LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saturn >> 2005 >> Relay AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 3.5L >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

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

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

  6. Remove the engine hoist from the engine.
  7. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.
  8. Install the transaxle brace. Refer to Automatic Transmission Brace Replacement (Front Wheel Drive) or Automatic Transmission Brace Replacement (All Wheel Drive) or Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive) in Automatic Transaxle - 4T40-E/4T45-E.
    9. Fig 2: Identifying Engine Mount Lower Nuts
    GM96002Courtesy of GENERAL MOTORS CORP.
  9. Install the engine mount lower nuts.

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

  10. Install the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  11. Install the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  12. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  13. Position the transaxle table with the powertrain/frame under the vehicle.
    14. Fig 3: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  14. Lower the vehicle until the frame contacts the transaxle table.
  15. Install the new frame bolts. Refer to Frame Replacement - Front in Frame and Underbody.
  16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  17. Remove the transaxle table.
    18. CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage may cause loss of steering control which could result in an accident and possible personal injury
  18. Install the intermediate shaft pinch bolt to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  19. Connect the drive axles to the transaxle. Refer to Wheel Drive Shaft Replacement - Front in Wheel Drive Shafts.
  20. Position compressor to the engine and Install the A/C compressor bolts. Refer to Compressor Replacement in Heating, Ventilation, and Air Conditioning.
  21. Install the lower ball joints to the knuckles. Refer to Lower Ball Joint Replacement in Front Suspension.
  22. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  23. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement (FWD) or Stabilizer Shaft Link Replacement (AWD) in Front Suspension.
  24. Install the engine splash shields. Refer to Splash Shield Replacement - Engine in Body Front End.
  25. Install the lower radiator air baffle assembly. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
  26. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  27. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
  28. Install rear propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft. (AWD Only)
  29. Lower the vehicle.
  30. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  31. Install the engine mount strut. Refer to Engine Mount Strut Replacement - Left  and Engine Mount Strut Replacement - Right .
  32. Connect the following electrical connectors:
    • The knock sensor (KS)
    • The camshaft position (CMP) sensor
    • The crankshaft position (CKP) sensor
    • The heated oxygen sensor (HO2S)
    • The manifold absolute pressure (MAP) sensor
    • The exhaust gas recirculation (EGR) valve
    • The evaporative emission (EVAP) canister purge solenoid
    • The electronic throttle control
    • The ignition coil
    • The body wiring harness-to-engine harness
    • The engine wiring harness from transmission
  33. Install the engine wiring harness ground nut to the transaxle stud.

    Tighten:  Tighten the nut to 35 N.m (26 lb ft).

  34. Install the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement in Automatic Transaxle - 4T65-E.
  35. Install the fuel lines to the fuel rail. Refer to Fuel Rail Assembly Replacement in Engine Controls - 3.5L.
  36. Install the brake booster vacuum hose to the upper intake manifold.
  37. Install the vacuum hoses to the upper intake manifold.
  38. Install the heater outlet and inlet hoses to the engine. Refer to Heater Hose/Pipe Replacement - Inlet/Outlet in Heating Ventilation and Air Conditioning.
  39. Install the radiator outlet hose to the engine. Refer to Radiator Hose Replacement - Outlet in Engine Cooling.
  40. Install the radiator inlet hose to the engine. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
  41. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5L.
  42. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  43. Fill cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  44. Perform a CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 3.5L.
  45. Inspect for leaks.
scientia non olet · About LEMON Manuals