Engine Replacement
REMOVAL PROCEDURE1. Remove the hood.
2. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect in Starting and Charging.
3. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
5. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
6. Remove the throttle body air inlet duct. Refer to Powertrain Management.
IMPORTANT: Relieve the fuel pressure. Refer to Powertrain Management.
7. Disconnect the fuel lines from the fuel rail. Lay the fuel lines aside. Refer to Powertrain Management.
8. Disconnect the throttle and cruise cables with the mounting bracket from the throttle body. Refer to Powertrain Management.
9. Remove the engine mount struts from the engine mount strut brackets. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right).
10. Remove the engine mount strut brackets from the upper radiator support. Refer to Engine Mount Strut Bracket Replacement (Upper Radiator Support).
11. Remove the Cooling System fans. Refer to Electric Cooling Fan Replacement in Cooling System.
12. Remove the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Hose Replacement (Vacuum Hose Replacement) in Hydraulic Brakes.
13. Remove the power steering pump from the engine. Lay the power steering pump aside. Refer to Power Steering Gear and Pump.
14. Remove the A/C compressor from the engine. Lay the A/C compressor aside. Secure the compressor to the frame. Refer to Heating and Air Conditioning.
15. Remove the electrical connections from the engine. Refer to Powertrain Management.
16. Disconnect the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement (3800 Engine) in Cooling System.
17. Disconnect the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement (3800 Engine) in Cooling System.
18. Disconnect the heater hoses from the engine. Refer to Heating and Air Conditioning.
19. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
20. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transmission/Transaxle.
21. Remove the starter motor. Refer to Starter Motor Replacement (3800 L36 (VIN K) with PG260 F2) in Starting and Charging.
22. Scribe the torque converter to the flywheel for installation.
23. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Automatic Transmission/Transaxle.
24. Remove the transaxle brace. Refer to AT Brace Replacement in Automatic Transmission/Transaxle.
25. Remove the engine mount lower nuts. Refer to Engine Mount Replacement.
26. Disconnect the three-way catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement (3800 L36 (VIN K)) in Emission Control Systems.
27. Remove the lower transaxle-to-engine bolt (6) and stud (1).
28. Remove the vehicle support.
29. Lower the vehicle.
30. Support the transaxle.
31. Remove the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2).
32. Remove the engine from the vehicle.
INSTALLATION PROCEDURE
1. Install the engine. Align the engine with the engine to transaxle dowel pins.
2. Install the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2).
^ Tighten the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2) to 75 Nm (55 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
3. Remove the transaxle support.
4. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
5. Install the lower transaxle-to-engine bolt (6) and stud (1).
^ Tighten the lower transaxle-to-engine bolt (6) and stud (1) to 75 Nm (55 ft. lbs.).
6. Connect the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement (3800 L36 (VIN K)) in Emission Control Systems.
7. Install the engine mount lower nuts. Refer to Engine Mount Replacement.
8. Install the transaxle brace. Refer to AT Brace Replacement in Automatic Transmission/Transaxle.
9. Install the engine flywheel-to-torque converter bolts. Align the scribe marks. Refer to Flywheel to Torque Converter Bolts in Automatic Transmission/Transaxle.
10. Install the starter motor. Refer to Starter Motor Replacement (3800 L36 (VIN K) with PG260 F2) in Starting and Charging.
11. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transmission/Transaxle.
12. Remove the vehicle support.
13. Lower the vehicle.
14. Connect the heater hoses to the engine. Refer to Heating and Air Conditioning.
15. Connect the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement (3800 Engine) in Cooling System.
16. Connect the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement (3800 Engine) in Cooling System.
17. Install the electrical connections to the engine. Refer to Powertrain Management,
18. Install the A/C compressor to the engine. Refer to Heating and Air Conditioning.
19. Install the power steering pump. Refer to Power Steering Gear and Pump.
20. Install the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Hose Replacement (Vacuum Hose Replacement) in Hydraulic Brakes.
21. Install the Cooling System fans. Refer to Electric Cooling Fan Replacement in Cooling System.
22. Install the engine mount strut brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement (Upper Radiator Support).
23. Install the engine mount struts to the engine mount struts brackets. Refer to Engine Mount Strut Replacement (Right) and Engine Mount Strut Replacement (Left).
24. Connect the throttle and cruise cables with the mounting bracket to the throttle body. Refer to Powertrain Management.
25. Connect the fuel lines to the fuel rail. Refer to Powertrain Management.
26. Install the throttle body air inlet duct. Refer to Powertrain Management.
27. Install the fuel injector sight shield Refer to Fuel Injector Sight Shield Replacement in Fuel Injector.
28. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect in Starting and Charging.
29. Install the hood.
30. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
31. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement.
32. Inspect all of the fluid levels.
33. Inspect for leaks.