GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 OUTLOOK - FWD 🢒 Engine 🢒 Engine Mechanical - 3.6L 🢒 Engine Replacement

Removal Procedure
  1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
  2. Release the clamp from the brake booster vacuum hose connection.
  3. Disconnect the brake booster vacuum hose from the intake manifold.
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  5. Discharge the fuel system. Refer to Fuel Pressure Relief.
  6. Disconnect the evaporative emission (EVAP) hose/pipe from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service.
  7. Disconnect the engine fuel hose/pipe from the chassis fuel hose/pipe. Refer to Metal Collar Quick Connect Fitting Service.
  8. Discharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging.
  9. 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.
  10. 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.
  11. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling.
  12. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
  13. Disconnect the inlet coolant heater hose from the engine. Refer to Heater Inlet Hose Replacement.
  14. Disconnect the outlet coolant heater hose from the engine. Refer to Heater Outlet Hose Replacement
  15. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
  16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  17. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
  18. Remove the exhaust flexible pipe and secure the rear half of the exhaust system to the vehicle underbody. Refer to Exhaust Flexible Pipe Replacement.
  19. Remove the front tires. Refer to Tire and Wheel Removal and Installation.
  20. Remove the steering intermediate shaft pinch bolt and discard the bolt.
  21. Disconnect the steering intermediate shaft from the steering gear.
  22. Disconnect the transaxle shift cable. Refer to Range Selector Lever Cable Replacement.
  23. Disconnect the transaxle cooler lines. Refer to Transmission Fluid Cooler Inlet Hose Replacement and Transmission Fluid Cooler Outlet Hose Replacement.
  24. Disconnect the negative battery extension cable. Refer to Battery Negative Cable Extension Cable Replacement.
  25. Disconnect all engine electrical connectors.

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

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

    28. Object Number: 1418666 Size: SH
  28. Remove the right and left lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement.
  29. Place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle/transfer case. Refer to Front Wheel Drive Shaft Replacement.
  30. On all wheel drive (AWD) models, remove the propeller shaft. Refer to Propeller Shaft Replacement.
  31. Lower the vehicle.
  32. Remove the engine mount strut. Refer to Engine Mount Strut Replacement - Right Side.

    33. Important: Insure the vehicle body is secured to the hoist.

  33. Raise the vehicle.
  34. Disconnect the power steering hoses at the power steering fluid cooler. Refer to Power Steering Cooler Pipe/Hose Replacement.
  35. Place a universal frame support fixture or jackstands under the frame.
  36. Lower the vehicle until the frame contacts the frame support fixture or jackstands.
  37. Remove the subframe to body bracket bolts.

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

    39. Important: 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. Object Number: 1834939 Size: SH
  40. Disconnect the engine electrical wiring harness from the following components:
    41. • Oxygen sensor  (1)
    • EVAP purge solenoid (2)
    • Ignition coils (3, 4, 10)
    • Ground lead (7)
    • Remove wire harness from retainers (5, 6, 8, 9)

    Object Number: 1835560 Size: SH
  41. Disconnect the left and right cylinder head engine electrical wiring harness from the following components:
    42. • Camshaft position sensors  (1)
    • Camshaft position actuators (2)

    Object Number: 1834981 Size: SH
  42. Disconnect the engine electrical wiring harness from the following components:
    43. • Generator (1)
    • Retainer clips (2, 3, 4, 5, 6, 7, 9)
    • A/C compressor hose (8)
    • Oil pressure switch (10)
    • A/C compressor (8)

    Object Number: 1835311 Size: SH
  43. Disconnect the engine electrical wiring harness from the following components:
    44. • Battery cable (1)
    • Retainer clips (2, 3)
    • Transmission module (4)

    Object Number: 1835015 Size: SH
  44. If equipped with an engine coolant heater, disconnect the coolant heater cord.
  45. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement.
  46. Remove the engine-to-transaxle brace bolts and brace.
  47. Remove the starter motor. Refer to Starter Motor Replacement.

    48. Object Number: 1371143 Size: SH
  48. Remove the torque converter bolts.
  49. Install an engine lift chain to the engine lift brackets.
  50. Support the engine weight with an engine hoist.

    51. Object Number: 1371142 Size: SH
  51. Remove the automatic transaxle bolts.
  52. Separate the automatic transaxle from the engine.
  53. Lift the engine away from the frame and the automatic transaxle.
  54. Secure the engine to an engine stand.
  55. 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. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the automatic transaxle bolts.

    4. Tighten
    Tighten the bolts 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: 1371143 Size: SH
  6. Install the torque converter bolts.

    7. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).

  7. Install the starter motor. Refer to Starter Motor Replacement.
  8. Install the engine to transaxle brace and bolts.

    9. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  9. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement.

    10. Object Number: 1835015 Size: SH
  10. If equipped with an engine coolant heater, connect the coolant heater cord.

    11. Object Number: 1835311 Size: SH
  11. Connect the engine electrical wiring harness to the following components:
    12. • Transmission module (4)
    • Retainer clips (3, 2)
    • Battery cable (1)

    Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1834981 Size: SH
  12. Connect the engine electrical wiring harness to the following components:
    13. • A/C compressor (8)
    • Oil pressure switch (10)
    • A/C compressor hose (8)
    • Retainer clips (2, 3, 4, 5, 6, 7, 9)
    • Generator (1)

    Tighten
    Tighten the nut to 13 N·m (115 lb in).


    Object Number: 1835560 Size: SH
  13. Connect the left and right cylinder head engine electrical wiring harness to the following components:
    14. • Camshaft position actuators (2)
    • Camshaft position sensors  (1)

    Object Number: 1834939 Size: SH
  14. Connect the engine electrical wiring harness to the following components:
    15. • Install wire harness to retainers (5, 6, 8, 9)
    • Ground lead (7)
    • Ignition coils (3, 4, 10)
    • EVAP purge solenoid (2)
    • Oxygen sensor  (1)

    Object Number: 933087 Size: SH
  15. Install NEW frame-to-body bolts.

    16. Tighten
    Tighten the bolts to 155 N·m (114 lb ft).

  16. Install the subframe to body bracket bolts.
  17. Raise the vehicle up away from the frame support fixture or jackstands and remove the support fixture or jackstands from under the vehicle.
  18. Connect the power steering hoses to the power steering fluid cooler. Refer to Power Steering Cooler Pipe/Hose Replacement.
  19. Lower the vehicle.
  20. Install the left transaxle mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side.
  21. Install the engine mount strut. Refer to Engine Mount Strut Replacement - Right Side.
  22. Raise the vehicle.
  23. On AWD models, install the propeller shaft. Refer to Propeller Shaft Replacement.
  24. On FWD models, install the right and left front wheel drive shafts into the transaxle. Refer to Front Wheel Drive Shaft Replacement.

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

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

    27. Object Number: 854972 Size: SH
  27. Install the right and left steering linkage outer tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement.
  28. Connect all engine electrical connectors.
  29. Connect the negative battery extension cable. Refer to Battery Negative Cable Extension Cable Replacement.
  30. Connect the transaxle shift cable. Refer to Range Selector Lever Cable Replacement.
  31. Connect the transaxle cooler lines. Refer to Transmission Fluid Cooler Inlet Hose Replacement and Transmission Fluid Cooler Outlet Hose Replacement.
  32. Connect the steering intermediate shaft to the steering gear.
  33. Install a NEW pinch bolt to the steering intermediate shaft.

    34. Tighten
    Tighten the bolt to 34 N·m (25 lb ft).

  34. Install the front tires. Refer to Tire and Wheel Removal and Installation.
  35. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.
  36. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
  37. Lower the vehicle.
  38. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement.
  39. Connect the outlet coolant heater hose to the engine. Refer to Heater Outlet Hose Replacement
  40. Connect the inlet coolant heater hose to the engine. Refer to Heater Inlet Hose Replacement.
  41. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
  42. Install the A/C compressor discharge hose assembly to the compressor. Refer to Discharge Hose Replacement.
  43. Install the A/C compressor suction hose assembly to the compressor. Refer to Suction Hose Replacement.

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

    47. Object Number: 1370533 Size: SH
  47. Connect the brake booster vacuum hose (2) to the intake manifold.
  48. Position the clamp (1) on the brake booster vacuum hose connection.
  49. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
  50. Fill the engine with engine oil. Refer to Approximate Fluid Capacities , Fluid and Lubricant Recommendations , and Maintenance Schedule.
  51. Fill the engine with coolant. Refer to Cooling System Draining and Filling.
  52. Check the transaxle fluid level. Refer to Adhesives, Fluids, Lubricants, and Sealers , Transmission General Specifications , and Approximate Fluid Capacities.
  53. Charge the AC system. Refer to Refrigerant Recovery and Recharging.
  54. Add power steering fluid and bleed air from the power steering system. Refer to Power Steering System Bleeding.
  55. Prime the fuel system.
    56. 55.1. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.
    55.2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    55.3. If the engine does not start, repeat the steps.