GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 Monte Carlo 🢒 Engine 🢒 Engine Mechanical - 3.9L 🢒 Engine Replacement

Removal Procedure

    Object Number: 1609656 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the hood. Refer to Hood Replacement .
  3. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  5. Remove the engine mount struts. Refer to Engine Mount Strut Replacement .
  6. Remove the drive belt. Refer to Drive Belt Replacement .
  7. Drain the cooling system. Refer to Cooling System Draining and Filling .
  8. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  9. Remove the oil pressure sensor heat shield nuts and shield.

    10. Object Number: 1608498 Size: SH
  10. Disconnect the oil pressure sensor electrical connector (1).
  11. Disconnect the knock sensor electrical connector (2).
  12. Disconnect the starter motor electrical connector (3).
  13. Disconnect the air conditioning (A/C) compressor electrical connector (4).

    14. Object Number: 1609295 Size: SH
  14. Disconnect the oil level sensor electrical connector.
  15. Remove the engine harness clips from the transaxle brace and the oil pan.
  16. Lower the vehicle.

    17. Object Number: 1608290 Size: SH
  17. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector (1).
  18. Disconnect the electronic throttle control (ETC) electrical connector (2).

    19. Object Number: 1608869 Size: SH
  19. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
  20. Reposition the generator terminal boot (2).
  21. Remove the generator terminal nut (5).
  22. Remove the generator terminal (4) from the stud.
  23. Disconnect the generator electrical connector (3).
  24. Disconnect the ignition coil electrical connector (6).

    25. Object Number: 1608276 Size: SH
  25. Disconnect the fuel injector inline (1) electrical connector.
  26. Remove the engine harness clips (2, 3) from the brackets.

    27. Object Number: 1611455 Size: SH
  27. Disconnect the camshaft phasor sensor electrical connector (2).
  28. Remove the engine harness clip bolt (3).
  29. Remove the engine harness clip (4) from the transaxle bracket.

    30. Object Number: 1609170 Size: SH
  30. Remove the connector position assurance (CPA) retainer (3).
  31. Disconnect the rear upper heated oxygen sensor (HO2S) electrical connector (2).

    32. Object Number: 1612884 Size: SH
  32. Disconnect the knock sensor electrical connector (1).
  33. Disconnect the crankshaft position (CKP) sensor electrical connector (4).
  34. Remove the engine harness clips (2, 3) from the transaxle brace.

    35. Object Number: 1612887 Size: SH
  35. Remove the engine harness ground bolt (2).
  36. Remove the engine harness ground terminals (1) from the transmission.
  37. Remove the engine harness clip bolt (3) from the transmission.
  38. Reposition all branches of the engine harness out of the way.
  39. Remove the catalytic converter. Refer to Catalytic Converter Replacement .

    40. Object Number: 1607922 Size: SH
  40. Remove the engine mount lower nuts.

    41. Object Number: 1612979 Size: SH
  41. Remove the torque converter cover. Refer to Torque Converter Cover Replacement .
  42. Remove the starter motor. Refer to Starter Motor Replacement .
  43. Remove the torque converter bolts.

    44. Object Number: 1608216 Size: SH
  44. Remove the A/C compressor front bolt and nut.

    45. Object Number: 1608220 Size: SH
  45. Remove the A/C compressor rear bolt and reposition the compressor off to the side. DO NOT discharge the A/C system.

    46. Object Number: 1609665 Size: SH
  46. Remove the transaxle brace to transaxle bolts.
  47. Remove the transaxle brace to engine bolts.
  48. Remove the transaxle brace.

    49. Object Number: 1613156 Size: SH
  49. Remove the transaxle-to-engine lower rear bolt.

    50. Object Number: 1613134 Size: SH
  50. Reposition the radiator outlet hose clamp at the thermostat housing.
  51. Remove the radiator outlet hose from the thermostat housing.
  52. Lower the vehicle and support the transaxle.

    53. Object Number: 1608820 Size: SH
  53. Remove the brake booster vacuum hose from the intake manifold.

    54. Object Number: 1608325 Size: SH
  54. Reposition the heater inlet and outlet hose clamps at the engine.
  55. Remove the heater inlet and outlet hoses from the engine pipes.
  56. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement.
  57. Disconnect the fuel feed line from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  58. Disconnect the EVAP purge line from the canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.

    59. Object Number: 1613132 Size: SH
  59. Reposition the radiator inlet hose clamp at the engine.
  60. Remove the radiator inlet hose from the engine.

    61. Object Number: 1613157 Size: SH
  61. Remove the power steering pump bolts and reposition. Refer to Power Steering Pump Replacement .
  62. Install a engine lifting device to the engine.

    63. Object Number: 1612980 Size: SH
  63. Remove the transaxle-to-engine bolts/studs.
  64. Remove the engine from the vehicle.
  65. Remove the flywheel. Refer to Engine Flywheel Removal .
  66. Install the engine to a engine stand.

Installation Procedure

    Object Number: 1612980 Size: SH
  1. Install a engine lifting devise to the engine.
  2. Remove the engine from the engine stand.
  3. Install the flywheel. Refer to Engine Flywheel Removal .
  4. Install the engine to the vehicle.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the transaxle-to-engine bolts/studs.

    6. Tighten
    Tighten the bolts/stud to 75 N·m (55 lb ft).


    Object Number: 1613157 Size: SH
  6. Remove the engine lifting device from the engine.
  7. Position and install the power steering pump bolts. Refer to Power Steering Pump Replacement .

    8. Object Number: 1613132 Size: SH
  8. Install the radiator inlet hose to the engine.
  9. Position the radiator inlet hose clamp at the engine.

    10. Object Number: 1608325 Size: SH
  10. Connect the EVAP purge line to the canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Connect the fuel feed line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  12. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .
  13. Install the heater inlet and outlet hoses to the engine pipes.
  14. Position the heater inlet and outlet hose clamps at the engine.

    15. Object Number: 1608820 Size: SH
  15. Install the brake booster vacuum hose to the intake manifold.

    16. Object Number: 1613134 Size: SH
  16. Install the radiator outlet hose to the thermostat housing.
  17. Position the radiator outlet hose clamp at the thermostat housing.
  18. Raise and support the vehicle.

    19. Object Number: 1613156 Size: SH
  19. Install the transaxle-to-engine lower rear bolt.

    20. Tighten
    Tighten the bolt to 75 N·m (55 lb ft).


    Object Number: 1609665 Size: SH
  20. Install the transaxle brace.
  21. Install the transaxle brace to engine bolts.
  22. Install the transaxle brace to transaxle bolts.

    23. Tighten
    Tighten the bolts to 63 N·m (46 lb ft).


    Object Number: 1608216 Size: SH
  23. Position the A/C compressor and install the compressor front bolt and nut.

    24. Tighten
    Tighten the bolt/nut to 50 N·m (37 lb ft).


    Object Number: 1608220 Size: SH
  24. Install the A/C compressor rear bolt.

    25. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).


    Object Number: 1612979 Size: SH
  25. Install the torque converter bolts.

    26. Tighten
    Tighten the bolts to 63 N·m (46 lb ft).

  26. Install the starter motor. Refer to Starter Motor Replacement .
  27. Install the torque converter cover. Refer to Torque Converter Cover Replacement .

    28. Object Number: 1607922 Size: SH
  28. Install the engine mount lower nuts.

    29. Tighten
    Tighten the nuts to 50 N·m (37 lb ft).


    Object Number: 1612887 Size: SH
  29. Install the catalytic converter. Refer to Catalytic Converter Replacement .
  30. Position the engine harness over the engine.
  31. Position the engine harness ground terminals (1) to the transmission.
  32. Install the engine harness ground bolt (2).

    33. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  33. Install the engine harness clip bolt (3) to the transmission.

    34. Object Number: 1612884 Size: SH
  34. Connect the CKP sensor electrical connector (4).
  35. Connect the knock sensor electrical connector (1).
  36. Install the engine harness clips (2, 3) to the transaxle brace.
  37. Lower the vehicle.

    38. Object Number: 1609170 Size: SH
  38. Connect the rear upper HO2S electrical connector (2).
  39. Install the CPA retainer (3).

    40. Object Number: 1611455 Size: SH
  40. Install the engine harness clip (4) to the transaxle bracket.
  41. Install the engine harness clip bolt (3).

    42. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  42. Connect the camshaft phasor sensor electrical connector (2).

    43. Object Number: 1608276 Size: SH
  43. Connect the fuel injector inline (1) electrical connector.
  44. Install the engine harness clips (2, 3) to the brackets.

    45. Object Number: 1608869 Size: SH
  45. Connect the ignition coil electrical connector (6).
  46. Connect the generator electrical connector (3).
  47. Install the generator terminal (4).
  48. Install the generator terminal nut (5).

    49. Tighten
    Tighten the nut to 30 N·m (22 lb ft).

  49. Position the generator terminal boot (2).
  50. Connect the MAP sensor electrical connector (1).

    51. Object Number: 1608290 Size: SH
  51. Connect the ETC (2) electrical connector.
  52. Connect the EVAP canister purge solenoid (1) electrical connector.

    53. Object Number: 1609295 Size: SH
  53. Raise the vehicle.
  54. Connect the oil level sensor electrical connector.
  55. Install the engine harness clips to the transaxle brace and the oil pan.

    56. Object Number: 1608498 Size: SH
  56. Connect the A/C compressor electrical connector (4).
  57. Connect the starter motor electrical connector (3)
  58. Connect the knock sensor (2) electrical connector.
  59. Connect the oil pressure sensor (1) electrical connector.

    60. Object Number: 1609656 Size: SH
  60. Install the oil pressure sensor heat shield and nuts.

    61. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  61. Lower the vehicle.
  62. Install the engine mount struts. Refer to Engine Mount Strut Replacement .
  63. Install the drive belt. Refer to Drive Belt Replacement .
  64. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  65. Install the hood. Refer to Hood Replacement .
  66. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  67. Fill the cooling system. Refer to Cooling System Draining and Filling .
  68. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  69. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .