GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 OUTLOOK - AWD 🢒 Engine 🢒 Engine Mechanical - 2.8L, 3.0L, 3.2L, or 3.6L 🢒 Engine Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
  3. Release the clamp from the brake booster vacuum hose connection.
  4. Disconnect the brake booster vacuum hose from the intake manifold.
  5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  6. Discharge the fuel system. Refer to Fuel Pressure Relief.
  7. Disconnect the evaporative emission (EVAP) hose/pipe from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service.
  8. Disconnect the engine fuel hose/pipe from the chassis fuel hose/pipe. Refer to Metal Collar Quick Connect Fitting Service.
  9. Discharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging.
  10. Remove the A/C compressor suction hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to Suction Hose Replacement.
  11. Remove the A/C compressor discharge hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to Discharge Hose Replacement.
  12. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling.
  13. Tie the radiator, A/C condenser and fan module assembly to the upper radiator support to keep the assembly with the vehicle when the frame and drivetrain is removed.
  14. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
  15. Disconnect the inlet coolant heater hose from the engine. Refer to Heater Inlet Hose Replacement.
  16. Disconnect the outlet coolant heater hose from the engine. Refer to Heater Outlet Hose Replacement.
  17. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
  18. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  19. Remove the exhaust flexible pipe and secure the rear half of the exhaust system to the vehicle underbody. Refer to Exhaust Flexible Pipe Replacement.
  20. Remove the front tires. Refer to Tire and Wheel Removal and Installation.
  21. Remove the engine splash shield. Refer to Engine Splash Shield Replacement.
  22. Remove the steering intermediate shaft pinch bolt and discard the bolt.
  23. Disconnect the steering intermediate shaft from the steering gear.

    24. Object Number: 854972 Size: SH
  24. Remove the right and left steering linkage outer tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.

    25. Object Number: 927949 Size: SH
  25. Remove the right and left stabilizer shaft links from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement.

    26. Object Number: 1418666 Size: SH
  26. Remove the right and left lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement.
  27. On front wheel drive (FWD) models, place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle. Refer to Front Wheel Drive Shaft Replacement.
  28. On all wheel drive (AWD) models, remove the driveline torque tube. Refer to Driveline Torque Tube Replacement.

    29. Object Number: 1403676 Size: SH
  29. On all models, place a block of wood (1) between the frame and the engine oil pan in order to support the engine once the bolts are removed from the right engine mount.

    30. Object Number: 1403679 Size: SH
  30. Place a block of wood (1) between the frame and the transaxle in order to support the transaxle once the bolts are removed from the left transaxle mount bracket.
  31. Lower the vehicle.
  32. Remove the engine mount strut. Refer to Engine Mount Strut Replacement - Right Side.

    33. Note: Ensure the vehicle body is secured to the hoist.

  33. Disconnect and reposition the engine harness as necessary.
  34. Raise the vehicle.
  35. Disconnect the power steering hoses at the power steering fluid cooler. Refer to Power Steering Cooler Pipe/Hose Replacement.
  36. Place a universal frame support fixture or jackstands under the frame.
  37. Lower the vehicle until the frame contacts the frame support fixture or jackstands.

    38. Object Number: 933087 Size: SH
  38. Remove the frame-to-body and frame reinforcement bolts. Discard the bolts.

    39. Note: Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain.

  39. Carefully raise the vehicle body up away from the powertrain.
  40. Disconnect all necessary engine electrical wiring harness connectors.
  41. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement.
  42. Remove the starter motor. Refer to Starter Replacement.

    43. Object Number: 2084161 Size: SH
  43. Remove the torque converter bolts (1).
  44. Install the engine lift hooks.
  45. Install an engine lift chain to the engine lift hooks.
  46. Remove the engine and transmission mount nuts from the frame.
  47. Support the engine weight with an engine hoist and raise the engine and transmission assembly off the frame.

    48. Object Number: 1371142 Size: SH
  48. Lower the engine/transmission assembly to a suitable work area.
  49. Remove the automatic transaxle bolts.
  50. Separate the automatic transaxle from the engine.
  51. Lift the engine away from the automatic transaxle.
  52. Secure the engine to an engine stand.
  53. Remove any additional engine components as necessary. Refer to appropriate component sections in manual if needed.

Installation Procedure
  1. Remove the engine from the engine stand.

    2. Object Number: 1371142 Size: SH
  2. Align the engine to the frame and automatic transaxle.

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

  3. Install the automatic transaxle bolts and tighten to 75 N·m (55 lb ft).
  4. Place a block of wood between the frame and the engine oil pan in order to support the engine on the frame once the engine hoist is removed.
  5. Remove the engine hoist and lift chain.

    6. Object Number: 2084161 Size: SH
  6. Install the torque converter bolts and tighten to 60 N·m (44 lb ft).
  7. Install the starter motor. Refer to Starter Replacement.
  8. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement.
  9. Connect all necessary engine electrical wiring harness connectors.

    10. Object Number: 933087 Size: SH
  10. Install NEW frame-to-body bolts and tighten to 155 N·m (114 lb ft).
  11. Raise the vehicle up away from the frame support fixture or jackstands and remove the support fixture or jackstands from under the vehicle.
  12. Connect the power steering hoses to the power steering fluid cooler. Refer to Power Steering Cooler Pipe/Hose Replacement.
  13. Lower the vehicle.
  14. Install the left transaxle mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side.
  15. Install the engine mount strut. Refer to Engine Mount Strut Replacement - Right Side.
  16. Raise the vehicle.

    17. Object Number: 1403679 Size: SH
  17. Remove the block of wood (1) between the frame and the transaxle used to support the transaxle while the bolts were removed from the left transaxle mount bracket.

    18. Object Number: 1403676 Size: SH
  18. Remove the block of wood (1) between the frame and the engine oil pan used to support the engine while the bolts were removed from the right engine mount.
  19. On AWD models, install the driveline torque tube. Refer to Driveline Torque Tube Replacement.
  20. On FWD models, install the right and left front wheel drive shafts into the transaxle. Refer to Front Wheel Drive Shaft Replacement.

    21. Object Number: 1418666 Size: SH
  21. On all models, install the right and left lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement.

    22. Object Number: 927949 Size: SH
  22. Install the right and left stabilizer shaft links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement.

    23. Object Number: 854972 Size: SH
  23. Install the right and left steering linkage outer tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
  24. Connect the steering intermediate shaft to the steering gear.
  25. Install a NEW pinch bolt to the steering intermediate shaft and tighten to 34 N·m (25 lb ft).
  26. Install the engine splash shield. Refer to Engine Splash Shield Replacement.
  27. Install the front tires. Refer to Tire and Wheel Removal and Installation.
  28. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.
  29. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
  30. Lower the vehicle.
  31. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
  32. Connect the outlet coolant heater hose to the engine. Refer to Heater Outlet Hose Replacement.
  33. Connect the inlet coolant heater hose to the engine. Refer to Heater Inlet Hose Replacement.
  34. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
  35. Untie the radiator, AC condenser, and fan module assembly from the upper radiator support.
  36. Install the A/C compressor discharge hose assembly to the compressor. Refer to Discharge Hose Replacement.
  37. Install the A/C compressor suction hose assembly to the compressor. Refer to Suction Hose Replacement.

    38. Object Number: 1371132 Size: SH
  38. Connect the engine fuel hose/pipe (3) to the chassis fuel hose/pipe (2). Refer to Metal Collar Quick Connect Fitting Service.
  39. Connect the EVAP hose/pipe to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service.
  40. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

    41. Object Number: 1370533 Size: SH
  41. Connect the brake booster vacuum hose (2) to the intake manifold.
  42. Position the clamp (1) on the brake booster vacuum hose connection.
  43. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
  44. Fill the engine with engine oil. Refer to Approximate Fluid Capacities , Fluid and Lubricant Recommendations , and Maintenance Schedule.
  45. Fill the engine with coolant. Refer to Cooling System Draining and Filling.
  46. Check the transaxle fluid level. Refer to Adhesives, Fluids, Lubricants, and Sealers , Transmission General Specifications , and Approximate Fluid Capacities.
  47. Charge the AC system. Refer to Refrigerant Recovery and Recharging.
  48. Add power steering fluid and bleed air from the power steering system. Refer to Power Steering System Bleeding.
  49. Prime the fuel system.
    50. 49.1. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.
    49.2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    49.3. If the engine does not start, repeat the steps.