame (2) to the vehicle.
    Fig 12: Installing Frame Mounting Bolts
    G02554345Courtesy of GENERAL MOTORS CORP.

    Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.

    Tighten 

    Tighten the frame mounting bolts to 191 N.m (141 lb ft).

  28. Install the nut securing the right engine mount to the engine mount bracket.
    Fig 13: Installing Nut Securing Right Engine Mount To Engine Mount Bracket
    G02554346Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the right engine mount nut to 80 N.m (59 lb ft).

  29. Remove the block of wood between the front of the engine oil pan and the engine frame.
  30. Install the nut (1) securing the left transaxle mount to the transaxle mount bracket.
    Fig 14: Installing Nut Securing Left Transaxle Mount To Transaxle Mount Bracket
    G02554347Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the left transaxle mount nut to 80 N.m (59 lb ft).

  31. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  32. Remove the J 39580  powertrain support dolly from under the engine frame.
    Fig 15: Removing Universal Engine Support Table Powertrain Support Dolly
    G02554348Courtesy of GENERAL MOTORS CORP.

    Important:  Line up the flywheel and converter, using the alignment marks made during disassembly.

  33. Install the bolts securing the flywheel to the torque converter.

    Tighten 

    Tighten the flywheel to torque converter bolts to 60 N.m (44 lb ft).

  34. Install the torque converter cover. Refer to TORQUE CONVERTER COVER REPLACEMENT in Automatic Transaxle - 4T80-E.
  35. Install the oil pan to transaxle brace.
    Fig 16: Installing Oil Pan To Transaxle Brace
    G02554349Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the oil pan to transaxle brace bolts to 50 N.m (37 lb ft).

  36. Connect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS HEAT SHIELD REPLACEMENT in Engine Exhaust.
    CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
  37. Connect the intermediate shaft to the steering gear.
  38. Install the pinch bolt.
    Fig 17: Installing Pinch Bolt
    G02554350Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the intermediate shaft to steering gear pinch bolt to 45 N.m (33 lb ft).

  39. Connect the A/C suction hose to the compressor.

    Tighten 

    Tighten the A/C suction hose nut to 20 N.m (15 lb ft).

    Fig 18: Connecting A/C Suction Hose To Compressor
    G02554351Courtesy of GENERAL MOTORS CORP.
  40. Connect the A/C discharge hose to the compressor.

    Tighten 

    Tighten the A/C discharge hose nut to 20 N.m (15 lb ft).

  41. Connect the A/C pressure sensor.
    Fig 19: Connecting A/C Discharge Hose To Compressor
    G02554352Courtesy of GENERAL MOTORS CORP.
  42. Connect the 2 rear brake pipes at the rear of the engine frame.

    Tighten 

    Tighten the brake pipes to 15 N.m (11 lb ft).

    Fig 20: Connecting Rear Brake Pipes At Rear Of Engine Frame
    G02554353Courtesy of GENERAL MOTORS CORP.
  43. Connect the front brake pipes to the retainers at the body frame rails.
  44. Install the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.

    Tighten 

    Tighten the brake pipe frame bracket nuts to 15 N.m (11 lb ft).

    Fig 21: Installing Nuts Securing Front Brake Pipe Frame Brackets To Body Frame Rails
    G02554354Courtesy of GENERAL MOTORS CORP.
  45. Connect the secondary AIR inlet hose to the secondary AIR pump.
    Fig 22: Connecting Secondary AIR Inlet Hose To Secondary AIR Pump
    G02554355Courtesy of GENERAL MOTORS CORP.
  46. Install the front fascia extensions. Refer to FASCIA EXTENSION REPLACEMENT - FRONT in Bumpers.
  47. Install the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT - FRONT in Body Front End.
  48. Attach the front wheel speed sensor electrical leads (2) to the body frame rail.
    Fig 23: Attaching Front Wheel Speed Sensor Electrical Leads To Body Frame Rail
    G02554356Courtesy of GENERAL MOTORS CORP.
  49. Install the rear exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT - REAR (L47) in Engine Exhaust.
  50. Install the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  51. Lower the vehicle ONLY enough to allow the threaded holes in the strut to align with the holes in the strut towers.
  52. Install the right and left side strut tower bolts.

    Tighten 

    Tighten the strut tower bolts to 45 N.m (33 lb ft).

  53. Lower the vehicle.
    Fig 24: Installing Right And Left Side Strut Tower Bolts
    G02554357Courtesy of GENERAL MOTORS CORP.
  54. Remove the J 42640  from the steering column.
    Fig 25: Removing Steering Column Lock Pin From Steering Column
    G02554358Courtesy of GENERAL MOTORS CORP.

    Important:  Ensure the transaxle oil cooler pipe is positioned upwards while tightening.

  55. Connect the lower transaxle oil cooler pipe fitting to the radiator.

    Tighten 

    Tighten the transaxle oil cooler pipe fitting to 35 N.m (26 lb ft).

    Fig 26: Connecting Lower Transaxle Oil Cooler Pipe Fitting To Radiator
    G02554359Courtesy of GENERAL MOTORS CORP.
  56. Install the upper transaxle oil cooler pipe retaining bolt to the fan shroud.

    Tighten 

    Tighten the transaxle oil cooler pipe retaining bolt to 6 N.m (53 lb in).

    Fig 27: Installing Upper Transaxle Oil Cooler Pipe Retaining Bolt To Fan Shroud
    G02554360Courtesy of GENERAL MOTORS CORP.
  57. Push the upper transaxle oil cooler pipe into the radiator quick connect fitting, until a click is heard.
  58. Tug gently on the cooler pipe to ensure proper retention.
  59. Slide the plastic cap (1) over the quick connect fitting.
    Fig 28: View Of Radiator Quick Connect Fitting
    G02554361Courtesy of GENERAL MOTORS CORP.
  60. Install the 2 master cylinder brake pipes (1) to the BPMV (2) using the location recorded during the removal procedure.

    Tighten 

    Tighten the brake pipes to 15 N.m (11 lb ft).

    Fig 29: Installing Master Cylinder Brake Pipes To BPMV
    G02554362Courtesy of GENERAL MOTORS CORP.
  61. Connect the heater hoses (1, 2) to the heater pipes.
    Fig 30: Connecting Heater Hoses To Heater Pipes
    G02554363Courtesy of GENERAL MOTORS CORP.
  62. Connect the surge tank inlet hose (2) to the surge tank (1).
    Fig 31: Connecting Surge Tank Inlet Hose To Surge Tank
    G02554364Courtesy of GENERAL MOTORS CORP.
  63. Position the J 38185  to the clamp in order to connect the radiator outlet hose (2) to the thermostat housing.
  64. Position the J 37097-A  to the clamp in order to connect the radiator inlet hose (1) to the engine.
    Fig 32: Connecting Radiator Hoses
    G02554365Courtesy of GENERAL MOTORS CORP.
  65. Install the shift cable (1) to the manual shift lever (2) and the bracket.
    Fig 33: Installing Shift Cable To Manual Shift Lever And Bracket
    G02554366Courtesy of GENERAL MOTORS CORP.
    CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
  66. Install a NEW accelerator control cable to the throttle body. Refer to ACCELERATOR CONTROL CABLE .
  67. Install the cruise control cable (2) to the throttle body lever (1).
  68. Slide the cruise control fully into the throttle body bracket until it snaps into place.
    Fig 34: Installing Cruise Control Cable To Throttle Body Lever
    G02554367Courtesy of GENERAL MOTORS CORP.
  69. Install the bolt (1) securing the engine ground cable (2) to the right side body frame rail.

    Tighten 

    Tighten the engine ground cable bolt to 50 N.m (37 lb ft).

    Fig 35: Installing Bolt Securing Engine Ground Cable To Right Side Body Frame Rail
    G02554368Courtesy of GENERAL MOTORS CORP.
  70. Connect the wiring harness electrical connectors to the following components:
    • The PCM.

      Refer to POWERTRAIN CONTROL MODULE .

    • The C101 (1)
      Fig 36: Connecting C101
      G02554369Courtesy of GENERAL MOTORS CORP.
    • The engine electrical harness.

      Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.

  71. Install the nut (1) securing the battery positive cable to the remote positive terminal.
    Fig 37: Installing Nut Securing Battery Positive Cable To Remote Positive Terminal
    G02554370Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the battery positive cable to remote positive terminal nut to 12 N.m (106 lb in).

  72. Attach the secondary AIR relay (1) to the relay bracket.
    Fig 38: Attaching Secondary AIR Relay To Relay Bracket
    G02554371Courtesy of GENERAL MOTORS CORP.
  73. Install the air cleaner assembly.
  74. Connect the hose (4) to the evaporative emission canister purge valve (3).
    Fig 39: Connecting Hose To Evaporative Emission Canister Purge Valve
    G02554372Courtesy of GENERAL MOTORS CORP.
  75. Connect the fuel inlet and return quick-connect fittings at the fuel rail. Refer to FUEL LINE DISCONNECT FITTINGS .
  76. Connect the vacuum brake booster hose to the vacuum connection.
    Fig 40: Connecting Vacuum Brake Booster Hose To Vacuum Connection
    G02554373Courtesy of GENERAL MOTORS CORP.
  77. Position the intake manifold sight shield (1) to the engine.
    Fig 41: Installing Intake Manifold Sight Shield
    G02554374Courtesy of GENERAL MOTORS CORP.
  78. Install the 2 intake manifold sight shield nuts (2).

    Tighten 

    Tighten the intake manifold sight shield nuts to 3 N.m (27 lb in).

  79. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  80. Fill the engine with oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  81. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  82. Bleed the hydraulic brake system. Refer to MANUAL BLEEDING or PRESSURE BRAKE BLEEDING .
  83. Recharge the A/C refrigerant system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
  84. Bleed the power steering system. Refer to BLEEDING THE POWER STEERING SYSTEM in Power Steering System.
  85. Measure the wheel alignment. Refer to MEASURING WHEEL ALIGNMENT in Wheel Alignment.
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