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Installation Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
  3. If applicable, install the clutch pressure plate and disk.
  4. Align the engine to the transmission.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The number 3 bolt location is not used.
  5. Secure the engine to the transmission.

    Tighten:  Tighten the transmission to engine bolts to 75 N.m (55 lb ft).

    6. Fig 1: Securing Engine To Transmission
    GM851293Courtesy of GENERAL MOTORS CORP.
  6. If applicable, install the torque converter bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

  7. Install the starter. Refer to Starter Motor Replacement (2.2L (L61)) or Starter Motor Replacement (2.0L (LSJ)) in Engine Electrical.
    8. Fig 2: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  8. Remove the engine lift from the engine.
  9. Raise and position the frame and powertrain assembly to the vehicle.
  10. Hand start all the frame bolts while aligning the frame to the paint marks.
  11. Tighten the frame bolts.

    Tighten:  Tighten the frame bolts to 100 N.m (74 lb ft +180 degrees).

  12. Remove the lift table.
  13. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
    14. Fig 3: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  14. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
    15. Fig 4: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  15. Connect the intermediate steering shaft to the steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
    16. Fig 5: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
  16. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
    17. Fig 6: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  17. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    18. Fig 7: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  18. Install the side transmission mount. Refer to the following:
    19. Fig 8: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  19. Install the engine mount. Refer to Engine Mount Replacement .
    20. Fig 9: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  20. Remove the wood blocks between the powertrain and frame.
  21. Connect the transmission shift cable to the transmission.
  22. Connect the transmission harness connector.
  23. Connect the exhaust takedown pipe to the exhaust manifold.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

    24. Fig 10: View Of Exhaust Takedown Pipe
    GM878834Courtesy of GENERAL MOTORS CORP.
  24. Connect the generator harness connectors.

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

  25. Connect the starter harness connectors (3,4,5).

    Tighten:  Tighten the battery terminal nut to 17 N.m (13 lb ft).

    Tighten:  Tighten the S-terminal nut to 3 N.m (27 lb in).

    26. Fig 11: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  26. Install the AC compressor to the engine. Refer to Compressor Replacement (2.2L (L61)) or Compressor Replacement (2.0L (LSJ)) in Heating, Ventilation and Air Conditioning.
  27. Install the engine drive belt. Refer to Drive Belt Replacement .
  28. Connect the following harness connectors:
    • IAC motor
    • TPS
    • Map sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
  29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Hose Replacement - Inlet (2.2L (L61)) or Heater Hose Replacement - Inlet (2.0L (LSJ)) and Heater Hose Replacement - Outlet (2.2L (L61)) or Heater Hose Replacement - Outlet (2.0L (LSJ)) in Heating, Ventilation and Air Conditioning.
    30. Fig 12: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  30. Install the radiator outlet hose. Refer to Radiator Hose Replacement - Inlet (2.2L (L61)) or Radiator Hose Replacement - Inlet (2.0L (LSJ)) in Engine Cooling.
  31. Connect the fuel line to the fuel rail.
    32. Fig 13: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
  32. Connect the brake booster hose at the brake booster.
  33. Connect the accelerator cable. Refer to Accelerator Controls Cable Replacement in Engine Controls - 2.2L (L61).
  34. Release the cooling module from the upper body structure.
    35. Fig 14: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  35. Install the air inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
  36. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  37. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  38. Fill the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) in Engine Cooling.
  39. Road test the vehicle.
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