- 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.
- Install the crankshaft balancer. Refer to
Crankshaft Balancer Replacement
.
- Install the engine lift brackets.
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.
- Install the left
and the right engine lift bracket bolts and nuts.
Tighten
Tighten the engine lift bracket bolts and nuts to 30 N·m
(22 lb ft).
- Install the generator brace bracket to the right cylinder head.
- Install the generator brace bracket bolts.
Tighten
Tighten the generator brace bracket bolts to 50 N·m (37 lb ft).
- Install the upper intake manifold or supercharger. Refer to
Upper Intake Manifold Replacement
or
Supercharger Replacement
.
- Install the EGR valve adapter to the right cylinder head. Refer
to
Exhaust Gas Recirculation Inlet Pipe Replacement
in Engine Controls - 3.8L.
- Install the fuel injector sight shield bracket.
- Install the fuel injector sight shield bracket nuts.
Tighten
Tighten the engine sight shield nuts to 30 N·m (22 lb ft).
- Install the A/C compressor
bracket and bolts.
Tighten
Tighten the A/C compressor bracket bolts to 50 N·m (37 lb ft).
- 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
.
- Install the ignition control module bracket and the ignition control
module. Refer to
Ignition Control Module Replacement
in Engine Controls - 3.8L.
- Install the drive belt tensioner. Refer to
Drive Belt Tensioner Replacement
.
- Install the engine mount
bracket and the right side engine mount bracket bolts.
- Install the left side
engine mount bracket bolts.
Tighten
Tighten the engine mount bracket bolts to 102 N·m (75 lb ft).
- Install the oil indicator tube to the engine. Ensure that the O-ring
is in place. Ensure that the oil level indicator tube is fully seated in
the engine.
Tighten
Tighten the oil level indicator tube nut to 19 N·m (14 lb ft).
- Remove the engine from the engine stand.
- Install the flywheel. Refer to
Engine Flywheel Replacement
.
- With assistance install the engine to the vehicle.
- 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).
- Remove the engine lifting device.
- Install the A/C compressor
and the A/C compressor nuts to the A/C compressor bracket.
Tighten
Tighten the A/C compressor nuts to 30 N·m (22 lb ft).
- Install the heater hoses to the drive belt tensioner. Refer to
Heater Hoses Replacement
in Heating Ventilation
and Air Conditioning.
- Install the radiator outlet hose to the engine. Refer to
Radiator Outlet Hose Replacement
in Engine Cooling.
- Install the radiator inlet hose to the engine. Refer to
Radiator Inlet Hose Replacement
in Engine Cooling.
- Reposition the engine wiring to the engine.
- 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 |
- Install the upper engine wiring harness to the retaining clips.
- Install the power steering
pump to the engine.
Tighten
Tighten the power steering bolts to 34 N·m (25 lb ft).
- Connect the A/C vacuum hose to the engine.
- Install the vacuum booster hose to the engine. Refer to
Vacuum Brake Booster Check Valve and/or Hose Replacement
in Hydraulic Brakes.
- Install the engine cooling fans. Refer to
Engine Cooling Fan Replacement
in Engine Cooling.
- Connect the positive battery cable.
Tighten
Tighten the positive battery cable terminal nut to 15 N·m
(11 lb ft).
- Install the engine mount brackets to the radiator support. Refer
to
Engine Mount Strut Bracket Replacement - Upper Radiator Support
.
- Install the engine mount struts to the engine mount strut brackets.
Refer to
Engine Mount Strut Replacement - Right Side
and
Engine Mount Strut Replacement - Left Side
.
- Install the water pump
pulley.
- Install the water pump pulley bolts.
Tighten
Tighten the water pump pulley bolts to 13 N·m (116 lb in).
- Install the drive belt.
- 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.
- Connect the fuel vapor line.
- Connect the fuel lines (1, 2)
to the fuel rail. Refer to
Fuel Hose/Pipes Replacement - Filter to Engine
in Engine Controls - 3.8L.
- Install the throttle body air inlet duct and the air cleaner assembly.
Refer to
Air Cleaner Assembly Replacement
in Engine Controls - 3.8L.
- Raise the vehicle and remove the transaxle support.
- 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).
- Install the engine ground to the transaxle stud.
Tighten
Tighten the engine ground nut to 35 N·m (26 lb ft).
- Install the oil filter adapter housing. Refer to
Oil Filter Adapter and Bypass Valve Assembly Replacement
.
- Reposition and connect the electrical connectors to the following:
• | The heated oxygen (H02) sensor |
• | The oil pressure sensor |
• | The vehicle speed sensor (VSS) |
- 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).
- Install the three-way catalytic converter pipe to the right exhaust
manifold. Refer to
Catalytic Converter Replacement
in Engine Exhaust.
- Install the engine mount
lower nuts.
Tighten
Tighten the engine mount lower nuts to 78 N·m (58 lb ft).
- Install the transaxle brace. Refer to
Transmission Brace Replacement
in Automatic Transaxle - 4T65-E.
- Install the engine flywheel-to-torque converter bolts. Refer to
Flywheel to Torque Converter Bolt Replacement
in
Automatic Transaxle - 4T65-E.
- Install the starter motor. Refer to
Starter Motor Replacement
in Engine Electrical.
- Install the torque converter cover. Refer to
Torque Converter Cover Replacement
in Automatic Transaxle - 4T65-E.
- Lower the vehicle.
- Install the fuel injector sight shield. Refer to
Fuel Injector Sight Shield Replacement
.
- Install the hood. Refer to
Hood Replacement
in Body Front End.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Fill the crankcase with engine oil. Refer to
Engine Oil and Oil Filter Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Inspect for leaks.
- Perform the CKP system variation learn procedure. Refer to
Crankshaft Position System Variation Learn
in Engine
Controls - 3.8L.