Aztek, Rendezvous 2001-2005

Engine

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Removal & Installation



3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    Failure to remove the intermediate shaft from the steering gear may result in damage to the gear or intermediate shaft and may cause a loss of steering control.



    Negative battery cable
     
    Throttle body air inlet duct
     
    Cruise control cable
     
    Accelerator control cable
     
    Radiator hoses from the engine
     
    Heater hoses from the engine
     
    Engine mount struts
     
    Fuel lines from the fuel rail
     
    Engine wiring harness connectors
     
    Vacuum hoses
     
    Brake booster vacuum hose
     
    Automatic transaxle range selector cable
     
    Wiring harness grounds
     
    Catalytic converter three-way pipe from the right side exhaust manifold
     
    Rear propeller shaft, on AWD vehicles
     
    Front wheels
     
    Lower radiator baffle
     
    Splash shields
     
    Stabilizer shaft links from the lower control arms
     
    Tie rod ends from the steering knuckles
     
    Lower ball joints from the steering knuckles
     
    Cooler lines and bracket from the transaxle
     
    A/C compressor bolts and position compressor aside
     
    Axles from the transaxle and secure them to the steering knuckle/struts
     



    Intermediate shaft from the steering gear
     

  10.  
  11. Lower the vehicle until the frame is in contact with a suitable transaxle table/engine stand (such as J 39580). Make certain that an engine stand (such as J 39580) is aligned below the engine.

    Frame bolts

    Click image to see an enlarged view

    Fig. Use a engine stand to support the assembly during frame removal-3.4L Engine

     

  12.  
  13. Raise the vehicle to separate the assembly from the vehicle.

    Starter
     
    Flywheel-to-torque converter bolts
     

  14.  
  15. Install a suitable engine hoist

    Engine to transaxle bolts and studs
     
    Engine from the transaxle and place it on the engine stand
     

  16.  

To install:

  1. Install or connect the following:

    Engine to the transaxle/frame and install the bolts. Torque the bolts to 55 ft. lbs. (75 Nm).
     
    Engine mount-to-frame nuts. Torque the nuts to 32 ft. lbs. (43 Nm).
     

  2.  
  3. Remove the engine hoist.

    Torque converter to flywheel bolts. Torque the bolts to 47 ft. lbs. (63 Nm).
     
    Starter
     

  4.  
  5. Position the transaxle table with powertrain/frame under the vehicle. Lower the vehicle until the frame contacts the transaxle table.
    CAUTION
    When installing the intermediate shaft be certain that the shaft is seated properly before installing the pinch bolt. If the pinch bolt is inserted into the coupling before the shaft, the mating surfaces disengage. Disengagement of the two shafts may lead to a loss of steering control.


    CAUTION
    Whenever the engine has been removed from the vehicle it is necessary to install a new accelerator control cable to avoid damage or personal injury.



    New frame to body bolts. Torque the front bolts to 111 ft. lbs. (150 Nm) and the rear bolts to 122 ft. lbs. (165 Nm). Remove the transaxle table.
     
    Intermediate shaft to the steering gear
     



    Pinch bolt at the intermediate shaft. Torque the bolt 35 ft. lbs. (48 Nm).
     
    Drive axles to the transaxle
     
    Cooler lines and bracket to the transaxle. Torque the fasteners to 17 ft. lbs. (23 Nm).
     
    Lower ball joints to the steering knuckles. Torque to 40 ft. lbs. (55 Nm).
     
    Tie rod ends to the steering knuckles
     
    Stabilizer shaft links to the lower control arms. Torque the bolts 17 ft. lbs. (23 Nm).
     
    Inner fender splash shield. Torque the fasteners to 18 inch lbs. (2 Nm).
     
    Front wheels
     
    Catalytic converter pipe to the right side exhaust manifold. Torque the nuts to 25 ft. lbs. (34 Nm).
     
    Wiring harness grounds
     
    Rear propeller shaft, if removed
     
    Brake booster vacuum hose
     
    Vacuum hoses to the engine
     
    Range selector cable. Torque the screw to 14 ft. lbs. (20 Nm).
     
    Engine wiring harness connectors
     
    Fuel lines to the fuel rail. Torque the fasteners to 13 ft. lbs. (17 Nm).
     
    Throttle body brackets and cables. Torque the fasteners to 18 ft. lbs. (25 Nm).
     
    Engine mount strut. Torque the bolt to 35 ft. lbs. (48 Nm).
     
    Heater hoses
     
    Radiator hoses
     



    New accelerator control cable
     
    Cruise control cable
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  6.  
  7. Fill the engine with oil.
  8.  
  9. Fill the engine with coolant.
  10.  
  11. Inspect the transmission fluid level and top off, if necessary.
  12.  
  13. Turn the ignition to the ON position several times to pressurize the fuel system.
  14.  
  15. Start the engine and inspect for leaks, repair if necessary.
  16.  
  17. Check and top off the fluid levels if required.
  18.  

 
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