Tools Required

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Disconnect the positive battery cable.



3. Disconnect the intake air temperature (IAT) sensor electrical connector.



4. Remove the air intake duct.
5. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
8. If equipped remove the torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transmission-4L60E.
9. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement
10. Remove the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
12. Remove the 3-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
13. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement in Propeller Shaft.
14. Remove the torque arm. Refer to Torque Arm Replacement in Rear Suspension.



15. If equipped with a automatic transmission, remove the transmission range selector lever cable from the range selector lever.



16. Remove the retainer from the range selector lever cable.



17. Remove the range selector lever cable from the cable bracket.



18. If equipped with a manual transmission, disconnect the clutch actuator cylinder line from the actuator cylinder using theJ 36221 .
19. Remove the left side front air deflector. Refer to Front Bumper Fascia Air Deflector Replacement in Bumpers.
20. Remove the stabilizer bar brackets. Refer to Stabilizer Shaft Insulator Replacement in Front Suspension.



21. Remove the intermediate steering shaft bolt and shaft from the rack. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.



22. Remove the wiring harness ground bolt and RF (Radio Frequency) ground strap and cruise control ground lead from the front rail.
23. Disconnect the knock sensor electrical connectors.



24. Disconnect the wheel speed sensors electrical connectors.



25. Remove the A/C compressor and condenser hose bolt from the compressor.
26. Discard the O-ring.



27. Remove the A/C compressor and condenser hose nut from the condenser.
28. Discard the O-ring.



29. Remove the front fuel pipe heat shield nuts (1).
30. Remove the front fuel pipe heat shield (2).
31. Remove the brake lines from the brake pipe clip.
32. Lower the vehicle.



33. Remove the engine wiring harness ground bolt (1).
34. Remove the engine ground.



35. Remove the A/C compressor and condenser hose bolt from the accumulator.
36. Discard the O-ring.



37. Remove the heater hoses from the drive belt tensioner.
38. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.8L.
39. Disconnect the fuel lines (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
40. Disconnect the fuel vapor line (4) from the EVAP canister purge valve (5). Refer to Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.



41. Disconnect the electronic throttle control (ETC) electrical connector (1).
42. Remove the forward lamp harness branch from the wire harness clip.



43. Remove the inlet hose from the water outlet.



44. Remove the outlet hose from the coolant pump.



45. Remove the brake booster vacuum hose (2) from the intake manifold fitting (1).
46. Remove the front 2 brake pipes from the brake modulator.



47. Disconnect the forward lamp harness from the engine harness.
48. Disconnect the engine harness vacuum tube from the bottom of the vacuum check valve.
49. Remove the PCM from the vehicle. Refer to Powertrain Control Module Replacement in Engine Controls - 3.8L.
50. Remove the right side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel, Gauges, and Console.
51. Remove the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement in Interior Trim.



52. Disconnect the engine wiring harness from the instrument panel wiring harness.



53. Remove the engine wire harness through the front of the cowl. Place the harness on top of the engine.
54. If equipped with the manual transmission remove the transmission shift control. Refer to Shift Control Assembly Replacement in Manual Transmission M49.
55. Raise the vehicle.



56. Remove the right and left side shock absorber lower mounting bolts.
57. Remove the cotter pins and nuts from the left and right upper ball joints.
58. Remove the left and right upper ball joints from the steering knuckles using the J 39549 .
59. Support the left and right steering knuckles.
60. Position the J 39580 under the vehicle.
61. Lower the vehicle on the J 39580 .



62. Remove the crossmember bolts.



63. Remove the transmission support bolts.
64. Raise the vehicle and remove the engine and transmission from the vehicle.
65. Secure the crossmember to the J 39580 .
66. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
67. Remove the A/C compressor and the A/C compressor mounting bracket. Refer to Compressor Mounting Bracket Replacement in Heating, Ventilation and Air Conditioning.



68. Remove the power steering pump nuts (3).
69. Reposition the power steering pump to crossmember.



70. Disconnect the generator electrical connector.



71. Remove the positive cable nut from the generator terminal.
72. Remove the generator from the engine.
73. Install a lifting device to the engine.



74. Remove the right engine mount bracket bolts (1, 2) and the right engine mount bracket (3).



75. Remove the left engine mount bracket bolts (3).
76. Remove the left engine mount bracket stud (2) and the left engine mount bracket (1).
77. With the aide of an assistant, raise the engine and transmission from the crossmember.



78. If equipped with the automatic transmission remove the following from the right side:

•	The transmission support brace bolts (1, 2, 3)

•	The transmission support nut (6)

•	The transmission support (4)




79. If equipped with the automatic transmission remove the following from the left side:

•	The transmission support brace bolts (3, 5)

•	The transmission support nut (1)

•	The transmission support (4)




80. If equipped with the manual transmission remove the following from the right side:

•	The transmission support bolts (3, 4)

•	The transmission support (1)




81. If equipped with the manual transmission remove the following from the left side:

•	The transmission support bolts (2, 3)

•	The transmission support (1)

82. Disconnect the electrical connectors from the transmission.
83. Place the transmission on a suitable table.



84. For the automatic transmission, remove the transmission to engine bolts and nut.
85. Separate the engine from the transmission.
86. Attach the J 21366 to the transmission to secure the torque converter.



87. For the manual transmission, remove the transmission to engine bolts (1, 2) and nuts (3).
88. Separate the engine from the transmission.
89. Remove the engine flywheel. Refer to Engine Flywheel Replacement .
90. Install the engine to a engine stand.
91. Remove the lifting device from the engine.
92. Disconnect and remove the engine wiring harness from the engine.
93. Remove the left and right exhaust manifolds. Refer to Exhaust Manifold Replacement - Left Side and Exhaust Manifold Replacement - Right Side in Engine Exhaust.

1. Install the left and right exhaust manifolds. Refer to Exhaust Manifold Replacement - Left Side and Exhaust Manifold Replacement - Right Side in Engine Exhaust.
2. Install and connect the engine wiring harness to the engine.
3. Install the lifting device to the engine.
4. Remove the engine from the engine stand.
5. Install the engine flywheel. Refer to Engine Flywheel Replacement .
6. Install the engine to the transmission.

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.




7. For the manual transmission, install the flywheel housing to engine bolts (1, 2) and nuts (3).

Tighten
Tighten the flywheel housing to engine bolts (1, 2) and nuts (3) to 95 N·m (70 lb ft).

8. If equipped with a automatic transmission remove the J 21366 from the transmission.



9. For the automatic transmission, install the transmission to engine bolts and nut.

Tighten
Tighten the transmission to engine bolts and nut to 95 N·m (70 lb ft).

10. Connect the electrical connectors to the transmission.



11. If equipped with the manual transmission install left side transmission support (1).
12. Install the left side transmission support brace bolts (2, 3).

Tighten

•	Tighten the left side transmission support brace bolts (2) to the transmission to 50 N·m (37 lb ft).

•	Tighten the left side transmission support brace bolts (3) to the engine to 28 N·m (21 lb ft).




13. If equipped with the manual transmission install right side transmission support (1).
14. Install the right side transmission support brace bolts (3, 4).

Tighten
Tighten the right side transmission support brace bolts (3, 4) to 50 N·m (37 lb ft).




15. If equipped with the Automatic transmission install left side transmission support (4).
16. Install the left side transmission support bolts (3, 5).
17. Install the left side transmission support nut (1).

Tighten

•	Tighten the left side transmission support bolt (3) to 8.5 N·m (75 lb in).

•	Tighten the left side transmission support bolt (5) to 28 N·m (21 lb ft).

•	Tighten the left side transmission support nut (1) to 80 N·m (59 lb ft).




18. If equipped with the automatic transmission install right side transmission support (4).
19. Install the right side transmission support brace bolts (1, 2, 3).
20. Install the right side transmission support nut (6).

Tighten

•	Tighten the right side transmission support brace bolt (1) to 8.5 N·m (75 lb in).

•	Tighten the right side transmission support bolts (2,3) to 50 N·m (37 lb ft).

•	Tighten the right side transmission support nut (6) to 80 N·m (59 lb ft).

21. With the aide of an assistant, lower the engine and transmission to the crossmember.



22. Install the left engine mount bracket (1) and mount bracket stud (2).
23. Install the left engine mount bracket bolts (3).

Tighten

•	Tighten the left engine mount bracket bolt (3) to 102 N·m (75 lb ft).

•	Tighten the left engine mount bracket stud (2) to 87 N·m (64 lb ft).




24. Install the right engine mount bracket (3) and the engine mount bracket bolts (1, 2).

Tighten

•	Tighten the two right engine mount bracket bolts (1) to 102 N·m (75 lb ft).

•	Tighten the right engine mount bracket bolt (2) to 50 N·m (37 lb ft).

25. Remove the lifting device from the engine.



26. Install the generator to the engine.
27. Install the positive cable nut to the generator terminal.

Tighten
Tighten the positive cable nut to generator terminal to 22 N·m (16 lb ft).




28. Connect the generator electrical connector.



29. Install the power steering pump.
30. Install the power steering pump nuts (3).

Tighten
Tighten the power steering nuts (3) to 30 N·m (22 lb ft).

31. Install the A/C compressor bracket and compressor. Refer to Compressor Mounting Bracket Replacement in Heating, Ventilation and Air Conditioning.
32. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
33. Remove the safety straps from the crossmember and J 39580
34. Lower the vehicle and install the engine and transmission to the vehicle.
35. Align the crossmember to the vehicle body.



36. Install the front crossmember bolts.

Tighten

•	Tighten the four crossmember bolts to 125 N·m (92 lb ft).

•	Tighten the two crossmember bolts to 145 N·m (107 lb ft).




37. Install the transmission support bolts.

Tighten
Tighten the transmission support bolts to 57 N·m (42 lb ft).

38. Raise the vehicle.
39. Remove the J 39580 from under the vehicle.
40. Install the ball joints to the steering knuckles.
41. Install the left and right upper ball joint nuts.

Tighten
Tighten the upper ball joint nuts to 53 N·m (39 lb ft).

42. Install the cotter pins to the left and right upper ball joints.



43. Instal the right and left side shock absorber lower mounting bolts.

Tighten
Tighten the shock absorber lower mounting bolts to 65 N·m (48 lb ft).

44. Lower the vehicle.
45. If equipped with the manual transmission Install the transmission control. Refer to Shift Control Assembly Replacement in Manual Transmission M49.



46. Install the engine wire harness through the front of the cowl.



47. Connect the engine wiring harness to the instrument panel wiring harness.
48. Install the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement in Interior Trim.
49. Install the right side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel, Gauges, and Console.
50. Install the PCM. Refer to Powertrain Control Module Replacement in Engine Controls - 3.8L.



51. Install the engine harness vacuum tube to the bottom of the vacuum check valve.
52. Connect the forward lamp harness to the engine harness.
53. Install the front 2 brake pipes to the brake modulator.



54. Install the brake booster vacuum hose (2) to the intake manifold fitting (1).



55. Install the outlet hose to the coolant pump.



56. Install the inlet hose to the water outlet.



57. Install the forward lamp harness to the wiring harness clip.
58. Connect the electronic throttle control (ETC) electrical connector (1).



59. Install the fuel vapor line  (4) to the EVAP canister purge valve (5).
60. Install the fuel pipes (2) to the fuel rail.



61. Install the heater hoses to the drive belt tensioner.



62. Install a new O-ring.
63. Install the A/C compressor and condenser hose bolt to the accumulator.

Tighten
Tighten A/C compressor and condenser hose bolt at the accumulator to 48 N·m (36 lb ft).




64. Install the engine ground.
65. Install the engine wiring harness ground bolt (1).

Tighten
Tighten the engine wiring harness ground bolt to 25 N·m (18 lb ft).

66. Raise the vehicle.
67. Install the brake lines to the brake pipe clip.



68. Install the front fuel pipe heat shield (2).
69. Install the front fuel pipe heat shield nuts (1).

Tighten
Tighten the front fuel pipe heat shield nuts (1) to 5 N·m (44 lb in).




70. Install a new O-ring.
71. Install the A/C compressor and condenser hose nut to the condenser.

Tighten
Tighten the A/C compressor and condenser hose nut to the condenser to 16 N·m (12 lb ft).




72. Install a new O-ring.
73. Install the A/C compressor and condenser hose bolt to the compressor.

Tighten
Tighten the A/C compressor and condenser hose bolt to 33 N·m (24 lb ft).




74. Connect the wheel speed sensors electrical connectors.
75. Connect the knock sensors electrical connectors.



76. Install the RF ground strap, cruise control lead and wiring harness ground bolt to the front rail.

Tighten
Tighten the wiring harness ground bolt to 12 N·m (106 lb in).




77. Install the intermediate steering shaft and bolt to the rack. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column (Tilt).
78. Install the stabilizer bar brackets. Refer to Stabilizer Shaft Insulator Replacement in Front Suspension.
79. Install the left side front air deflector. Refer to Front Bumper Fascia Air Deflector Replacement in Bumpers.



80. On vehicles equipped with a manual transmission, install the clutch actuator cylinder line to the actuator cylinder.



81. If equipped with a automatic transmission, install the range selector lever cable to the cable bracket.



82. Install the retainer to the range selector lever cable.



83. Install the transmission range selector lever cable to the transmission range selector.
84. Install the torque arm. Refer to Torque Arm Replacement in Rear Suspension.
85. Install the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement in Propeller Shaft.
86. Install the 3-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
87. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
88. If equipped install the torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transmission - 4L60E.
89. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
90. Lower the vehicle.



91. Install the air intake duct.



92. Connect the intake air temperature (IAT) sensor electrical connector.



93. Install the positive battery cable to the battery.

Tighten
Tighten the positive battery terminal to 15 N·m (11 lb ft).

94. Install the negative battery cable to the battery.

Tighten
Tighten the negative battery terminal to 15 N·m (11 lb ft).

95. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
96. Check and fill the transmission fluid as necessary.
97. Refill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
98. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
99. Bleed the brakes. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
100. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding in Clutch.
101. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.8L.