Notice: Refer to Engine Emission Notice in the Preface section.

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
6. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
7. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
8. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
9. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
10. Scribe the torque converter to the flywheel for installation.
11. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.



12. Remove the engine mount lower nuts.



13. Remove the right exhaust manifold pipe stud nuts from the catalytic converter.
14. Remove the oil level sensor harness retainer bolt.
15. Remove the oil level harness retainer from the engine.
16. Disconnect and reposition the electrical connectors from the following:

•	The vehicle speed sensor (VSS)

•	The oil pressure sending unit

•	The oil level sensor

•	The knock sensors

•	The H02 sensor

17. Remove the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
18. Remove the engine ground nut and engine ground from the transaxle stud.



19. Remove the lower transaxle-to-engine bolt (6) and stud (1).
20. Lower the vehicle while supporting the transaxle.
21. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.

Important: Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.8L.




22. Disconnect the fuel lines (1,2) from the fuel rail. Lay the fuel lines aside. Refer to Fuel Hose/Pipes Replacement - Filter to Engine in Engine Controls - 3.8L.
23. Disconnect the fuel vapor line.
24. Remove the throttle and cruise control cables and bracket from the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.



25. Loosen the water pump pulley bolts.
26. Remove the drive belt. Refer to Drive Belt Replacement .
27. Remove the water pump pulley bolts and the water pump pulley.
28. Remove the right and the left engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side .
29. Remove the engine mount strut brackets from the radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
30. Disconnect the positive battery cable.
31. Remove the fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
32. Remove the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement in Hydraulic Brakes.
33. Remove the A/C vacuum hose from the engine.



34. Remove the power steering pump and the power steering bolts from the engine. Lay the power steering pump aside.
35. Disconnect the upper engine electrical connectors from the following:

•	The fuel injectors

•	The throttle position (T/P) sensor

•	The idle air control (IAC) valve

•	The EVAP purge solenoid

•	The exhaust gas recirculation (EGR) valve

•	The manifold absolute pressure (MAP) sensor

36. Remove upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal.
37. Remove the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
38. Remove the radiator outlet hose from the water pump. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
39. Remove the heater hoses from the drive belt tensioner. Refer to Heater Hoses Replacement in Heating Ventilation and Air Conditioning.



40. Remove the A/C compressor nuts and the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
41. Install the engine lifting device.



42. Remove the upper transaxle-to-engine bolts (2,3,4 and 5).
43. With assistance remove the engine from the vehicle.
44. Remove the flywheel. Refer to Engine Flywheel Replacement .
45. Install the engine to the engine stand.



46. Remove the oil level indicator tube nut from the exhaust manifold.
47. Remove the oil level indicator tube.
48. Remove the engine mount bracket with the engine mount. Refer to Engine Mount and Bracket Replacement .
49. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
50. Remove the ignition control module and the ignition control module bracket. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
51. Remove the left and right side engine mount brackets. Refer to Engine Mount Strut Bracket Replacement - Left Side and Engine Mount Strut Bracket Replacement - Right Upper .



52. Remove the A/C compressor mounting bracket bolts and the A/C compressor bracket.



53. Remove the fuel injector sight shield bracket nuts.
54. Remove the fuel injector sight shield bracket
55. Remove the EGR valve adapter from the right cylinder head. Refer to Exhaust Gas Recirculation Inlet Pipe Replacement in Engine Controls - 3.8L.
56. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .



57. Remove the generator brace bracket bolts.
58. Remove the generator brace bracket from the right cylinder head.
59. Remove the engine lift brackets.
60. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
61. Remove the right exhaust manifold, the left exhaust manifold and the exhaust crossover. Refer to Exhaust Manifold Replacement - Right Side and Exhaust Manifold Replacement - Left Side in Engine Exhaust.

Notice: Refer to Engine Emission Notice in the Preface section.

1. Install the right exhaust manifold, the left exhaust manifold and the exhaust crossover. Refer to Exhaust Manifold Replacement - Right Side and Exhaust Manifold Replacement - Left Side in Engine Exhaust.
2. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

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.

3. Install the engine lift brackets.
4. Install the engine lift brackets bolts and nuts.

Tighten
Tighten the engine lift bracket bolts and nuts to 30 N·m (22 lb ft).




5. Install the generator brace bracket to the right cylinder head.
6. Install the generator brace bracket bolts.

Tighten
Tighten the generator brace bracket bolts to 50 N·m (37 lb ft).

7. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
8. Install the EGR valve adapter to the right cylinder head. Refer to Exhaust Gas Recirculation Inlet Pipe Replacement in Engine Controls - 3.8L.



9. Install the fuel injector sight shield bracket.
10. Install the fuel injector sight shield bracket nuts.

Tighten
Tighten the engine sight shield nuts to 30 N·m (22 lb ft).




11. Install the A/C compressor mounting bracket and the A/C compressor mounting bracket bolts.

Tighten
Tighten the A/C compressor mounting bracket bolts to 50 N·m (37 lb ft).

12. Install the left and right side engine mount brackets. Refer to Engine Mount Strut Bracket Replacement - Left Side and Engine Mount Strut Bracket Replacement - Right Upper .
13. Install the ignition control module bracket and the ignition control module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
15. Install the engine mount bracket with the engine mount to the engine. Refer to Engine Mount and Bracket Replacement .



16. Ensure that the O-ring is in place and Install the oil level indicator tube to the engine.
17. Install the oil level indicator tube nut to the exhaust manifold stud.

Tighten
Tighten the oil level indicator tube nut to 19 N·m (14 lb ft).

18. Remove the engine from the engine stand.
19. Install the flywheel. Refer to Engine Flywheel Replacement .
20. With assistance install the engine to the vehicle.



21. Install the upper transaxle-to-engine bolts (2,3,4 and 5).

Tighten
Tighten the upper transaxle-to-engine bolts to 75 N·m (55 lb ft).

22. Remove the engine lifting device.



23. Install the A/C compressor to the engine.
24. Install the A/C compressor mounting nuts to the A/C compressor.

Tighten
Tighten the A/C compressor nuts to 30 N·m (22 lb ft).

25. Install the heater hoses to the drive belt tensioner. Refer to Heater Hoses Replacement in Heating Ventilation and Air Conditioning.
26. Install the radiator outlet hose to the water pump. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
27. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
28. Reposition the engine wiring to the engine.
29. Connect the upper engine electrical connectors to the following:

•	The manifold absolute pressure (MAP) sensor

•	The exhaust gas recirculation (EGR) valve

•	The EVAP purge solenoid

•	The idle air control (IAC) valve

•	The throttle position (T/P) sensor

•	The fuel injectors

30. Install the upper engine wiring harness to the retaining clips.



31. Install the power steering pump and the power steering bolts to the engine.

Tighten
Tighten the power steering pump bolts to 34 N·m (25 lb ft).

32. Connect the A/C vacuum hose to the engine.
33. Install the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement in Hydraulic Brakes.
34. Install the fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
35. Connect the positive battery cable.

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

36. Install the engine mount brackets to the radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
37. Install the right and the left engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side .



38. Install the water pump pulley.
39. Install the water pump pulley bolts.

Tighten
Tighten the water pump pulley bolts to 13 N·m (116 lb in).

40. Install the drive belt. Refer to Drive Belt Replacement .
41. Install the throttle cable, the cruise control cable and bracket to the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
42. Connect the fuel vapor line.



43. Connect the fuel lines (1,2) to the fuel rail.
44. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
45. Raise the vehicle and remove the transaxle support.



46. Install the lower transaxle-to-engine bolt (6) and stud (1).

Tighten
Tighten the transaxle to engine bolt and stud to 75 N·m (55 lb ft).

47. Install the engine ground to the transaxle stud.

Tighten
Tighten the engine ground nut to 35 N·m (26 lb ft).

48. Install the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
49. Reposition and connect the electrical connectors to the following:

•	The H02 sensor

•	The knock sensors

•	The oil level sensor

•	The oil pressure sensor

•	The vehicle speed sensor (VSS)

50. Install the oil level sensor harness retainer to the engine.

Tighten
Tighten the oil level sensor harness retainer bolt to 10 N·m (89 lb in).




51. Install the catalytic converter pipe to the right exhaust manifold.
52. Install right exhaust manifold stud nuts.

Tighten
Tighten the right exhaust manifold stud nuts to 32 N·m (24 lb ft).




53. Install the engine mount lower nuts.

Tighten
Tighten the engine mount lower nuts to 78 N·m (58 lb ft).

54. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
55. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
56. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
57. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
58. Lower the vehicle.
59. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
60. Install the hood. Refer to Hood Replacement in Body Front End.
61. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
62. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
63. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
64. Inspect for leaks.
65. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.8L.