GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Am 🢒 Engine 🢒 Engine Mechanical - 3.4L 🢒 Engine Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Relieve fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.4L.
  3. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the engine air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.
  5. Remove the hood. Refer to Hood Replacement in Body Front End.
  6. Remove the drive belt. Refer to Drive Belt Replacement .

    7. Object Number: 63668 Size: SH
  7. Remove the hoses from the surge tank.
  8. Remove the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
  9. Remove the engine wiring harness from the top of the engine. Refer to Harness Routing Views in Wiring Systems.

    10. Set the harness aside.

  10. Disconnect the throttle cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.4L.
  11. Disconnect the cruise control cable. Refer to Cruise Control Cable Replacement in Cruise Control.
  12. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  13. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
  14. Remove the air conditioning (A/C) compressor with the lines attached. Refer to Air Conditioning Compressor Replacement in HVAC Systems - Manual.

    15. Position the A/C compressor aside.

  15. Disconnect and position aside the lower engine wiring harness. Refer to Harness Routing Views in Wiring Systems.
  16. Disconnect the catalytic converter flange from the rear exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  17. Remove the bolts that secure the torque converter to the flywheel.
  18. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  19. Remove the brace that joins the transaxle to the engine. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  20. Remove front transmission mount and bracket. Refer to Transmission Front Mount Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  21. Remove the 2 outer transmission mounting bolts. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  22. Lower the vehicle.
  23. Disconnect the upper and the lower radiator hoses. Refer to Radiator Inlet Hose Replacement or Radiator Outlet Hose Replacement in Engine Cooling.
  24. Disconnect the fuel lines at the quick-connects.
  25. Disconnect the engine vacuum hoses from the brake booster.

    26. Object Number: 545 Size: SH
  26. Disconnect the heater hoses.
  27. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  28. Install the engine lifting device.
  29. Remove the engine mount and the adapter. Refer to Engine Mount Replacement - Right Side .
  30. Remove the bolts that retain the transaxle to the engine. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  31. Remove the engine from the vehicle.
  32. Remove the engine flywheel. Refer to Engine Flywheel Replacement .
  33. Mount the engine onto a suitable engine stand.

Installation Procedure
  1. Attach the engine lifting device.

    2. Remove the engine from the engine stand.

  2. Install the engine flywheel. Refer to Engine Flywheel Replacement .
  3. Position the engine in the vehicle and align the engine with the transaxle.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the upper transaxle mounting bolts.

    5. Tighten
    Tighten the bolts to 90 N·m (66 lb ft).

  5. Install the engine mount assembly. Refer to Engine Mount Replacement - Right Side .
  6. Remove the engine lifting device.
  7. Install the power steering pump to the engine front cover. Refer to Power Steering Pump Replacement in Power Steering System.
  8. Connect the upper and the lower radiator hoses. Refer to Radiator Inlet Hose Replacement or Radiator Outlet Hose Replacement in Engine Cooling.
  9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  10. Install the 2 mounting bolts that secure the outer transaxle to the engine.

    11. Tighten
    Tighten the bolts to 90 N·m (66 lb ft).

  11. Install the transaxle to engine brace. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  12. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  13. Install the bolts that secure the flywheel to the torque converter.
  14. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems - Manual.
  15. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  16. Install the flywheel inspection shield.
  17. Install the catalytic converter to the rear exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  18. Install a new oil filter.
  19. Install the lower engine wiring harness and the retainers. Refer to Harness Routing Views in Wiring Systems.
  20. Lower the vehicle.
  21. Connect the fuel lines at the quick-connects.

    22. Object Number: 545 Size: SH
  22. Install the heater hoses.
  23. Install the engine wiring harness and the retainers at the top of the engine. Refer to Harness Routing Views in Wiring Systems.
  24. Connect the vacuum hoses.
  25. Connect the cruise control cable. Refer to Cruise Control Cable Replacement in Cruise Control.

    26. 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.

  26. Replace the throttle control cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.4L.
  27. Install and connect the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
  28. Install the drive belt. Refer to Drive Belt Replacement .

    29. Object Number: 63668 Size: SH
  29. Connect the surge tank hoses.
  30. Install the hood. Refer to Hood Replacement in Body Front End.
  31. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.
  32. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  33. Fill the crankcase to the correct level. Use the recommended oil. Refer to Engine Oil and Oil Filter Replacement .
  34. Start the engine and inspect for leaks.
  35. Stop the engine.
  36. Inspect the fluid levels.