GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2009 🢒 G6 🢒 Engine 🢒 Engine Mechanical - 3.9L 🢒 Engine Replacement

Removal Procedure

    Object Number: 1583634 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  3. Remove the hood. Refer to Hood Replacement.
  4. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  5. Remove the engine mount snubber and drive belt. Refer to Drive Belt Replacement.
  6. Remove the power steering pump and disconnect the power steering lines, if equipped. Refer to Power Steering Pump Replacement.
  7. Drain the cooling system. Refer to Cooling System Draining and Filling.
  8. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
  9. Remove the oil pressure sensor heat shield nuts and shield.

    10. Object Number: 1581861 Size: SH
  10. Disconnect the oil pressure sensor (1) electrical connector.
  11. Disconnect the knock sensor (2) electrical connector.

    12. Object Number: 1583669 Size: SH
  12. Disconnect the air conditioning (A/C) compressor electrical connector.
  13. Lower the vehicle.

    14. Object Number: 1581869 Size: SH
  14. Disconnect the evaporative emission (EVAP) canister purge solenoid (1) electrical connector.
  15. Disconnect the electronic throttle control (ETC) (2) electrical connector.
  16. Remove the connector position assurance (CPA) retainer (5).
  17. Disconnect the heated oxygen sensor (HO2S) (3) electrical connector.

    18. Object Number: 1582011 Size: SH
  18. Disconnect the manifold absolute pressure (MAP) sensor (1) electrical connector.
  19. Disconnect the ignition control module (2) electrical connector.

    20. Object Number: 1582090 Size: SH
  20. Disconnect the inlet manifold valve (1) electrical connector.
  21. Disconnect the fuel injector inline (2) electrical connector.

    22. Object Number: 1583635 Size: SH
  22. Disconnect the camshaft phasor sensor electrical connector.

    23. Object Number: 1583636 Size: SH
  23. Remove the CPA retainer.
  24. Disconnect the rear upper HO2S electrical connector (1).

    25. Object Number: 1583637 Size: SH
  25. Disconnect the knock sensor electrical connector (1).
  26. Disconnect the crankshaft position (CKP) sensor electrical connector (2).

    27. Object Number: 1583652 Size: SH
  27. Disconnect the engine harness connector (1) from the body harness connector (2).

    28. Object Number: 1583653 Size: SH
  28. Disconnect the body harness electrical connector from the powertrain control module (PCM).

    29. Object Number: 1583655 Size: SH
  29. Disconnect the engine harness electrical connectors (1) from the PCM.

    30. Object Number: 1583656 Size: SH
  30. Disconnect the engine harness electrical connector from the transmission control module (TCM).

    31. Object Number: 1583639 Size: SH
  31. Remove the engine harness clip nut (2).
  32. Remove the engine harness clip (1) from the transmission stud.

    33. Object Number: 1583641 Size: SH
  33. Remove the engine harness ground nut (2).
  34. Remove the engine harness ground terminal (1) from the transmission stud.

    35. Object Number: 1583643 Size: SH
  35. Remove the engine harness rear clip nut (2).
  36. Remove the engine harness rear clip (1) from the transmission stud.
  37. Remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
  38. Remove the engine mount. Refer to Engine Mount Replacement.
  39. Remove the torque converter cover. Refer to Torque Converter Cover Replacement.
  40. Remove the starter motor. Refer to Starter Motor Replacement.
  41. Remove the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement.
  42. Unbolt and reposition the A/C compressor to the side. DO NOT discharge the A/C system.

    43. Object Number: 1736974 Size: SH
  43. Remove the transaxle brace to oil pan bolts.
  44. Remove the transaxle brace to transaxle bolt and remove the brace.

    45. Object Number: 1736976 Size: SH
  45. Remove the transaxle brace to oil pan bolts, if equipped with regular production option (RPO) MT2.
  46. Remove the transaxle brace to transaxle bolt and remove the brace, if equipped with RPO MT2.

    47. Object Number: 1736975 Size: SH
  47. Remove the transaxle brace to oil pan lower bolt (6), if equipped with RPO M15.
  48. Remove the lower transaxle-to-engine bolt and stud.

    49. Object Number: 1583645 Size: SH
  49. Reposition the radiator outlet hose clamp at the thermostat housing.
  50. Remove the radiator outlet hose from the thermostat housing.
  51. Lower the vehicle and support the transaxle.

    52. Object Number: 1582936 Size: SH
  52. Reposition the radiator surge tank hose clamp at the surge tank pipe.
  53. Remove the radiator surge tank hose from the surge tank pipe.

    54. Object Number: 1582014 Size: SH
  54. Reposition the brake booster vacuum hose clamp at the intake manifold.
  55. Remove the brake booster vacuum hose (1) from the intake manifold.
  56. Reposition the heater inlet and outlet hose clamps at the engine.
  57. Remove the heater outlet and inlet hoses from the engine.
  58. Disconnect the fuel feed line from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  59. Disconnect the EVAP purge line from the canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.

    60. Object Number: 1583647 Size: SH
  60. Reposition the radiator inlet hose clamp at the engine.
  61. Remove the radiator inlet hose from the engine.
  62. Install a engine lifting device to the engine.

    63. Object Number: 1583649 Size: SH
  63. Remove the remaining transaxle-to-engine bolts/studs if equipped with a manual transmission.

    64. Object Number: 1583650 Size: SH
  64. Remove the remaining transaxle-to-engine bolts/studs if equipped with a automatic transmission.
  65. Remove the engine from the vehicle.
  66. Remove the flywheel. Refer to Engine Flywheel Replacement.
  67. Install the engine to the engine stand.

Installation Procedure

    Object Number: 1583650 Size: SH
  1. Install an engine lifting device to the engine.
  2. Remove the engine from the engine stand.
  3. Install the flywheel. Refer to Engine Flywheel Replacement.
  4. Install the engine to the vehicle.

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the transaxle-to-engine bolts/studs if equipped with a automatic transmission and tighten to 75 N·m (55 lb ft).

    6. Object Number: 1583649 Size: SH
  6. Install the transaxle-to-engine bolts/studs if equipped with a manual transmission and tighten to 75 N·m (55 lb ft).

    7. Object Number: 1583647 Size: SH
  7. Remove the engine lifting device from the engine.
  8. Install the radiator inlet hose to the engine.
  9. Position the radiator inlet hose clamp at the engine.

    10. Object Number: 1582014 Size: SH
  10. Connect the EVAP purge line to the canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  11. Connect the fuel feed line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  12. Install the heater outlet and inlet hoses to the engine.
  13. Position the heater inlet and outlet hose clamps at the engine.
  14. Install the brake booster vacuum hose (1) to the intake manifold.
  15. Position the brake booster vacuum hose clamp at the intake manifold.

    16. Object Number: 1582936 Size: SH
  16. Install the radiator surge tank hose to the surge tank pipe.
  17. Position the radiator surge tank hose clamp at the surge tank pipe.

    18. Object Number: 1583645 Size: SH
  18. Raise and support the vehicle.
  19. Install the radiator outlet hose to the thermostat housing.
  20. Position the radiator outlet hose clamp at the thermostat housing.
  21. Install the lower transaxle-to-engine bolt and stud and tighten to 75 N·m (55 lb ft).

    22. Object Number: 1736975 Size: SH
  22. Install the transaxle brace to oil pan lower bolt (6), if equipped with RPO M15 and tighten to 50 N·m (37 lb ft).

    23. Object Number: 1736976 Size: SH
  23. Position the transaxle brace and install the transaxle brace to transaxle bolt until snug, if equipped with RPO MT2.
  24. Install the transaxle brace to oil pan bolts, if equipped with RPO MT2 and tighten to 50 N·m (37 lb ft.

    25. Object Number: 1736974 Size: SH
  25. Position the transaxle brace and install the transaxle brace to transaxle bolt until snug.
  26. Install the transaxle brace to oil pan bolts and tighten to 50 N·m (37 lb ft).
  27. Position and bolt up the A/C compressor and tighten the bolt to 50 N·m (37 lb ft).
  28. Install the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement.
  29. Install the starter motor. Refer to Starter Motor Replacement.
  30. Install the torque converter cover. Refer to Torque Converter Cover Replacement.
  31. Install the engine mount. Refer to Engine Mount Replacement.

    32. Object Number: 1583643 Size: SH
  32. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
  33. Install the engine harness rear clip (1) to the transmission stud.
  34. Install the engine harness rear clip nut (2) and tighten to 25 N·m (18 lb ft).

    35. Object Number: 1583641 Size: SH
  35. Install the engine harness ground terminal (1) to the transmission stud.
  36. Install the engine harness ground nut (2) and tighten to 25 N·m (18 lb ft).

    37. Object Number: 1583639 Size: SH
  37. Install the engine harness clip (1) to the transmission stud.
  38. Install the engine harness clip nut (2) and tighten to 25 N·m (18 lb ft).

    39. Object Number: 1583656 Size: SH
  39. Connect the engine harness electrical connector to the TCM.

    40. Object Number: 1583655 Size: SH
  40. Connect the engine harness electrical connectors (1) to the PCM.

    41. Object Number: 1583653 Size: SH
  41. Connect the body harness electrical connector to the PCM.

    42. Object Number: 1583652 Size: SH
  42. Connect the engine harness connector (1) to the body harness connector (2).

    43. Object Number: 1583637 Size: SH
  43. Connect the CKP sensor electrical connector (2).
  44. Connect the knock sensor electrical connector (1).

    45. Object Number: 1583636 Size: SH
  45. Connect the rear upper HO2S electrical connector (1).
  46. Install the CPA retainer.

    47. Object Number: 1583635 Size: SH
  47. Connect the camshaft phasor sensor electrical connector.

    48. Object Number: 1582090 Size: SH
  48. Connect the fuel injector inline (2) electrical connector.
  49. Connect the inlet manifold valve (1) electrical connector.

    50. Object Number: 1582011 Size: SH
  50. Connect the ignition control module (2) electrical connector.
  51. Connect the MAP sensor (1) electrical connector.

    52. Object Number: 1581869 Size: SH
  52. Connect the HO2S (3) electrical connector.
  53. Install the CPA retainer.
  54. Connect the ETC (2) electrical connector.
  55. Connect the EVAP canister purge solenoid (1) electrical connector.
  56. Raise and support the vehicle.

    57. Object Number: 1583669 Size: SH
  57. Connect the A/C compressor electrical connector.

    58. Object Number: 1581861 Size: SH
  58. Connect the knock sensor (2) electrical connector.
  59. Connect the oil pressure sensor (1) electrical connector.

    60. Object Number: 1583634 Size: SH
  60. Install the oil pressure sensor heat shield and nuts and tighten the nuts to 25 N·m (18 lb ft).
  61. Lower the vehicle.
  62. Connect the power steering lines and install the power steering pump, if equipped. Refer to Power Steering Pump Replacement.
  63. Install the drive belt and engine mount snubber. Refer to Drive Belt Replacement.
  64. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  65. Install the hood. Refer to Hood Replacement.
  66. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  67. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
  68. Fill the cooling system. Refer to Cooling System Draining and Filling.
  69. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  70. Inspect for leaks.