GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Alero Export 🢒 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. 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.
  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 air conditioning (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 torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle-4T40-E/4T45-E.
  18. Remove the engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
  19. Remove the transaxle to engine brace. 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 Transmission/Transaxle-Automatic Transmission.
  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 Hose Replacement in Engine Cooling.
  24. Disconnect the fuel lines at quick-connects.
  25. Disconnect the engine vacuum hoses to 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 .
  30. Remove the transaxle to the engine retaining bolts. 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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the upper transaxle mounting bolts.

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

  5. Install engine mount assembly. Refer to Engine Mount Replacement .
  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 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 outer transaxle to engine mounting bolts.

    11. Tighten
    Tighten 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 engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
  13. Install the flywheel to torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement .
  14. Install the air conditioning (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 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 quick-connects.
  22. Install heater hoses to engine.
  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. 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 engine and inspect for leaks.
  35. Stop the engine.
  36. Inspect the fluid levels.