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

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
3. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the hood. Refer to Hood Replacement in Body Front End.
5. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
6. Carefully remove the throttle body air inlet duct and the air filter assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
7. Remove the inlet radiator hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
8. Remove the outlet radiator hose from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
9. Disconnect the A/C compressor from the engine. Secure the compressor to the frame. Refer to Compressor Replacement (3.8L) in HVAC.
10. Disconnect the starter motor wiring harness. Refer to Starter Motor Replacement in Engine Electrical.

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.
11. Disconnect the throttle and cruise cables from the linkage. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.8L and Cruise Control Cable Replacement in Cruise Control.
12. Remove the wiring harness from the top of the engine. Refer to Engine Controls - 3.8L.




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

13. Disconnect the fuel lines (1, 2) from the fuel rail. Lay the fuel lines aside. Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
14. Disconnect the fuel vapor line.



15. Disconnect the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
16. Disconnect the A/C vacuum hose from the engine.
17. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement (3.8L) in HVAC.
18. Remove the engine mount struts from the engine mount strut brackets. Refer to Engine Mount Strut Replacement .
19. Disconnect the power steering pump from the engine. Lay the power steering pump aside. Refer to Power Steering Pump Replacement Power Steering System.
20. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
21. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
22. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
23. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
24. Remove the engine mount-to-frame nuts. Refer to Engine Mount Replacement .
25. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
26. Remove the three-way catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.



27. Remove the lower transmission-to-engine bolts (1, 6).
28. Lower the vehicle.
29. Install the engine lifting device.



30. Remove the upper transmission-to-engine bolts (2 - 5).
31. Remove the engine from the vehicle.
32. Remove the flywheel. Refer to Engine Flywheel Replacement .
33. Install the engine to the engine stand.
34. Remove the generator. Refer to Generator Replacement in Engine Electrical.
35. Remove the ignition control module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
36. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
37. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .

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

1. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
2. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
3. Install the ignition control module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
4. Install the generator. Refer to Generator Replacement in Engine Electrical.
5. Install the flywheel. Refer to Engine Flywheel Replacement .
6. Install the engine to the vehicle.




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. Install the upper transmission-to-engine bolts (2 - 5).

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

8. Remove the engine lifting device.
9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



10. Install the lower transmission-to-engine bolts (1, 6).

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

11. Install the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
12. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
13. Install the engine mount to frame nuts. Refer to Engine Mount Replacement .
14. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
15. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
16. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
17. Lower the vehicle.
18. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement in Power Steering System.
19. Install the engine mount struts to the engine mount strut brackets. Refer to Engine Mount Strut Replacement .
20. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement (3.8L) in HVAC.
21. Connect the A/C vacuum hose to the engine.



22. Connect the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
23. Connect the fuel vapor line.



24. Connect the fuel lines (1, 2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
25. Install the wiring harness connections to the engine. Refer to Engine Controls - 3.8L.

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. Connect the throttle and cruise cables. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.8L and Cruise Control Cable Replacement in Cruise Control.
27. Install the starter motor wiring harness. Refer to Starter Motor Replacement in Engine Electrical.
28. Install the A/C compressor to the engine. Refer to Compressor Replacement (3.8L) in HVAC.
29. Install the outlet radiator hose to the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
30. Install the inlet radiator hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
31. Carefully install the throttle body air inlet duct and the air filter assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
32. Install the hood. Refer to Hood Replacement in Body Front End.
33. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
34. Install a new oil filter and fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
35. Fill the cooling system with engine coolant. Bleed the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
36. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
37. Inspect all of the fluid levels.
38. Inspect for leaks.