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Home >> Pontiac >> 2004 >> Aztek Base, AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 3.4L >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  1. Remove engine from engine stand.
  2. Install and align the engine to the transaxle/frame.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1, 2).

    Tighten:  Tighten the bolts (3, 4, 5, 6) and studs (1, 2) to 75 N.m (55 lb ft).

  4. Install engine mount to frame nuts.

    Tighten:  Tighten nuts to 43 N.m (32 lb ft).

  5. Remove engine hoist from engine.
  6. Install the engine flywheel to torque converter bolts.

    Tighten:  Tighten bolts to 62 N.m (46 lb ft).

  7. Install starter. Refer to Starter Motor Replacement (LA1) in Engine Electrical.
  8. Position the transaxle table with the powertrain/frame under the vehicle.
    9. Fig 2: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  9. Lower the vehicle until the frame contacts the transaxle table.
  10. Install the new frame bolts. Refer to Frame Replacement - Front (W/AWD) or Frame Replacement - Front (W/FWD) in Frame and Underbody.
  11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  12. Remove the transaxle table.
    13. 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.
  13. Install the intermediate shaft pinch bolt to steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  14. Install the drive axles to the transaxle. Refer to Wheel Drive Shaft Replacement - Front in Drive Axle.
  15. Install the transaxle cooler lines and bracket to the transaxle. Refer to Automatic Transmission Oil Cooler Hose Replacement in Automatic Transaxle - 4T65-E.
  16. Install A/C compressor and bolts.
  17. Install the lower ball joints to the knuckles. Refer to Lower Ball Joint Replacement in Front Suspension.
  18. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  19. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  20. Install the engine splash shields. Refer to Splash Shield Replacement - Engine in Body Front End.
  21. Install lower radiator baffle.
  22. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  23. Install the three-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
  24. Install the lower engine wiring harness to engine and transmission.
  25. Install rear propshaft. Refer to Propeller Shaft Replacement in Driveline/Axle-Propeller Shaft. (AWD Only)
  26. Lower the vehicle.
  27. Install the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement in Automatic Transaxle - 4T65-E.
  28. Install the vacuum brake booster hose.
  29. Install the vacuum hoses to the engine. Refer to Emission Hose Routing Diagram in Engine Controls - 3.4L.
  30. Install the upper engine wiring harness to engine and transmission.
  31. Install the fuel lines at quick connects. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.4L.
  32. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left  and Engine Mount Strut Replacement - Right .
  33. Connect the heater hoses to the engine. Refer to Heater Hose Replacement - Inlet (LA1) and Heater Hose Replacement - Outlet (LA1) in HVAC Systems - Manual.
  34. Connect the radiator hoses to the engine. Refer to Radiator Hose Replacement - Inlet (LA1) and Radiator Hose Replacement - Outlet (LA1) in Engine Cooling.
    35. 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.
  35. Install the NEW accelerator control cable to the engine. Refer to Accelerator Controls Cable Replacement in Engine Controls - 3.4L.
  36. Install the cruise control cable to the engine. Refer to Cruise Control Cable Replacement in Cruise Control.
  37. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
  38. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling.
  39. Adjust the transaxle fluid level. Refer to the following information:
  40. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  41. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (LA1) in Engine Electrical.
  42. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 3.4L.
  43. Inspect for proper fluid levels and possible fluid leaks.
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