Removal and Installation
Removal
1. Drain engine cooling system.
2. Disconnect battery ground cable (14301).
3. Disconnect wiring connector from engine compartment lamp.
4. Remove cowl vent screens.
5. Mark position of hood hinges (16796) and remove the hood (16612).
6. Remove cowl extension and wiper module assembly.
NOTE: 3.8L SC engines require special procedures for removing the charge air cooler (CAC) (6K775) and tube assemblies.
7. Remove charge air cooler inlet tube (6F072) at supercharger (6F066) and charge air cooler . Remove bolt retaining charge air cooler inlet tube to generator mounting bracket (10153) and remove tube (3.8L SC engine only).
8. Remove radiator upper sight shield (8C291).
9. Remove lower radiator hose (8286) at water pump.
10. Release drive belt tension and remove drive belt (8620).
11. Remove air cleaner outlet tube (9B659).
12. Disconnect cooling fan motor.
13 Remove cooling fan motor, fan blade (8600) and fan shroud (8146) as an assembly.
14. Remove upper radiator hose (8260).
15. Disconnect fluid cooler inlet tube (7A030) andfluid cooler tube (7A031) (automatic transmission).
16. Disconnect heater water hoses (18472).
17. Remove radiator retaining bolts and radiator (8005) . On 3.8L SC engines, it will also be necessary to remove the bolts retaining the charge air cooler to the radiator.
18. Disconnect power steering pressure hose (3A719).
19. Disconnect fuel charging wiring (9D930) from A/C clutch (2884).
20. Recover A/C system.
21. Disconnect A/C compressor lines. Cap or plug open lines.
22. Remove A/C compressor retaining bolts and remove A/C compressor (19703).
23. Remove radiator coolant recovery reservoir (8A080)
24. Remove accelerator cable and bracket and position aside.
25. Release fuel system pressure. Disconnect fuel supply hose.
26. Disconnect fuel return hose.
27. Disconnect powertrain control module (PCM) (12A650) from engine control sensor wiring (12A581) and fuel charging wiring.
28. Disconnect vacuum hoses.
29. On 3.8L non-SC 49 state engine equipped vehicles, disconnect ignition control module (ICM) (12A297) at wiring connector.
30. Remove ignition coil retaining screws and position ignition coil (12029) aside (3.8L SC engine).
31. Remove nuts retaining charge air cooler outlet tube (6F073) to charge air cooler to intake manifold adapter (6C643) and remove charge air cooler outlet tube bracket and remove charge air cooler outlet tube retaining bolt and retaining nut at generator mounting bracket (3.8L SC engine).
32. Remove generator mounting bracket bolts, disconnect generator wiring and remove generator (GEN) (10346) (3.8L SC engine).
33. Remove power steering pump (3A674) and bracket and position aside (3.8L SC engine).
34. Disconnect fuel vapor hose.
35. Raise vehicle on hoist.
36. Position drain pan beneath oil pan (6675).
37. Drain engine oil.
38. Remove oil bypass filter (6714).
39. Position drain pan away from vehicle.
40. Remove LH exhaust manifold shield and remove dual converter Y pipe-to-exhaust manifold nuts.
41. Disconnect heated oxygen sensors (HO2S) (9F472).
42. Remove inspection plug from engine rear plate (7007) and remove torque converter nuts (automatic transmission).
43. Remove engine-to-transmission bolts.
44. Remove front engine support insulator through bolts. On 3.8L SC engine, remove LH front engine support insulator retaining strap bolt.
NOTE: If crankshaft damper and pulley have to be separated, mark the damper and pulley so that they may be reassembled in the same relative position. This is important as the damper and pulley are initially balanced as a unit.
NOTE: If the crankshaft damper is being replaced, check if the original crankshaft damper has balance pins installed. If so, new balance pins (E0SZ-6A328-A or equivalent) must be installed on the new crankshaft damper in the same position as the original crankshaft damper. The pulley (new or original) must also be installed in the same relative position as originally installed.
45. Remove pulley from damper.
46. Remove starter motor (11002).
47. Remove ground cable and remove starter motor wire harness retainers.
48. Disconnect knock sensor.
49. Partially lower vehicle.
50. Disconnect oil pressure sensor (9278).
51. Position floor jack under transmission.
52. Install engine lifting eyes (17A084).
53 Position engine lifting equipment and attach to engine lifting eyes.
54. Remove engine assembly from vehicle.
55. Remove engine flywheel and engine rear plate.
56. Remove exhaust gas recirculation valve to exhaust manifold tube.
57. Place engine on a work stand.
58. Remove engine lifting eyes.
Installation
NOTE: 3.8L SC engines require special procedures for installing the charge air cooler and tube assemblies.
NOTE: Lightly oil bolt and stud bolt threads before installation except those specifying special sealant.
1. Install engine lifting eyes.
2. Install engine lifting equipment to the engine lifting eyes and remove engine assembly from work stand.
3. Install EGR valve to exhaust manifold tube.
4. Install engine rear plate.
5. Apply pipe sealant with Teflon (D8AZ-19554-A) or equivalent to flywheel bolts and tighten to 73-87 Nm (54-64 lb ft).
6. Position engine assembly in vehicle.
7. Install two engine-to-transmission bolts.
NOTE: Seat LH side locating pin before RH side.
8. Lower engine onto front engine support insulators (6038) and remove lifting equipment.
9. Remove engine lifting eyes.
10. Remove floor jack from under transmission.
11. Tighten two engine-to-transmission bolts.
12. Connect oil pressure sensor.
13. Raise vehicle.
14. Install remaining engine-to-transmission bolts. Tighten all bolts to 55-68 Nm (40-50 lb ft).
15. Install torque converter nuts and tighten to 27-46 Nm (20-34 lb ft). Install inspection plug to engine rear plate.
16. Install and tighten front engine support insulator through bolts and LH front engine support insulator retaining strap bolt.
17. Install starter motor.
18. Install starter motor wire harness retainer, ground cable and transmission oil cooler line bracket.
19. Install dual converter "Y" pipe-to-exhaust manifold nuts.
20. Install exhaust shield.
21. Install pulley to crankshaft damper, if removed. Tighten bolts to 26-38 Nm (20-28 lb ft).
22. Connect heated oxygen sensors at wiring connector.
23. Install oil bypass filter.
24. Connect knock sensor.
25. Lower vehicle.
26. Connect fuel vapor hose.
27. Install charge air cooler outlet tube,
28. Connect power steering hoses and power steering pump and bracket (3.8L SC engine).
29. Install generator (GEN) (10300) , connect wiring, and install generator mounting bracket bolts (3.8L SC engine).
30. Install ignition coil and retaining bolts (3.8L SC engine).
31. Install radiator coolant recovery reservoir.
32. Connect generator-to-voltage regulator wiring.
33. Connect vacuum hoses.
34. Connect engine control sensor wiring and fuel charging wiring.
35 On 3.8L non-SC 49 state engine-equipped vehicles, connect ground wire assembly and coil wire. On 3.8L SC and 3.8L non-SC California engines, connect ignition control module wiring at wiring connector.
36. Reconnect fuel return and supply lines.
37. Install accelerator cable bracket (9723).
38. Install A/C compressor and retaining bolts. Tighten to 41-61 Nm (30-45 lb ft).
39. Remove caps or plugs on A/C compressor lines and connect lines to A/C compressor.
40. Connect fuel charging wiring to the A/C clutch.
41. Install power steering pump and bracket (3.8L non-SC engines).
42. Install radiator and retaining bolts. On 3.8L SC engines, install charge air cooler to radiator and install bolts.
43. Install heater water hoses.
44. Install fluid cooler inlet tube and fluid cooler tube (automatic transmission).
45. Install upper radiator hose.
46. Install cooling fan motor,fan blade and fan shroud as an assembly.
47. Connect cooling fan motor (3.8L SC engines).
48. Position drive belts (accessory/supercharger).
49. Connect lower radiator hose to water pump.
50. Install radiator upper sight shield.
51. Install charge air cooler tube and bolts retaining charge air cooler tube to power steering bracket. Install charge air cooler tube to supercharger and charge air cooler (3.8L SC engine).
52. Install wiper module.
53. Install hood to previously marked position.
54. Connect engine compartment lamp wiring.
55. Install air cleaner outlet tube.
56. Install cowl vent screens.
57. Connect battery ground cable.
58. Refill crankcase to proper level with specified engine oil.
59. Refill cooling system.
60. Evacuate; pressure test and recharge A/C system.
61. Start engine and inspect for leaks.