Tools Required

J 39580 Universal Engine Support Table

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the drive belt. Refer to Drive Belt Replacement .
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .



4. Remove the power steering pump from the engine. Position the power steering pump aside. Refer to Power Steering Pump Replacement in Power Steering System.



5. Remove the throttle body air inlet duct (3). Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
6. Remove the engine mount strut from the engine mount strut bracket. Refer to Engine Mount Strut Replacement .




Important: Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.5L.

7. Disconnect the fuel lines from the fuel rail. Lay the fuel lines aside. Refer to Quick Connect Fitting Service in Engine Controls - 3.5L.
8. Disconnect the fuel vapor line.

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.
9. Disconnect the throttle and cruise cables with the mounting bracket from the throttle body. Refer to Accelerator Control Cable Replacement and Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L.
10. Disconnect the automatic range selector cable from the PNP switch. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65-E.



11. Disconnect the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.



12. Disconnect the A/C vacuum hose from the engine.
13. Disconnect the wiring harness connections from the engine and transmission. Refer to Engine Controls Component Views in Engine Controls - 3.5L.
14. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
15. Disconnect the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
16. Disconnect the transaxle oil cooler lines from the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Automatic Transaxle - 4T65-E.
17. Remove the thermostat housing. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
18. Disconnect the surge tank inlet hose. Refer to Surge Tank Hose Replacement in Engine Cooling.
19. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement (3.5L) in HVAC.
20. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
21. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
22. Remove the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.



23. Disconnect the AIR pipe from the AIR inlet valve. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls - 3.5L.
24. Remove the battery cables from the retainers.
25. Disconnect the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
26. Remove the generator. Refer to Generator Replacement in Engine Electrical.
27. Remove the A/C compressor mounting bolts and nuts. DO NOT discharge the system. Secure the compressor. Refer to Compressor Replacement (3.5L) in HVAC.
28. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
29. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
30. Scribe the torque converter to the flywheel for installation.
31. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
32. Remove the three-way catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.



33. Remove the lower transaxle-to-engine bolts.
34. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
35. Remove the inner fender engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
36. Disconnect the fog lamp electrical connectors.
37. Remove the wheel speed sensor harness conduits from the retainers in the lower control arms.
38. Remove the tie rod ends from the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
39. Remove the lower ball joints from the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
40. Disconnect the drive axles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
41. Secure the drive axles.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

42. Remove the pinch bolt at the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.



43. Disconnect the intermediate shaft (1) from the steering gear (2). Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
44. Place the J 39580 under the engine/transmission/frame.
45. Lower the vehicle to the frame table in order to support the engine/transmission/frame.
46. Suitably secure the vehicle to the hoist. Refer to Lifting and Jacking the Vehicle in General Information.
47. Remove the frame-to-body bolts. Refer to Frame Removal in Frame and Underbody.

Important: Carefully adjust the A/C compressor as the vehicle is raised.

48. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
49. Remove the frame table with the engine/transmission/frame from under the vehicle.
50. Remove the engine mount bracket-to-engine bolts. Refer to Engine Mount Bracket Replacement .
51. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.



52. Remove the upper transmission-to-engine bolts.
53. Remove the engine from the transmission/frame.

1. Install the engine. Align the engine with the engine-to-transmission dowel pins.




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.

Important: The transmission-to-engine bolts must be returned to their original position. The bolt installed in position (5) is two millimeters shorter than the other transmission-to-engine bolts and requires the use of thread sealant.

2. Install the upper transmission-to-engine bolts.

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

3. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
4. Install the engine mount bracket to engine bolts. Refer to Engine Mount Bracket Replacement .
5. Place the J 39580 with the engine/transmission/frame under the vehicle.

Important: Carefully adjust the A/C compressor as the vehicle is lowered.

6. Lower the vehicle.
7. Install the frame-to-body bolts. Refer to Frame Removal in Frame and Underbody.
8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Remove the frame table from under the vehicle.




Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

10. Connect the intermediate shaft (1) to the steering gear (2). Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
11. Install the pinch bolt at the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
12. Install the drive axles to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
13. Install the lower ball joints to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
14. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
15. Install the wheel speed sensor harness conduits to the retainers in the lower control arms.
16. Install the inner fender engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
17. Install the fog lamp electrical connectors.
18. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.




Important: The transmission-to-engine bolts must be returned to their original position. The bolt installed in position (5) is two millimeters shorter than the other transmission-to-engine bolts and requires the use of thread sealant.

19. Install the lower transmission-to-engine bolt.

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

20. Install the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
21. Align the mark scribed on the torque converter to the mark scribed on the flywheel.
22. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
23. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
24. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.

Notice: Ensure the proper bolts for mounting the A/C compressor and/or the generator are being installed. The mounting bolts for the A/C compressor and the generator are very similar. The A/C compressor mounting bolts have an overall length of approximately 74 mm (2.9 in). The generator mounting bolts have an overall length of approximately 69 mm (2.7 in). Installation of the generator using the longer A/C compressor mounting bolts will result in internal damage to the cylinder head and engine coolant leakage.

25. Install the A/C compressor. Refer to Compressor Replacement (3.5L) in HVAC.
26. Install the generator. Refer to Generator Replacement in Engine Electrical.
27. Connect the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
28. Install the battery cables to the retainers.



29. Connect the AIR pipe to the AIR inlet valve. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls - 3.5L.
30. Install the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
31. Lower the vehicle and remove security to hoist.
32. Install the thermostat housing. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
33. Install the heater hoses to the engine. Refer to Heater Hoses Replacement (3.5L) in HVAC.
34. Install the surge tank inlet hose. Refer to Surge Tank Hose Replacement in Engine Cooling.
35. Connect the transaxle oil cooler lines to the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Automatic Transaxle - 4T65-E.
36. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
37. Install the wiring harness connections to the engine and transaxle. Refer to Engine Controls Component Views in Engine Controls - 3.5L.



38. Connect the A/C vacuum hose to the engine.



39. Connect the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
40. Connect the automatic range selector cable to the PNP switch. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65-E.

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.
41. Connect the throttle and cruise cables with the mounting bracket to the throttle body. Refer to Accelerator Control Cable Replacement and Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L.
42. Connect the fuel vapor line.



43. Connect the fuel lines to the fuel rail. Refer to Quick Connect Fitting Service in Engine Controls - 3.5L.
44. Install the engine mount strut to the engine mount strut bracket. Refer to Engine Mount Strut Replacement .



45. Install the throttle body air inlet duct (3). Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.



46. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement in Power Steering System.
47. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
48. Install the drive belt. Refer to Drive Belt Replacement .
49. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
50. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
51. Install the new oil filter and fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
52. Inspect all of the fluid levels.
53. Inspect for leaks.