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Installation Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion Red Line. 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. Align the engine to the transmission.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The number 3 bolt location is not used.
  4. Secure the engine to the transmission.

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

    5. Fig 1: Securing Engine To Transmission
    GM851293Courtesy of GENERAL MOTORS CORP.
  5. Install the starter. Refer to Starter Motor Replacement (2.2L (L61)) or Starter Motor Replacement (2.0L (LSJ)) in Engine Electrical.
    6. Fig 2: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  6. Remove the engine lift from the engine.
  7. Raise and position the frame and powertrain assembly to the vehicle.
  8. Hand start all the frame bolts while aligning the frame to the paint marks.
  9. Tighten the frame bolts.

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

    10. Fig 3: View Of Frame
    GM851651Courtesy of GENERAL MOTORS CORP.
  10. Remove the lift table.
  11. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
    12. Fig 4: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  12. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
    13. Fig 5: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  13. Connect the intermediate steering shaft to the steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
    14. Fig 6: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
  14. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
    15. Fig 7: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  15. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    16. Fig 8: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  16. Install the left transmission mount. Refer to Transmission Mount Replacement - Left in Manual Transmission - MU3.
    17. Fig 9: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  17. Install the engine mount. Refer to Engine Mount Replacement .
    18. Fig 10: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  18. Remove the wood blocks between the powertrain and frame.
  19. Connect the transmission shift cable to the transmission.
  20. Connect the exhaust takedown pipe to the exhaust manifold.

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

    21. Fig 11: View Of Exhaust Takedown Pipe
    GM878834Courtesy of GENERAL MOTORS CORP.
  21. Connect the generator harness connectors.

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

  22. 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).

    23. Fig 12: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  23. Install the compressor and condenser hose assembly to the compressor. Refer to Compressor Hose Assembly Replacement (2.2L (L61)) or Compressor Hose Assembly Replacement (2.0 L (LSJ)) in Heating, Ventilation, and Air Conditioning.
  24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  25. Install the engine drive belt. Refer to Drive Belt Replacement .
  26. Connect the following harness connectors:
    • TMAP sensor
    • ETC
    • Map sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • BARO sensor
    • Ignition coil modules
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid
  27. 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.
    28. Fig 13: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  28. 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.
  29. Connect the fuel line to the fuel rail.
    30. Fig 14: View Of Fuel Line
    GM1387192Courtesy of GENERAL MOTORS CORP.
  30. Install the surge tank to the cylinder head pipe.

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

  31. Release the cooling module from the upper body structure.
    32. Fig 15: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  32. Install the air outlet duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.0L (LSJ).
  33. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  34. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  35. 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.
  36. Road test the vehicle.
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