Tools Required

J 38185 Hose Clamp Pliers

1. Remove the hood. Refer to Hood Replacement in Body Front End.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
4. Disconnect the vacuum brake booster hose from the vacuum connections and position aside.
5. Disconnect the fuel feed and return lines from the fuel rail and secure to the air inlet grill. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls-3.8L.
6. Remove the evaporative emission canister purge valve and secure the hose to the air inlet grill. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls-3.8L.



7. Push the lock release and remove the cruise control cable from the throttle body bracket and lever.
8. Disconnect the electrical connector from the cruise control module.



9. Remove the retaining nuts (2) and the cruise control module (1) from the mounting studs.

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.
10. Remove the accelerator control cable. Refer to Cruise Control Cable Replacement in Cruise Control.
11. Remove the drive belt. Refer to Drive Belt Replacement .
12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



13. Remove the bolt securing both the battery negative cable and the engine harness ground lead to the engine block.



14. Disconnect the wiring harness connectors from the following components:

•	The A/C compressor clutch (1)

•	The A/C pressure senso  (2)

•	The knock sensor #1 (3)

•	The engine coolant block heater (4)

•	The oil level sensor (7)




15. Disconnect the wiring harness from the harness clip at the rear of the A/C compressor.
16. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle-4T65-E.
17. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
18. Remove the bolts securing the flywheel to the torque converter.



19. Disconnect and secure the following wiring harness electrical connectors to the cowl:

•	The knock sensor #2 located behind the right exhaust manifold

•	The oil pressure sensor (2)

•	The vehicle speed sensor (VSS) (3)




20. Remove the 2 bolts securing the transaxle brace to the transaxle.




Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

21. Remove the 2 nuts attaching the exhaust manifold pipe to the right exhaust manifold.
22. Remove the exhaust manifold pipe from the right exhaust manifold studs, allowing it to rest on top of the power steering gear heat shield.
23. Remove the gasket. Do not reuse the gasket.
24. Remove the right front fascia extension. Refer to Front Bumper Fascia Extension Replacement in Bumpers.



25. Remove the front A/C compressor mounting nuts.
26. Remove the rear A/C compressor mounting bolt.
27. Slide the A/C compressor forward off of the mounting studs and allow the compressor to rest on top of the engine frame.
28. Lower the vehicle.



29. Remove the bolt securing the PCM ground located at the left front cylinder head.



30. Disconnect the wiring harness electrical connectors from the following components on the left side of the engine:

•	The fuel injectors

•	The ignition harness

•	The boost control solenoid, L67 only

•	The engine coolant temperature (ECT) sensor

•	The throttle position (TP) sensor

•	The idle air control (IAC) valve

•	The mass air flow (MAF) sensor




31. Disconnect the wiring harness connectors from the following components on the right side of the engine:

•	The fuel injectors

•	The exhaust gas recirculation (EGR) valve

•	The manifold absolute pressure (MAP) sensor

•	The heated oxygen sensor (HO2S)

•	The generator

32. Secure the engine wiring harness rearward to the air inlet grill.
33. Remove the generator. Refer to Generator Replacement in Engine Electrical.
34. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.8L.
35. Install the engine support fixture. Refer to Engine Support Fixture .



36. Remove the 2 front power steering pump mounting bolts.
37. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
38. Remove the side power steering pump mounting bolt.
39. Position the power steering pump against the cowl, allowing it to rest on top of the transaxle housing.
40. Remove the right engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .



41. Remove the right lower engine to transaxle mounting bolt (1).
42. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
43. Lower the vehicle.



44. Position the J 38185 to the clamp in order to remove the radiator inlet hose from the water pump.



45. Position the J 38185 to the clamp in order to remove the radiator outlet hose from the thermostat housing.



46. Remove the heater hoses from the drive belt tensioner fittings.
47. Using a block of wood between a floor jack and the transaxle, support the transaxle at the pan.
48. Remove the engine support fixture. Refer to Engine Support Fixture .



49. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.
50. Remove the remaining engine to transaxle mounting bolts.

Important: Ensure clearance is maintained between the engine and the following:

•	The A/C accumulator

•	The A/C accumulator hose

•	The A/C compressor

•	The A/C compressor hose

•	The engine wiring electrical harness

•	The vacuum brake booster

51. Carefully raise the engine from the engine compartment.
52. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .



53. Remove the 2 bolts securing the transaxle brace to the engine.
54. Remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.

1. Loosely install the 2 bolts securing the transaxle brace to the engine. Do not tighten at this time.
2. Install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.




Important: Ensure clearance is maintained between the engine and the following:

•	The A/C accumulator

•	The A/C accumulator hose

•	The A/C compressor

•	The A/C compressor hose

•	The engine wiring electrical harness

•	The vacuum brake booster

3. Carefully lower the engine into the engine compartment.
4. Align the engine dowels to the transaxle cover.

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.

5. Install the 5 upper engine to transaxle mounting bolts.

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

6. Remove the engine lift chain from the engine lift brackets.
7. Install the engine support fixture. Refer to Engine Support Fixture .
8. Remove the support jack from under the transaxle.



9. Connect the heater hoses to the drive belt tensioner fittings.



10. Position the J 38185 to the clamp in order to connect the radiator outlet hose to the thermostat housing.



11. Position the J 38185 to the clamp in order to connect the radiator inlet hose to the water pump.
12. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



14. Install the right lower engine to transaxle mounting bolt (1).

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

15. Install the right engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side .



16. Position the power steering pump to the engine.
17. Loosely install the side power steering pump mounting bolt. Do not tighten at this time.
18. Lower the vehicle.
19. Install the 2 front power steering pump mounting bolts.

Tighten
Tighten the power steering pump mounting bolts to 27 N·m (20 lb ft).

20. Remove the engine support fixture. Refer to Engine Support Fixture .
21. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.8L.
22. Install the generator. Refer to Generator Replacement in Engine Electrical.



23. Position the engine wiring electrical harness to the engine.
24. Connect the wiring harness electrical connectors to the following components on the right side of the engine:

•	The fuel injectors

•	The exhaust gas recirculation (EGR) valve

•	The manifold absolute pressure (MAP) sensor

•	The heated oxygen sensor (HO2S)

•	The generator




25. Connect the wiring harness electrical connectors to the following components on the left side of the engine:

•	The fuel injectors

•	The ignition harness

•	The boost control solenoid (L67 only)

•	The engine coolant temperature (ECT) sensor

•	The throttle position (TP) sensor

•	The idle air control (IAC) valve

•	The mass air flow (MAF) sensor




26. Install the bolt securing the PCM ground to the left front cylinder head.

Tighten
Tighten the PCM ground lead bolt to 50 N·m (37 lb ft).

27. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
28. Tighten the side power steering pump mounting bolt previously installed in step 14.

Tighten
Tighten the power steering pump mounting bolt to 27 N·m (20 lb ft).




29. Slide the A/C compressor rearward over the mounting studs.
30. Install the rear A/C compressor mounting bolt.
31. Install the front A/C compressor mounting nuts.

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




32. Place a NEW exhaust manifold pipe gasket over the right exhaust manifold studs.
33. Position the exhaust manifold pipe to the right exhaust manifold.
34. Install the 2 nuts attaching the exhaust manifold pipe to the right exhaust manifold.

Tighten
Tighten the exhaust manifold pipe nuts to 40 N·m (30 lb ft).




35. Install the 2 bolts securing the transaxle brace to the transaxle.

Tighten the 2 bolts previously installed in step 1.

Tighten
Tighten the transaxle brace bolts to 65 N·m (48 lb ft).




36. Connect the wiring harness electrical connectors to the following components

•	The knock sensor #2, located behind the right exhaust manifold

•	The oil pressure sensor (2)

•	The vehicle speed sensor (VSS) (3)

37. Install the bolts securing the flywheel to the torque converter.

Tighten
Tighten the flywheel to torque converter bolts to 63 N·m (46 lb ft).

38. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
39. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle-4T65-E.



40. Connect the wiring harness to the harness clip at the rear of the A/C compressor.



41. Connect the wiring harness connectors to the following components:

•	The A/C compressor clutch (1)

•	The A/C pressure sensor (2)

•	The knock sensor #1 (3)

•	The engine coolant block heater (4)

•	The oil level sensor  (7)




42. Install the bolt in order to secure both the battery negative cable and the engine harness ground lead to the engine block.

Tighten
Tighten the battery negative cable to engine block bolt to 25 N·m (18 lb ft).

43. Install the right front fascia extension. Refer to Front Bumper Fascia Extension Replacement in Bumpers.
44. Lower the vehicle.
45. Install the drive belt. Refer to Drive Belt Replacement .

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.
46. Remove the accelerator control cable. Refer to Cruise Control Cable Replacement in Cruise Control.



47. Position the cruise control module (1) to the mounting studs on the cowl.

Install the 2 cruise control module bracket retaining nuts (2).

Tighten
Tighten the cruise control module bracket retaining nuts to 9 N·m (80 lb ft).

48. Connect the electrical connector to the cruise control module.



49. Install the cruise control cable to the throttle body lever.
50. Slide the cruise control cable fully into the throttle body bracket until it snaps into place.
51. Install the evaporative emission canister purge valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls-3.8L.
52. Connect the fuel feed and return lines to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls-3.8L.
53. Connect the vacuum brake booster hose to the vacuum connections.
54. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
55. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
56. Install the hood. Refer to Hood Replacement in Body Front End.
57. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement .

Complete the following procedure after the engine is installed in the vehicle:

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Inspect for oil, coolant and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP variation learn. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.8L.
9. Perform a final inspection for the proper engine oil and coolant levels.
10. Road test the vehicle.