CTS 2003-2005

Engine 2

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Removal & Installation



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system" or "remove the radiator." In most instances, a detailed removal procedure can be found elsewhere in this product.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts, washers, retainers, clips and other fasteners involved, store and label these components separately in suitable cans and containers. They should save time at installation.
 
After unbolting the transaxle, make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have the system properly discharged by a qualified technician using a refrigerant recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting equipment be attached to them.
 
Lift the engine slowly, checking that no wires, hoses or other components are still connected.
 
After the engine is clear of the vehicle, place it on a suitable engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined herein.
 

2.8L & 3.6L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Center the steering wheel and install Special Tool J-42640 Steering Column Anti-Rotation Pin to the steering column.
  12.  
  13. Remove or disconnect the following:
    WARNING
    Do NOT disconnect suction hose from A/C compressor.


    NOTE
    Do NOT disconnect the liquid line from the condenser.


    NOTE
    Do NOT disconnect the brake lines from the master cylinder.


    NOTE
    Do NOT remove the washer bottle.


    NOTE
    Cap the brake lines to minimize fluid loss.


    NOTE
    Secure the shock modules to the lower control arm with a strap to prevent damage to the front brake hoses.



    Negative battery cable
     
    Engine shroud
     
    Battery
     
    Air intake assembly
     
    Cooling fan wiring harnesses
     
    Surge tank hoses
     
    Heater hoses
     
    Vacuum hose from purge solenoid
     
    Fuel hose
     
    Wiper module
     
    A/C suction hose from the evaporator
     



    A/C pressure switch electrical connector and liquid line
     



    Radiator support brackets
     
    Brake booster vacuum hoses
     
    Brake fluid level switch electrical connector
     
    Mass air flow sensor electrical connector
     
    Engine wiring harnesses from the underhood electrical center
     
    Transmission control module (TCM) wiring harness
     
    Ground wire
     
    Master cylinder and secure to the engine
     



    Muffler assembly
     
    Driveshaft
     
    Air deflector
     
    Washer bottle bracket
     



    Radiator side baffles
     
    Left front brake line retainer
     
    Right front brake line from bundle
     
    Rear brake lines from the brake pressure modulator valve (BPVM)
     



    Front wheels
     
    Intermediate steering shaft
     
    Lower engine mount nuts
     
    Transmission shift linkage
     
    Low oil level sensor electrical connector. Secure to the engine mount bracket.
     
    Headlight leveling sensors
     
    Left and right shock module upper mounting bolts
     

  14.  
  15. Place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
  16.  
  17. Position a suitable powertrain lift table below the frame, engine and transmission. Raise the lift table to support the frame, engine and transmission.
  18.  
  19. Remove the transmission brace and front frame mounting bolts.
  20.  
  21. Lower the lift table to remove the engine, transmission front frame and front suspension assembly.
  22.  
  23. Remove or disconnect the following:
    NOTE
    Cap the power steering lines to prevent fluid loss and contamination.



    Engine control module (ECM) harness
     
    Catalytic converters
     
    Thermostat housing with heater hoses, heater lines and surge tank hoses
     
    Starter motor
     
    Flywheel bolts
     
    Heater Oxygen sensor (HO2S) connector bracket from left cylinder head
     
    Remaining engine wiring harnesses
     
    Transmission oil cooler (TOC) lines
     
    Radiator hoses from water outlet and coolant inlet housing
     
    Power steering cooler hoses
     



    Condenser, radiator and fan module (CRFM) with radiator houses attached
     

  24.  
  25. Install engine lift brackets EN-46114 to the engine.
  26.  
  27. Attach an engine hoist to the lift brackets and partially support the engine. Position a second powertrain lift table below the transmission.
  28.  
  29. Remove or disconnect the following:

    Transmission
     
    Accessory drive belt
     
    Left and right drive belt tensioners
     
    Idler pulley
     
    Alternator and mounting bracket
     
    A/C compressor
     
    Power steering pump
     
    Power steering reservoir
     
    Oil level indicator tube
     
    Left exhaust manifold
     
    Oil filter adapter
     
    Right exhaust manifold
     
    Crankshaft pulley
     
    Flywheel
     
    Intake manifold
     
    Water outlet
     
    Block heater
     
    ECM and mounting bracket
     

  30.  
  31. Using the engine hoist, remove the engine assembly from the frame.
  32.  

To install:

  1. Using an engine hoist, lower the engine assembly to the frame.
  2.  
  3. Install or connect the following:

    ECM with the mounting bracket
     
    Water outlet
     
    Block heater
     
    Flywheel
     
    Intake manifold
     
    Crankshaft pulley. Tighten to 74 ft. lbs. (100 Nm) plus 150 degrees.
     
    Right exhaust manifold
     
    Oil filter adapter
     
    Left exhaust manifold
     
    Oil level indicator tube
     
    Alternator with mounting bracket
     
    Power steering pump
     
    Power steering reservoir
     
    A/C compressor
     
    Idler pulley. Tighten to 37 ft. lbs. (50 Nm).
     
    Left and right drive belt tensioners
     
    Accessory drive belt
     
    Transmission
     
    Flywheel-to-torque converter bolts
     
    Starter
     

  4.  
  5. Remove the engine lifting brackets from the engine.
  6.  
  7. Install or connect the following:

    CRFM with radiator hoses to the frame
     
    Power steering cooler hoses to the CRFM
     
    Radiator hoses to the water outlet and coolant inlet housing
     
    TOC lines
     
    Engine wiring harnesses
     
    HO2S connector bracket to the left cylinder head
     
    Thermostat housing with heater hoses, heater lines and surge tank hoses
     
    Catalytic converters
     
    Fuel lines
     
    ECM upper electrical connector
     

  8.  
  9. Raise the lift table to install the engine, transmission, front frame and front suspension assembly into the vehicle.
  10.  
  11. Install the front frame and transmission support mounting bolts. Tighten as follows:
    1. Front frame bolts: 141 ft. lbs. (191 Nm)
    2.  
    3. Transmission support bolts: 44 ft. lbs. (60 Nm)
    4.  

  12.  
  13. Remove the powertrain lift table.
  14.  
  15. Install or connect the following:

    Left and right shock module upper mounting bolts
     
    Headlight leveling sensors
     
    Transmission shift linkage
     
    Low oil level sensor electrical connector
     
    Lower engine mount nuts. Tighten to 59 ft. lbs. (80 Nm).
     
    Intermediate steering shaft
     
    Front wheels
     
    Brake lines
     
    Radiator side air baffles to the radiator
     
    Washer bottle bracket
     
    Air deflector
     
    Drive shaft
     
    Muffler assembly
     
    Brake master cylinder
     
    Ground wire
     
    TCM wiring harness
     
    Engine wiring harnesses to the underhood electrical connector
     
    Mass air flow sensor electrical connector
     
    Brake fluid level switch electrical sensor
     
    Brake booster vacuum hoses
     
    Radiator support brackets
     
    Vacuum hose to the purge solenoid
     
    Heater hoses
     
    Air intake assembly
     
    Surge tank lines
     
    A/C pressure switch electrical connector and liquid line to the evaporator
     
    A/C suction hose to the evaporator
     
    Cooling fan wiring harnesses
     
    Wiper module
     
    Battery and battery cables
     
    Engine shroud
     

  16.  
  17. Remove the steering column anti-rotation pin.
  18.  
  19. Fill and bleed the power steering system.
  20.  
  21. Refill the engine oil.
  22.  
  23. Fill and bleed the coolant system.
  24.  
  25. Recharge the A/C system and check for leaks.
  26.  
  27. Start the vehicle and inspect for leaks.
  28.  

3.1L Engines

The cylinder block is made of cast alloy iron and has six cylinders arranged in a V shape with three cylinders in each bank. The cylinders are set at a 60 degree angle from each other. The right bank cylinders are 1,3,5 and the left bank cylinders are 2,4,6 starting from the front of the engine.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hood panel using the following procedure and observing the following cautions:
  4.  


WARNING
DO NOT allow the hood to fold back onto the windshield. Windshield and paint damage will result from improper handling of the hood. When removing any body panel, apply tape to the corners of the panel and adjacent surfaces to help prevent paint damage.

  1. Open and support the hood.
  2.  
  3. Disconnect the underhood lamp wire.
  4.  
  5. Mark the upper hood hinge location with a grease pencil to aid in reassembly alignment.
  6.  
  7. With an assistant, remove the hood hinge bolts and carefully lift the hood from the vehicle.
  8.  

  1. Remove the air cleaner duct.
  2.  
  3. Drain the engine coolant into a suitable container.
  4.  
  5. Remove the engine mount struts The struts are wish-bone shaped pieces that, on one end, attach to the cylinder head and on the other end, to the radiator support. Both ends attach with a through-bolt that should be removed, then the struts can be removed.
  6.  
  7. Remove the right side strut bracket using the following procedure:
    1. Remove the horizontal bolts from the air conditioning compressor and set the compressor aside.
    2.  
    3. Remove the vertical bolt from the right side engine mount strut bracket.
    4.  

  8.  
  9. Carefully tag for identification all engine wiring harness connectors. Be neat and accurate. A minute spent now will save much time later. Unplug these connectors from engine components, the engine sensors and the engine grounds.
  10.  
  11. Remove the accelerator control and cruise control servo cables from the throttle body.
  12.  
  13. Remove the accelerator control cable bracket with the accelerator control and cruise control servo cables and set aside.
  14.  
  15. Remove the power steering pump with the lines still attached and set aside.
  16.  
  17. Disconnect the heater outlet hose from the thermostat bypass pipe.
  18.  
  19. Disconnect the heater inlet hose from the inlet pipe.
  20.  
  21. Disconnect the lower radiator hose from the water pump.
  22.  
  23. Disconnect the power brake vacuum booster hose from the upper intake manifold.
  24.  
  25. Carefully tag for identification all engine vacuum hoses. Disconnect the vacuum hoses from the engine to the body.
  26.  
  27. Disconnect the fuel lines.
  28.  
  29. Remove the automatic transaxle vacuum modulator pipe. This is a piece of steel tubing bent to conform to the engine, that allows engine vacuum to reach the transaxle vacuum modulator, to help smooth shifting. It has rubber connectors on both ends. A clip should hold the pipe to the engine about halfway up the pipe.
  30.  
  31. Raise and safely support the vehicle
  32.  
  33. Drain the engine oil.
  34.  
  35. Disconnect the three-way catalytic converter pipe from the right side (rear) exhaust manifold.
  36.  
  37. Remove the automatic transaxle fluid filler tube using the following procedure:
    1. Disconnect the front exhaust manifold pipe.
    2.  
    3. Remove the power steering gear heat shield.
    4.  
    5. Remove the bolt from the filler tube bracket and remove the filler tube.
    6.  

  38.  
  39. Remove the transaxle brace. This is a small bracket at the top of the transaxle bellhousing.
  40.  
  41. Remove the engine mount lower nuts using the following procedure:
  42.  


WARNING
Use a block of wood under the oil pan when raising or supporting the engine. Jacking against the oil pan may cause the oil pan to bend against the pump screen and result in a damaged pickup unit.

  1. Remove the right front wheel and tire.
  2.  
  3. Remove the right engine splash shield. Use care since the Anti-lock Brake System (ABS) harness runs through the splash shield. Remove the push-in retainers to release the ABS harness.
  4.  

  1. Remove the push-in retainers from the splash shield and remove the splash shield from the lower flange of the engine compartment side rail.
    1. The engine mount rests on the drivetrain cradle and two studs face downward from the mount, through the cradle. Remove the engine mount lower nuts from the studs.
    2.  

  2.  
  3. Remove the starter motor. Please see the procedure in Section 2.
  4.  
  5. Remove the torque converter-to-flywheel bolts.
  6.  
  7. Remove the lower engine-to-transaxle bolts.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the upper engine to transaxle bolts.
  12.  
  13. Suitably support the transaxle with safety stands.
  14.  
  15. Attach a suitable engine lifting device.
  16.  
  17. Remove the engine from the vehicle.
  18.  



Click image to see an enlarged view

Fig. Powertrain mounting-3.1L engine

To install:

  1. Verify that the transaxle torque converter is properly seated in the transaxle pump. Install the engine to the vehicle, using care to align the studs on the transaxle bellhousing with the correct openings in the engine block. Make sure the engine mount studs correctly fit the drivetrain cradle. Install the upper engine-to-transaxle bolts. When satisfied with the fit, torque the upper engine to transaxle bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Remove the engine lifting rig.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the lower engine-to-transaxle bolts and torque to 55 ft. lbs. (75 Nm).
  8.  
  9. Install the torque converter-to-flywheel bolts and torque to 45 ft. lbs. (63 Nm).
  10.  
  11. Install the starter motor. Please see Section 2.
  12.  
  13. Install the engine mount lower nuts and torque to 32 ft. lbs. (43 Nm). Install the splash shield using the push-in fasteners.
  14.  
  15. Install the transaxle brace.
  16.  
  17. Install the transaxle fluid filler tube, observing the following:
    1. When installing the filler tube, inspect the condition of the filler tube seal. Replace if the seal is damaged.
    2.  
    3. Place the seal in the transaxle case. Do not place the seal on the tube or the seal will be damaged at installation.
    4.  
    5. Install the retainer bolt and torque to 115 inch lbs. (13 Nm).
    6.  
    7. If removed, install the power steering gear heat shield.
    8.  

  18.  
  19. Connect the three-way catalytic converter pipe to the right (rear) exhaust manifold. Always use a new gasket. Tighten the nuts to the manifold to 26 ft. lbs. (35 Nm).
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the automatic transaxle vacuum modulator pipe.
  24.  
  25. Connect the fuel lines.
  26.  
  27. Connect the vacuum hoses from the engine to the body, following the identification tags made at removal.
  28.  
  29. Connect the power brake vacuum booster hose to the upper intake manifold.
  30.  
  31. Connect the lower radiator hose to the water pump and connect the upper radiator hose to the engine.
  32.  
  33. Connect the heater inlet hose to the inlet pipe and the heater outlet hose to the thermostat bypass pipe.
  34.  
  35. Install the power steering pump. Addition information may be found in Section 8.
  36.  
  37. Install the accelerator control cable bracket with the cables attached. Connect the accelerator and cruise control cables to the throttle body.
  38.  
  39. Plug in all engine electrical connectors to the engine components, sensors and the grounds, following the identification tags made at removal.
  40.  
  41. Install the right engine mount strut bracket, then install the struts, tightening the through bolts to 35 ft. lbs. (48 Nm).
  42.  
  43. Install the air cleaner duct.
  44.  
  45. Install the hood assembly, using the grease pencil marks made at removal to aid alignment. If necessary, fore-aft adjustment may be made by elongating the hood-side hinge holes. Vertical adjustment at the front may be made by adjusting the hood bumpers up or down. Gap tolerances are 0.10-0.22 inch (2.54-5.58mm) and flush tolerances are 0.0-0.06 inch (0-1.5mm). Adjust as required.
  46.  
  47. Fill the cooling system with DEX-COOL® coolant.
  48.  
  49. Fill the engine with oil. Verify that the a new oil filter is properly installed.
  50.  
  51. Connect the battery negative cable.
  52.  
  53. Inspect all fluid levels.
  54.  
  55. Inspect for leaks.
  56.  

3.2L 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. Recover the A/C refrigerant.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Support the engine whenever the transmission is removed. The motor mounts are silicone filled and do not provide sufficient rigidity to support the engine with the transmission removed.



    Battery
     
    Wiper arms
     
    Left and right air inlet grilles
     
    Hood
     
    Intake air resonator
     
    Air filter housing
     
    Harness connectors
     
    Body ground cable
     
    Power supply wires at the battery cable end
     
    Power steering hoses from the power steering pump
     
    Brake booster vacuum lines
     
    Electronic Control Module (ECM) and harness from the electrical center
     
    Relays and wiring harness from electrical center box
     
    Cruise control and accelerator cables
     
    Fuel lines from the fuel rail. Use a backup wrench to prevent damage to the fuel rail.
     
    Coolant hose from the throttle body
     
    Vacuum hose from the purge valve on the engine ventilation chamber
     
    Vacuum hose from the heater control valve
     
    Coolant reservoir hose from the coolant inlet pipe
     
    Electric water pump with hoses attached
     
    Coolant hoses from the heater core
     
    Radiator
     
    Refrigerant line from the A/C compressor and compressor bracket
     
    Condenser line from the A/C condenser
     
    A/C quick-connect hose near the low pressure service valve
     
    Splash shield
     
    A/C compressor electrical connector
     

  12.  
  13. Remove the transmission from the vehicle.
  14.  
  15. Attach a hoist to the engine lifting eyes. Raise the engine slightly and remove the engine support fixture.
  16.  
  17. Remove the engine mount nuts and lift the engine out of the vehicle. Raise the engine slowly after being certain all wiring, cables and hoses have been removed.
  18.  

To install:

  1. Install the engine.
  2.  
  3. Install the engine mount. Torque the upper motor mount nuts to 30 ft. lbs. (40 Nm). Torque the lower nuts to 41 ft. lbs. (55 Nm).
  4.  
  5. Install an engine support fixture and remove the chain hoist.
  6.  
  7. Install or connect the following:

    Transmission. Torque the mounting bolts to 44 ft. lbs. (60 Nm).
     
    A/C compressor electrical connector
     
    Splash shield and tighten securely
     
    Quick connects for the high and low pressure fittings
     
    A/C condenser line to the condenser
     
    A/C compressor line
     
    Radiator
     
    Coolant hoses to the heater core
     
    Electric water pump
     
    Coolant reservoir hose to the coolant inlet pipe
     
    Vacuum hose to the heater control valve
     
    Vacuum hose for the purge valve on the engine ventilation chamber
     
    Coolant hose to the throttle body
     
    Fuel return and supply lines. Torque the lines to 11 ft. lbs. (15 Nm).
     
    Cruise control and accelerator cables to the throttle body
     
    Relays and wiring harness to the electrical center box
     
    ECM
     
    Brake booster vacuum lines
     
    Power steering hoses to the steering pump. Torque the discharge hose fasteners to 21 ft. lbs. (28 Nm).
     
    Power supply wires at the battery cable ends
     
    Body ground cable
     
    Red, white and black wiring harness connectors
     
    Air filter housing
     
    Intake air resonator
     
    Hood
     
    Left and right air inlet grilles
     
    Wiper arms
     
    Battery
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the power steering system.
  10.  
  11. Refill the engine oil.
    NOTE
    An oil filter change is recommended.

  12.  
  13. Fill and bleed the coolant system.
    NOTE
    When refilling the coolant system add 2 crushed engine coolant supplement sealant pellets (PN 3634621) into the reservoir.

  14.  
  15. Recharge the A/C system and check for leaks.
  16.  
  17. Start the vehicle and inspect for leaks.
  18.  

3.4L Engine
VIN E Engine


Click image to see an enlarged view

Fig. Cutaway views of the 3.4L (VIN E) Engine

This engine was introduced with the 2000 model year. The cylinder block is made of cast alloy iron. The cylinder block has 6 cylinders that are arranged in a V shape. There are 3 cylinders in each bank. The cylinder banks are set at a 60 degree angle from each other. Starting at the front of the engine, the right bank cylinders are 1,3,5. The left bank cylinders are 2,4,6.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hood panel using the following procedure and observing the following cautions.
  4.  


WARNING
DO NOT allow the hood to fold back onto the windshield. Windshield and paint damage will result from improper handling of the hood. When removing any body panel, apply tape to the corners of the panel and adjacent surfaces to help prevent paint damage.

  1. Open and support the hood.
  2.  
  3. Disconnect the underhood lamp wire, if equipped.
  4.  
  5. Mark the upper hood hinge location with a grease pencil to aid reassembly alignment.
  6.  
  7. Disconnect the hood support struts by unsnapping the upper ball stud using a small, flat bladed tool to lift up on (but do not remove) the clip
  8.  
  9. With an assistant, remove the hood hinge bolts and carefully lift the hood from the vehicle.
  10.  

  1. Remove the cross vehicle brace.
  2.  
  3. Remove the throttle body air inlet duct and the air cleaner assembly.
  4.  
  5. Remove the engine mount struts from their brackets. The struts are "wish-bone" shaped pieces that, on one end, attach to the engine, and on the other end, to the radiator support. Both ends attach with a through-bolt that should be removed, then the struts can be removed.
  6.  
  7. Remove the accessory drive belt. Please see Section 1.
  8.  
  9. Carefully tag for identification the following engine wiring harness connectors. Be neat and accurate. A minute spent now will save much time later. Unplug the connectors from the following:

    Camshaft Position (CMP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Exhaust Gas Recirculation (EGR) valve
     
    Evaporative Emissions Canister Purge Solenoid valve
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Alternator
     
    Ignition coil pack
     
    Wiring harness grounds
     
    Two wiring harness-to-engine harness connectors
     

  10.  



Click image to see an enlarged view

Fig. Engine mounts, struts and transaxle brace arrangement-3.4L (VIN E) engine

  1. Raise and safely support the vehicle.
  2.  
  3. Drain the cooling system and the engine oil. Remove the oil filter.
  4.  
  5. Carefully tag for identification the following engine wiring harness connectors. Unplug the connectors from: the Knock Sensor (KS), the Heated Oxygen Sensor (HO2S), the Crankshaft Position (CKP) sensor, the starter motor, the air conditioning compressor and the wiring harness grounds.
  6.  
  7. Remove the engine mount lower nuts.
  8.  
  9. Remove the starter motor. Please see Section 2.
  10.  
  11. Remove the air conditioning compressor bolts. Relocate and secure the compressor out of the way. Do not disconnect the refrigerant hoses.
  12.  
  13. Remove the torque converter-to-flywheel bolts.
  14.  
  15. Remove the right engine splash shield. A door trim pad and garnish clip remover tool is recommended to remove the push-in retainers.
  16.  
  17. Remove the transaxle brace. It will be necessary to remove the right front tire for access to the brace bolts.
  18.  
  19. Remove the lower transaxle-to-engine bolts and the stud.
  20.  
  21. Disconnect the radiator outlet hose from the engine.
  22.  
  23. Lower the vehicle.
  24.  


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.

  1. Disconnect the accelerator control and cruise control cable from the throttle body and the cable bracket. Use the following procedure:
    1. Take note of the cable routing before removal. Correct cable routing is important.
    2.  
    3. Remove the accelerator cable shield, if equipped.
    4.  
    5. Disconnect the accelerator cable from the retaining clip.
    6.  
    7. Disconnect the accelerator cable from the throttle body lever.
    8.  
    9. Disconnect the accelerator cable from the cable bracket
    10.  

  2.  
  3. Tag for identification and remove the vacuum hoses from the upper intake manifold. Also disconnect the power brake booster vacuum hose.
  4.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the fuel feed and return hoses using the following procedure. Tool J 37088-A or equivalent is required to separate the fuel pipe quick connectors.
    1. Relieve the fuel system pressure at the fuel rail pressure test port. Please see Section 5.
    2.  
    3. Clean all engine fuel pipe connections.
    4.  
    5. Using the quick connector separator tool, disconnect the fuel feed and fuel return pipe fittings in the engine compartment
    6.  

  2.  
  3. Disconnect the Air Injection (AIR) system from the right side exhaust manifold.
  4.  
  5. Remove the power steering hoses from the power steering pump. Siphon as much fluid from the reservoir as possible to reduce spillage. Remove the power steering pump.
  6.  
  7. Disconnect the heater and remaining radiator hose(s). If disconnecting the heater hoses at the firewall, note the placement and position of the heater hose clamps. GM recommends that at installation, the clamps be positioned exactly as originally installed.
  8.  
  9. Suitably support the transaxle with safety stands.
  10.  
  11. Attach a suitable engine lift.
  12.  
  13. Remove the upper transaxle-to-engine bolts.
  14.  
  15. Carefully lift the engine from the vehicle, checking that all electrical, fuel, vacuum and mechanical attachments have been separated.
  16.  

To install:

  1. Inspect the engine mounts. Broken or deteriorated engine mounts should be replaced. Replace an engine mount if: the hard rubber surface is covered with heat cracks; the rubber has separated from the metal plate of the mount; the rubber has split through the center; there is fluid leaking from any of the hydraulic mounts.
  2.  
  3. Verify that the transaxle torque converter is properly seated in the transaxle pump. Install the engine to the vehicle. Connect the alternator harness while the alternator is still accessible. When setting the engine in place, use care to align the transaxle dowel pins with the correct openings in the engine block. Make sure the engine mount studs correctly fit the drivetrain cradle. Install the upper engine to transaxle bolts. When satisfied with the fit, torque the engine to transaxle bolts to 55 ft. lbs. (75 Nm).
  4.  
  5. Remove the engine lifting rig.
  6.  
  7. Remove the safety stands from the transaxle.
  8.  
  9. Connect the radiator inlet hose and the heater hoses to the engine. Place the clamps in the same position as originally installed.
  10.  
  11. Install the power steering pump and connect the power steering hoses.
  12.  
  13. Connect the AIR System to the exhaust manifold.
  14.  
  15. Before connecting the fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This should ensure proper reconnection and prevent a possible fuel leak. The reason for this is, during normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. Connect the fuel feed and return pipes to their quick-connect fittings.
  16.  
  17. Connect the brake booster hose to the upper intake manifold. Connect all other vacuum lines previously removed, following the reference tags made at removal.
  18.  


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.

  1. Connect the accelerator and cruise control cables to the throttle body lever. Install the retainer clip(s) and make sure the cable properly fits the bracket. Inspect the throttle operation. The throttle should operate freely, without binding, between full closed and wide open throttle.
  2.  


NOTE
Do not route flexible components (hoses, wires, conduits, etc.) within 2 inches of moving parts unless flexible components can be securely fastened. This is necessary to prevent possible interference and damage to the component.

  1. Raise and safely support the vehicle.
  2.  
  3. Install the radiator outlet hose to the engine.
  4.  
  5. Install the lower engine-to-transaxle bolts and torque to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the transaxle brace. Torque the transaxle brace-to-transaxle bolts to 32 ft. lbs. (43 Nm) and the brace-to-engine bolts to 46 ft. lbs. (63 Nm).
  8.  
  9. Install the splash shield and press the retaining clips back in place. Install the right front tire.
  10.  
  11. Install the torque converter bolts and tighten to 47 ft. lbs. (63 Nm).
  12.  
  13. Install the air conditioning compressor.
  14.  
  15. Install the starter motor. Please see Section 2. Install the torque converter cover.
  16.  
  17. Install the engine mount lower nuts and torque to 32 ft. lbs. (43 Nm).
  18.  
  19. Connect the three-way catalytic converter pipe to the right exhaust manifold. Use a new gasket.
  20.  
  21. Install a new oil filter.
  22.  
  23. Referring to the identification tags made at removal, connect the wiring harness connectors to the KS, HO2S, CKP sensor, starter motor, air conditioning compressor and the wiring harness grounds.
  24.  
  25. Lower the vehicle.
  26.  
  27. Fill the engine with new engine oil.
  28.  
  29. Fill the cooling system with the correct mix of DEX-COOL® and water. Please see Section 1
  30.  
  31. Referring to the identification tags made at removal, connect the wiring harness connectors to the CMP sensor, MAP sensor, EGR valve, Evaporative Emissions Canister Purge Solenoid valve, TP sensor, IAC valve, the alternator, ignition coil pack, wiring harness grounds and the two wiring harness to engine harness connectors.
  32.  
  33. Install the accessory drive belt. Please refer to Section 1.
  34.  
  35. Inspect the rubber in the engine mount struts for hardness, splitting and cracking. Replace, if necessary. Install the struts and torque all bolts to 35 ft. lbs. (48 Nm).
  36.  
  37. Install the air inlet duct and the air cleaner assembly.
  38.  
  39. Install the cross vehicle brace.
  40.  
  41. Refill the power steering fluid.
  42.  
  43. Check the transaxle fluid level and add, as required.
  44.  
  45. With an assistant, install the hood assembly, using the grease pencil marks made at removal to aid alignment. If necessary, fore-aft adjustment may be made by elongating the hood-side hinge holes. Vertical adjustment at the front may be made by adjusting the hood bumpers up or down. Gap tolerances are 0.10-0.22 inch (2.54-5.58mm) and flush tolerances are 0.0-0.06 inch (0-1.5mm). Adjust as required. Snap the hood struts into place.
  46.  
  47. Check and adjust all fluid levels as required.
  48.  
  49. Connect the negative battery cable.
  50.  
  51. Start the engine and check for leaks. Bleed the cooling system. Bleed the power steering system.
  52.  

VIN X Engine

On this engine, the cylinder block is made of cast iron and has six cylinders arranged in a V-shape with three cylinder in each bank. The cylinder banks are set at a 60 degree angle from each other. The right bank cylinders (cowl, or firewall side) are numbered 1,3,5 while the left bank cylinders (front, or radiator side) are numbered 2,4,6.



Click image to see an enlarged view

Fig. Views of the 3.4L (VIN X) DOHC engine



Click image to see an enlarged view

Fig. Powertrain mounting-3.4L (VIN X) DOHC engine


CAUTION
The automatic transaxle range selector lever cable is made out of two cable sections. After initial connection, never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle, remove the cable at the automatic transaxle range selector lever and at the lever cable bracket, If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cosmetic/acoustic cover (also called the fuel injector sight shield). It clips to the fuel rail. Pull the shield up from the rear intake manifold side. Pivot the shield forward and remove from the engine.
  4.  
  5. Remove the air cleaner duct.
  6.  
  7. Remove the hood panel using the following procedure and observing the following cautions.
  8.  


WARNING
DO NOT allow the hood to fold back onto the windshield. Windshield and paint damage will result from improper handling of the hood. When removing any body panel, apply tape to the corners of the panel and adjacent surfaces to help prevent paint damage.

  1. Open and support the hood.
  2.  
  3. Disconnect the underhood lamp wire, if equipped.
  4.  
  5. Mark the upper hood hinge location with a grease pencil to aid reassembly alignment.
  6.  
  7. Disconnect the hood support struts by unsnapping the upper ball stud using a small, flat bladed tool to lift up on (but do not remove) the clip
  8.  
  9. With an assistant, remove the hood hinge bolts and carefully lift the hood from the vehicle.
  10.  

  1. Drain the coolant into a suitable container.
  2.  
  3. Remove the coolant recovery reservoir by removing the hose clamp and disconnecting the hose, then removing the mounting clips.
  4.  
  5. Disconnect the heater hoses from the engine.
  6.  
  7. Remove the engine mount strut The strut is a dog-bone shaped piece that, on one end, attaches to the engine, and on the other end, to the radiator support. Both ends attach with a through-bolt that should be removed, then the strut can be removed. Unbolt the strut bracket from the radiator support.
  8.  
  9. Remove the engine cooling fan assemblies.
  10.  
  11. Disconnect the radiator hoses from the engine.
  12.  
  13. Disconnect the transaxle fluid cooler lines at the radiator.
  14.  
  15. Remove the radiator.
  16.  
  17. Disconnect the control cables from the throttle body bracket and from the throttle body.
  18.  
  19. Relieve the fuel system pressure, as outlined in Section 5.
  20.  
  21. Disconnect the fuel lines from the rail and the mounting bracket, observing the following.
    1. When servicing the fuel rail assembly or disconnecting the fuel lines, precautions must be taken to prevent dirt and other contaminates from entering the fuel passages. It is recommended that the fittings be capped, and the holes plugged during servicing.
    2.  
    3. Clean the fuel rail assembly and connections.
    4.  

  22.  
  23. Remove the fuel feed and return pipes from the fuel rail tubes by squeezing the tabs and pulling the lines apart.
  24.  
  25. Remove the exhaust crossover. A liberal application of penetrating oil may be required on the retaining nuts.
  26.  
  27. Disconnect the electrical ground straps from the transaxle bellhousing.
  28.  


WARNING
Siphon power steering fluid from the reservoir before disconnecting the power steering lines to avoid spilling fluid on the secondary timing belt cover. Use clean shop cloths when disconnecting to lines to make sure any remaining power steering fluid DOES NOT contact the secondary timing belt cover. Power steering fluid WILL DAMAGE the secondary timing belt.

  1. Siphon as much power steering fluid as possible from the reservoir. Disconnect the power steering lines at the pump and at the front cover. Plug the lines or drain into a container to keep fluid off the timing belt.
  2.  
  3. Remove the accessory drive belt. Please see Section 1.
  4.  
  5. Remove the upper air conditioning compressor bolts and detach the electrical connector from the compressor.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the right front tire assembly and remove the right front splash shield (fender liner).
  10.  
  11. Remove the lower air conditioning compressor bolts. Reposition and wire the compressor out of the way. Do NOT disconnect the refrigerant lines.
  12.  
  13. Remove the flywheel inspection cover.
  14.  
  15. Remove the oil filter.
  16.  
  17. Remove the starter motor. Please refer to Section 2.
  18.  
  19. Remove the front exhaust pipe and the catalytic converter.
  20.  



Click image to see an enlarged view

Fig. Engine mounts-3.4L (VIN X) DOHC engine

  1. The engine mount nuts are removed next, observing the following.
    1. Set up the engine hoist and take the weight off the engine mounts.
    2.  
    3. Remove the engine mount nuts at the frame and brackets. Use care when working around the drive axle boot. Some sort of protector shield is recommended to keep from damaging the boot.
    4.  
    5. On the right side, disconnect the right ball joint is from the control arm. Please see Section 8.
    6.  
    7. Remove the right side drive axle steel shield.
    8.  
    9. Remove the right side drive axle from the transaxle. Please see Section 7.
    10.  
    11. Remove the right side engine mount nuts.
    12.  
    13. On the left side, it will likely be necessary to disconnect the engine oil cooler hose from the 3-way fitting at the oil cooler.
    14.  

  2.  
  3. Carefully tag for identification all engine wiring harness connectors. Be neat and accurate. A minute spent now will save much time later. Unplug these connectors from engine components, the engine sensors and the engine grounds.
  4.  
  5. Remove the torque converter-to-flywheel bolts.
  6.  
  7. Remove the outer tie rod end.
  8.  
  9. Suitably support the transaxle with a jacking fixture.
  10.  
  11. Remove the engine mount bracket bolts and nuts from the transaxle.
  12.  
  13. Remove the transaxle support.
  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the plastic cover from the shock tower.
  18.  
  19. Remove the electrical connectors from the Powertrain Control Module (PCM). Use care. The connectors have small pins that are easily damaged.
  20.  
  21. Tag for identification and then remove the necessary vacuum lines.
  22.  
  23. Suitably support the transaxle.
  24.  
  25. Lift the engine. The alternator, normally inaccessible, may still have its electrical connections intact. If so, disconnect the alternator harness as soon as there is room to do so.
  26.  
  27. Carefully lift and remove the engine.
  28.  

To install:

  1. Inspect the engine mounts. Broken or deteriorated engine mounts should be replaced. Replace an engine mount if: the hard rubber surface is covered with heat cracks; the rubber has separated from the metal plate of the mount; the rubber has split through the center; there is fluid leaking from any of the hydraulic mounts.
  2.  
  3. Verify that the transaxle torque converter is properly seated in the transaxle pump. Install the engine to the vehicle. Connect the alternator harness while the alternator is still accessible. When setting the engine in place, use care to align the transaxle dowel pins with the correct openings in the engine block. Make sure the engine mount studs correctly fit the drivetrain cradle. Install the engine-to-transaxle bolts. When satisfied with the fit, torque the engine to transaxle bolts to 55 ft. lbs. (75 Nm).
  4.  
  5. Remove the engine lifting rig.
  6.  
  7. Connect any vacuum lines removed, noting the reference tags made at removal.
  8.  
  9. Connect the electrical harness to the PCM and reinstall the plastic cover on the shock tower.
  10.  
  11. Raise and safely support the vehicle. Suitable support the transaxle with jack.
  12.  
  13. Install the engine mount bracket bolts and nuts on the transaxle. When satisfied with the transaxle to mount fit, remove the transaxle support.
  14.  
  15. Install the drive axle. Please see Section 7.
  16.  
  17. Install the ball joint into the control arm. Install the right ball joint nut. Connect the outer tie rod end. Please see Section 8 for more information.
  18.  
  19. Reconnect all electrical harnesses noting the reference tags made at removal.
  20.  
  21. Install the torque converter-to-flywheel bolts and torque to 60 ft. lbs. (82 Nm).
  22.  
  23. Install the engine mount nuts at the frame and torque to 32 ft. lbs. (43 Nm).
  24.  
  25. Install the front exhaust pipe and the catalytic converter.
  26.  
  27. Install the starter motor. Please see Section 2.
  28.  
  29. Install the flywheel cover.
  30.  
  31. Position the air conditioning compressor to the bracket and install the lower bolts.
  32.  
  33. Install a new oil filter.
  34.  
  35. Install the right front splash shield and then the tire assembly.
  36.  
  37. Lower the vehicle.
  38.  
  39. Connect the wiring harness to the air conditioning compressor and install the upper compressor bolts.
  40.  
  41. Install the accessory drive belt.
  42.  
  43. Connect the power steering lines at the pump and the front cover.
  44.  
  45. Install the engine cover.
  46.  
  47. Connect the ground straps to the bell housing.
  48.  
  49. Install the exhaust crossover.
  50.  
  51. Connect the fuel lines using new O-rings. Make sure all fuel line retaining clips and brackets are properly installed.
  52.  
  53. Connect the control cables to the throttle body bracket and to the throttle body.
  54.  
  55. Install the radiator and connect the transaxle cooler lines. Connect the radiator and heater hoses to the engine.
  56.  
  57. Install the cooling fans.
  58.  
  59. Install the engine strut (sometimes called the "dogbone", or "wishbone") and bracket.
  60.  
  61. Connect the heater hoses to the engine. Install the coolant recovery reservoir.
  62.  
  63. Refill the engine with oil.
  64.  
  65. Refill the cooling system with the proper mix of DEX-COOL® and water. Please see Section 1
  66.  
  67. Refill the power steering fluid.
  68.  
  69. Check the transaxle fluid level and add, as required.
  70.  
  71. With an assistant, install the hood assembly, using the grease pencil marks made at removal to aid alignment. If necessary, fore-aft adjustment may be made by elongating the hood-side hinge holes. Vertical adjustment at the front may be made by adjusting the hood bumpers up or down. Gap tolerances are 0.10-0.22 inch (2.54-5.58mm) and flush tolerances are 0.0-0.06 inch (0-1.5mm). Adjust as required. Snap the hood struts into place.
  72.  
  73. Install the air cleaner duct.
  74.  
  75. Check and adjust all fluid levels as required.
  76.  
  77. Connect the negative battery cable.
  78.  
  79. Start the engine and check for leaks. Bleed the cooling system. Bleed the power steering system.
  80.  

3.5L Engine

The 3.5L (VIN H) engine is a Dual Over Head Camshaft (DOHC) engine and uses two intake and two exhaust valves per cylinder with individual cylinder head mounted camshafts for intake and exhaust functions. The cylinder bore is 3.52 inch (89.5mm) and the stroke is 3.62 inch (92mm). The cylinders are arranged in two banks of three on a 90 degree angle. The right (rear) bank of cylinders are numbered 1,3,5 and the left (front) bank of cylinders are 2,4,6. The Engine firing order is 1-2-3-4-5-6.

When servicing the engine, which is constructed largely of aluminum, particular care must be exercised to accommodate the characteristics of this material. Fasteners which thread into aluminum must not be over-torqued or damage to the threads may result. Tightening procedures must be strictly observed in order to assure proper gasket sealing. When cleaning gasket surfaces on aluminum or magnesium parts, tools specifically designed for these materials should be used. Soft wire brushes and dull scrapers are recommended to prevent gouging of the machined surfaces. To obtain valid bolt torque readings, excessive oil or coolant accumulations in the bolt holes must be avoided. Blow out the bolt holes with compressed air prior to installing the fasteners.



Click image to see an enlarged view

Fig. Major external components of the engine, front view-3.5L (VIN H) engine



Click image to see an enlarged view

Fig. Major external components of the engine, rear view-3.5L (VIN H) engine



Click image to see an enlarged view

Fig. Exploded view of the engine mounts and subframe-3.5L (VIN H) engine



Click image to see an enlarged view

Fig. Engine-to-transaxle attachment-3.5L (VIN H) engine


WARNING
The factory recommended procedure for removing this engine is a lengthy and difficult procedure requiring special lifting and support equipment. The steering shaft must be separated and the vehicle subframe must be loosened and lowered. The vehicle's powertrain assembly, including the entire engine/transaxle/subframe assembly is lowered out of the bottom of the engine compartment and then the vehicle is lifted up away from the removed powertrain. Careful work is required for reassembly. This is not a job for the inexperienced or ill-equipped.

  1. Disconnect the negative and positive battery cables. Remove the battery from the vehicle and place in a safe location.
  2.  
  3. Remove the drive belt. Please see Section 1.
  4.  
  5. Remove the cosmetic/acoustic engine cover by removing the two retaining nuts at the front of the shield, then lifting the shield up at the front and sliding it out of the engine bracket.
  6.  
  7. Remove the power steering pump from the engine using the following procedure:
    1. Place a drain pan under the vehicle.
    2.  
    3. Remove the coolant surge tank.
    4.  
    5. Remove the accessory junction block and move aside.
    6.  
    7. Try to siphon as much power steering fluid as possible from the reservoir to reduce spillage.
    8.  
    9. Disconnect the power steering lines and allow to drain into a container.
    10.  
    11. Remove the pump mounting bolts and remove the pump from the vehicle. Cover the hose ports to keep out dirt. The hose ends should also be capped or taped shut to prevent dirt entry.
    12.  

  8.  
  9. Remove the throttle body air duct.
  10.  
  11. Remove the wishbone-shaped engine mount strut from the bracket on the engine.
  12.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the fuel feed and return hoses using the following procedure. Tool J 37088-A or equivalent is required to separate the fuel pipe quick connectors.
    1. Relieve the fuel system pressure at the fuel rail pressure test port. Please see Section 5.
    2.  
    3. Clean all engine fuel pipe connections.
    4.  
    5. Using the quick connector separator tool, disconnect the fuel feed and fuel return pipe fittings in the engine compartment. Disconnect the fuel vapor line.
    6.  

  2.  


CAUTION
In order to avoid possible injury or vehicle damage, GM insists you 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.

  1. Disconnect the throttle and cruise control cables with the mounting bracket from the throttle body.
  2.  
  3. Disconnect the automatic transaxle range selector cable from the range switch on the transaxle.
  4.  
  5. Disconnect the power brake booster vacuum hose from the engine.
  6.  
  7. Disconnect the air conditioning system vacuum hose from the engine.
  8.  
  9. Tag for identification the wiring harness connections from the engine and transaxle. Be neat and accurate. A minute spent now will save much time later. Unplug these connectors.
  10.  
  11. Drain the cooling system into a suitable container.
  12.  
  13. Disconnect the radiator inlet hose from the engine.
  14.  
  15. Disconnect the transaxle cooler lines from the radiator.
  16.  
  17. Disconnect the radiator hose from the thermostat housing then remove the thermostat housing from the engine.
  18.  
  19. Disconnect the heater hoses from the engine, from the connection pipes at the top of cam cover.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Drain the engine oil into a suitable container.
  24.  
  25. Remove the lower radiator air deflector (also called an air dam or spoiler) from under the front of the vehicle. It should be retained by five bolts.
  26.  
  27. Disconnect the Air Injection (AIR) system pipe from the AIR inlet valve.
  28.  
  29. Remove the battery cables from their retainers.
  30.  
  31. Disconnect the radiator outlet hose from the engine.
  32.  
  33. Remove the alternator using the following procedure:
    1. Remove the battery tray.
    2.  
    3. Remove the cooling fan assembly.
    4.  
    5. The thermostat housing should have already been removed. If not, remove the thermostat housing now.
    6.  
    7. Remove the outboard alternator bolt first, then loosen inboard bolt.
    8.  
    9. Remove the idler pulley bolt and the idler pulley.
    10.  
    11. Detach the electrical connectors from the alternator.
    12.  
    13. Remove the alternator from the vehicle.
    14.  

  34.  
  35. Without disconnecting the refrigerant lines, remove the air conditioning compressor and secure it out of the way. The left front diagonal brace will likely need to be removed. The right side splash shield may also need to be removed for access.
  36.  
  37. Remove the torque converter cover and then remove the starter motor. Please see Section 2.
  38.  
  39. To retain the balance, scribe a mark on both the torque converter and the flywheel so they can be reassembled in the same relationship. Remove the flywheel-to-torque converter bolts.
  40.  
  41. Disconnect the three-way catalytic converter pipe from the rear exhaust manifold.
  42.  
  43. Remove the lower transaxle-to-engine bolts.
  44.  
  45. Remove both front tires.
  46.  
  47. The inner fender engine splash shield is held in place with push-in retainer clips. A door trim pad and garnish clip remover is recommended to remove these clips. Use care. A front brake Antilock Brake System (ABS) wheel speed sensor harness is attached to the splash shield. Remove the retainers holding the ABS lead to the splash shield then remove the splash shield from the lower flange of the engine compartment side rail.
  48.  
  49. Unplug the fog lamp harness connectors.
  50.  
  51. Remove the ABS wheel speed sensor harness conduits from the retainers in the lower control arms.
  52.  
  53. Remove the tie rod ends from the steering knuckles. Please see Section 8.
  54.  
  55. Remove the lower ball joints from the steering knuckles. Please see Section 8.
  56.  
  57. Disconnect both drive axles (halfshafts). Please see Section 7. Secure the axles.
  58.  


CAUTION
Failure to disconnect the steering 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.


WARNING
The steering wheel must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these instructions will cause improper alignments of some components during installation and result in damage to the air bag SIR coil assembly in the steering column.

  1. Remove the pinch bolt at the intermediate steering shaft using the following procedure:
    1. Reposition the steering column shaft seal (cover) to provide access to the intermediate steering shaft lower pinch bolt.
    2.  
    3. Remove the pinch bolt and disengage the steering shaft from the stub shaft on the rack and pinion assembly.
    4.  

  2.  


CAUTION
To avoid any vehicle damage, serious personal injury or death when major components such as these are removed from the vehicle while the vehicle is supported by a hoist, the following steps must be performed. Chain the vehicle to the hoist at the same end as the components that are being removed. Support the vehicle at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use suitable safety stands and/or frame stands to support the vehicle when lifting the vehicle with a jack. Remove or secure all of the vehicle's contents to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. Failure to perform these steps could result in damage to the lifting equipment, the vehicle and/or the vehicle's contents.

  1. Place a suitable jack assembly under the engine/transaxle/frame assembly. The factory tool recommended by GM is called a Frame Table and looks like a large, open rack with properly place supports for the powertrain, on casters for mobility. Use extreme care when using substitutes. It MUST support the engine/transaxle/frame assembly safely and be mobile enough to allow the powertrain assembly to be wheeled out from under the vehicle, for further service work.
  2.  
  3. Lower the entire vehicle onto the frame table or other suitable lifting/jacking equipment.
  4.  


CAUTION
The powertrain makes up a large percentage of the vehicle's weight. Once this weight is removed, the vehicle will tend to pitch nose upward and will want to fall off the hoist to the rear. Chain the vehicle to the hoist at the front and safely support the vehicle at the rear or it will fall off the hoist and may cause serious injury, or death and damage to the vehicle. THIS IS A MUST.

  1. With the powertrain secure on a suitable stand and the vehicle chained securely to the hoist, remove the frame to body bolts.
  2.  
  3. Carefully raise the vehicle on the hoist, checking for any overlooked wires, hoses or other components.
  4.  


NOTE
The air conditioning compressor will need to be readjusted for clearance as the vehicle is raised.

  1. Once the vehicle is safely raised, remove the frame table or equivalent with the engine/transaxle/subframe assembly from under the vehicle.
  2.  
  3. Attach an engine crane or other suitable engine lifting device and lift slightly, just enough to take the weight off the engine mounts.
  4.  
  5. Remove the engine mount bracket-to-engine bolts.
  6.  
  7. Remove the transaxle brace.
  8.  


WARNING
Before removing the engine-to-transaxle bolts, note that the bolts MUST be returned to their original locations. One of the bolts is 2mm shorter than the other bolts and requires the use of thread sealer. One technique is to make a reasonably accurate drawing of the transaxle bellhousing on cardboard. Poke holes through the cardboard where the bolts should go and push the bolts through the cardboard as they are removed, one by one. This should keep the bolts organized so they can be reinstalled in their proper locations.

  1. Remove the engine-to-transaxle bolts taking care to keep the bolts organized since they are not all the same length. Separate the engine from the transaxle and place in an engine stand or other suitable work fixture.
  2.  

To install:

  1. Verify that the transaxle torque converter is properly seated in the transaxle pump. Install the engine to the vehicle using care to align the engine with the engine to transaxle dowels pins. Make sure the engine mount studs correctly fit the subframe. Install the engine to transaxle bolts, taking care to see that the bolts are returned to their original location. Apply a thin coat of sealer to the bolt that is 2mm shorter than the rest. When satisfied with the fit, torque the engine to transaxle bolts to 55 ft. lbs. (75 Nm).
  2.  


NOTE
If the lower bolts are difficult to torque while the powertrain is on the frame table, tighten the top bolts for now and wait until the powertrain is installed to the vehicle. Working from underneath the vehicle, final torque the lower engine to transaxle bolts.

  1. Install the transaxle brace and torque the bolts to 32 ft. lbs. (43 Nm). Install the engine mount bracket bolts and tighten to 43 ft. lbs. (58 Nm). The engine mount nuts are tightened to 35 ft. lbs. (47 Nm).
  2.  
  3. The entire engine/transaxle/subframe assembly should now be on a frame table or other suitable lifting device. Roll the powertrain assembly under the vehicle.
  4.  
  5. Carefully and slowly, lower the vehicle over the powertrain. The air conditioning compressor may need to be repositioned for clearance as the body gets closer to the subframe. Carefully align the frame to body bolt holes with two 19mm pins at least 8 inches long in the alignment holes on the right side of the frame. GM specifies that new body bolts must be installed When the frame is in alignment and the body insulators and spacers are in place, install the new frame to body bolts. Torque the bolts to 133 ft. lbs. (180 Nm).
  6.  
  7. Raise and safely support the vehicle. Remove the frame table from under the vehicle.
  8.  


CAUTION
When installing the intermediate steering shaft, make sure that the shaft is properly 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.


WARNING
The steering wheel must be maintained in the straight ahead position and the steering column must be in the LOCK position before connecting the steering column or intermediate shaft. Failure to follow these instructions will cause improper alignments of some components and result in damage to the air bag SIR coil assembly in the steering column.

  1. Position the intermediate steering shaft onto the rack and pinion assembly stub shaft. Make absolutely certain that the two shafts are properly mated. When satisfied with the steering shaft fit, install the pinch bolt and tighten to 35 ft. lbs. (48 Nm). Reposition the steering shaft seal (cover) onto the rack and pinion steering gear.
  2.  
  3. Install the drive axles (halfshafts) to the transaxle. Please see Section 7.
  4.  
  5. Install the lower ball joints to the steering knuckles. Please see Section 8.
  6.  
  7. Install the tie rod ends to the steering knuckles. Please see Section 8.
  8.  
  9. Attach the ABS wheel speed sensor harness conduits to the retainers in the lower control arms.
  10.  
  11. Install the inner fender engine splash shields.
  12.  
  13. Plug in the fog lamp electrical connectors.
  14.  
  15. Install the front tires.
  16.  
  17. Install the three-way catalytic converter pipe to rear exhaust manifold.
  18.  
  19. Align the mark scribed on the torque converter to the mark scribed on the flywheel. Install the bolts and torque to 47 ft. lbs. (63 Nm).
  20.  
  21. Install the starter motor and then the torque converter cover. Please see Section 2.
  22.  
  23. Install the air conditioning compressor. The cast groove on the back of the compressor must capture the stud sticking out of the front of the block. Make sure the compressor is properly positioned. Tighten the front and rear nuts as well as the top bolts to 37 ft. lbs. (50 Nm). Attach the electrical connector.
  24.  
  25. Install the alternator. Attach the electrical connections. Tighten the output BAT terminal to 15 ft. lbs. (20 Nm). Press the protective boot on the BAT terminal. Install the outboard alternator bolt into the alternator housing. Install the alternator on the inboard bolt and finger-tighten the outboard bolt. Install the idler pulley and idler pulley bolt. Tighten the bolts in the following mandatory torque sequence:
    1. Tighten the idler pulley bolt to 37 ft. lbs. (50 Nm).
    2.  
    3. Tighten the alternator bolts to 37 ft. lbs. (50 Nm).
    4.  

  26.  
  27. Install the thermostat housing and radiator hose to the engine.
  28.  
  29. Install the battery cables to their retainers.
  30.  
  31. Install the cooling fan assembly.
  32.  
  33. Connect the AIR pipe to the AIR inlet valve.
  34.  
  35. Install the lower radiator air deflector. Tighten the bolts to 15 ft. lbs. (20 Nm).
  36.  
  37. Lower the vehicle and remove the security devices (chains, etc.) that secured the vehicle to the hoist while the powertrain was removed.
  38.  
  39. Install the heater hoses to the engine.
  40.  
  41. Install the surge tank and connect the inlet hose.
  42.  
  43. Connect the transaxle oil cooler lines to the radiator.
  44.  
  45. Connect the radiator inlet hose to the engine.
  46.  
  47. Attach all of the wiring connectors to the engine and transaxle, referring to the identification tags made at removal.
  48.  
  49. Connect the air conditioning vacuum hose to the engine.
  50.  
  51. Connect the vacuum booster hose to the engine.
  52.  
  53. Connect the automatic transaxle selector cable to the switch on the transaxle.
  54.  


CAUTION
In order to avoid possible injury or vehicle damage, GM insists that you always replace the accelerator control cable with a NEW cable whenever the engine is removed from the vehicle. To avoid cruise control cable damage, position the cable out of the way when the engine is removed and installed. Do not pry or lean against the cruise control cable and do no kink the cable. You must replace a damaged cable.

  1. Install a new replacement throttle cable using the following procedure:
    1. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal, then squeeze the retainer and push the cable through the bulkhead to remove it.
    2.  
    3. Thread the replacement throttle cable through the bulkhead opening and secure to the bulkhead.
    4.  
    5. Attach the end of the replacement throttle cable to the accelerator pedal.
    6.  

  2.  
  3. Connect the throttle and cruise control cables with the mounting bracket to the throttle body.
  4.  
  5. Connect the fuel vapor line.
  6.  
  7. Connect the fuel lines to the fuel rail. Pull on the quick connect fittings after assembly to verify correct installation.
  8.  
  9. Inspect the rubber portion of the engine mount strut for hardness, splitting and cracking. Replace as necessary. Install the engine mount strut to the strut bracket and torque the bolts to 35 ft. lbs. (48 Nm).
  10.  
  11. Install the throttle body air inlet duct to the throttle body air intake.
  12.  
  13. Install the power steering pump to the engine and tighten the mounting bolts to 25 ft. lbs. (34 Nm). Connect the fluid lines and install the pulley. Install the wiring junction block.
  14.  
  15. Install the engine cover.
  16.  
  17. Install the drive belt. Please see Section 1.
  18.  
  19. Install the battery tray, battery and connect the cables.
  20.  
  21. Fill the cooling system with the correct mix of DEX-COOL® and water. Please see Section 1.
  22.  
  23. Install a new oil filter and refill the engine with oil.
  24.  
  25. Inspect all fluid levels and adjust as required.
  26.  
  27. Start the engine and check for leaks.
  28.  

3.8L Engine

Starting at the front of the engine, cylinders in the left bank are numbered 1,3,5 and the cylinders in the right bank are numbered 2,4,6.

  1. Remove the hood panel using the following procedure and observing the following cautions.
  2.  


WARNING
DO NOT allow the hood to fold back onto the windshield. Windshield and paint damage will result from improper handling of the hood. When removing any body panel, apply tape to the corners of the panel and adjacent surfaces to help prevent paint damage.

  1. Open and support the hood.
  2.  
  3. Disconnect the underhood lamp wire.
  4.  
  5. Mark the upper hood hinge location with a grease pencil to aid reassembly alignment.
  6.  
  7. With an assistant, remove the hood hinge bolts and carefully lift the hood from the vehicle.
  8.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the cosmetic/acoustic engine cover (properly called the fuel injector sight shield). Use the following procedure:
    1. VIN K engine: Twist counter-clockwise to unlock the tube/oil fill cap from the rocker arm cover. Lift the shield up at the front and slide the tab out of the engine bracket. Install the oil fill cap to keep out dirt.
    2.  
    3. VIN 1 engine: Twist counter-clockwise to unlock the tube/oil fill cap from the rocker arm cover. Remove the nut that is on top of the shield, holding the shield to the fuel injector rail brace stud. Lift the shield up at the front and slide the tab out of the engine bracket. Install the oil fill cap to keep out dirt.
    4.  

  8.  
  9. Remove the air cleaner duct.
  10.  



Click image to see an enlarged view

Fig. Fuel system pressure can be relieved by attaching a hose to the fuel pressure test port on the fuel rail-3.8L engines shown

  1. Relieve the fuel system pressure, as outlined in Section 5.
  2.  
  3. Disconnect the fuel lines from the rail and the mounting bracket, observing the following.
    1. When servicing the fuel rail assembly or disconnecting the fuel lines, precautions must be taken to prevent dirt and other contaminates from entering the fuel passages. It is recommended that the fittings be capped, and the holes plugged during servicing.
    2.  
    3. Clean the fuel rail assembly and connections.
    4.  

  4.  
  5. Remove the fuel feed and return pipes from the fuel rail tubes by squeezing the tabs and pulling the lines apart.
  6.  
  7. Disconnect the throttle and cruise control cables, along with the mounting bracket from the throttle body.
  8.  
  9. Remove the engine mount struts. The struts are "wish-bone" shaped pieces that, on one end, attach to the cylinder head and on the other end, to the radiator support. Both ends attach with a through-bolt that should be removed, then the struts can be removed.
  10.  
  11. Remove the engine cooling fan assemblies, as outlined in this section.
  12.  
  13. On vehicles with the 3.8L VIN K engine (non-supercharged), remove the automatic transaxle vacuum modulator pipe. This is a piece of steel tubing bent to conform to the engine, that allows engine vacuum to reach the transaxle vacuum modulator, to help smooth shifting. It has rubber connectors on both ends.
  14.  
  15. Disconnect the power brake vacuum booster hose from the engine.
  16.  
  17. Remove the power steering pump assembly from the engine. It should not be necessary to disconnect the fluid lines. Use a piece of wire to hold the pump aside.
  18.  
  19. Remove the air conditioning compressor assembly from the engine. It should not be necessary to disconnect the refrigerant lines. Use a piece of wire to hold the compressor aside, securing it to the frame.
  20.  
  21. Carefully tag for identification all engine wiring harness connectors. Be neat and accurate. A minute spent now will save much time later. Unplug these connectors from engine components, the engine sensors and the engine grounds.
  22.  
  23. Remove the upper and lower radiator hoses.
  24.  
  25. Disconnect the heater hoses from the engine.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Remove the lower flywheel cover. It should be retained by just a few screws.
  30.  
  31. Remove the starter motor. Save any shims for reassembly. Please see Section 2.
  32.  
  33. To keep rotating parts in balance, scribe a mark on the torque converter and the flywheel so they can later be reassembled in the same relationship. This helps avoid vibration problems after assembly. Remove the torque converter bolts.
  34.  
  35. Remove the transaxle brace. This is a small bracket at the top of the transaxle bellhousing.
  36.  
  37. Remove the engine mount to frame retaining nuts.
  38.  



Click image to see an enlarged view

Fig. Exploded view of the powertrain mounting-3.8L engines shown

  1. Disconnect the three-way catalytic converter pipe from the manifold. This is the pipe from the rear (firewall side) of the engine. It is retained by nuts and uses a gasket which must be replaced with a new gasket at assembly.
  2.  
  3. Remove the lower transaxle to engine bolts.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the upper transaxle to engine bolts.
  8.  
  9. Attach a suitable engine lifting device.
  10.  
  11. Remove the engine from the vehicle.
  12.  

To install:

  1. Verify that the transaxle torque converter is properly seated in the transaxle pump. Install the engine to the vehicle using care to align the transaxle dowel pins with the correct openings in the engine block. Make sure the engine mount studs correctly fit the drivetrain cradle. Install the upper engine to transaxle bolts. When satisfied with the fit, torque the upper engine-to-transaxle bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Remove the engine lifting rig.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the lower engine to transaxle bolts and torque to 55 ft. lbs. (75 Nm).
  8.  
  9. Raise the vehicle again and safely support.
  10.  
  11. Install the three-way catalytic converter pipe to the rear exhaust manifold using a new gasket. Torque the nuts to 26 ft. lbs. (35 Nm).
  12.  
  13. Install the engine mount nuts to the studs and torque to 32 ft. lbs. (43 Nm).
  14.  
  15. Install the transaxle brace at the top of the transaxle bellhousing.
  16.  
  17. Carefully align the scribe marks on the flywheel and the torque converter made at removal. Install the torque converter to flywheel bolts and torque to 45 ft. lbs. (63 Nm).
  18.  
  19. Install the starter motor following the procedure in Section 2.
  20.  
  21. Install the flywheel cover.
  22.  
  23. Lower the vehicle.
  24.  
  25. Connect the heater hoses to the engine and install the radiator hoses.
  26.  
  27. Plug in all engine electrical connectors to the engine components, sensors and the grounds, following the identification tags made at removal.
  28.  
  29. Install the air conditioning compressor to the engine.
  30.  
  31. Install the power steering pump to the engine.
  32.  
  33. Connect the power brake booster vacuum hose to the engine.
  34.  
  35. If equipped with the VIN K engine, install the vacuum line to the transaxle vacuum modulator.
  36.  
  37. Install the cooling fans.
  38.  
  39. Install the right engine mount strut bracket, then install the struts, tightening the through bolts to 35 ft. lbs. (48 Nm).
  40.  
  41. Connect the throttle and cruise control cables with the mounting bracket to the throttle body.
  42.  
  43. Connect the fuel lines to the fuel rail and the mounting bracket.
  44.  
  45. Install the air cleaner duct.
  46.  
  47. Install the engine cover (fuel injector sight shield).
  48.  
  49. Connect the battery ground cable.
  50.  
  51. Install the hood assembly, using the grease pencil marks made at removal to aid alignment. If necessary, fore-aft adjustment may be made by elongating the hood-side hinge holes. Vertical adjustment at the front may be made by adjusting the hood bumpers up or down. Gap tolerances are 0.10-0.22 inch (2.54-5.58mm) and flush tolerances are 0.0-0.06 inch (0-1.5mm). Adjust as required.
  52.  
  53. Fill the cooling system with the proper mix of DEX-COOL® coolant and water. Please see Section 1.
  54.  
  55. Fill the engine with oil. Verify that the a new oil filter is properly installed.
  56.  
  57. Inspect all fluid levels and adjust, if necessary.
  58.  
  59. Inspect for leaks.
  60.  

5.7L 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. Recover the A/C refrigerant.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Center the steering wheel and install Special Tool J-42640 Steering Column Anti-Rotation Pin to the steering column.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Do NOT disconnect the lines from the cooler.


    NOTE
    Secure the shock modules to the front frame to avoid stretching the front brake hoses.



    Negative battery cable
     
    Shifter assembly mounting bolts
     
    Engine cross brace
     
    Engine shroud
     
    Air intake assembly
     
    Throttle body heater outlet hose from throttle body
     
    A/C suction hose from the evaporator
     
    A/C liquid line
     
    Brake booster vacuum hose from the brake booster
     
    Brake fluid level switch electrical connector
     
    Brake master cylinder mounting nuts and secure master cylinder to the engine with wire
     
    Electrical connectors from the top of right and left shock tower
     
    Chassis fuel line at the right rear of the engine
     
    Evaporative emissions (EVAP) hose at the right rear of the engine
     
    Engine wiring harness connector at the front of the dash
     
    Underhood fuse block wiring harness
     
    Battery
     
    Throttle actuator control (TAC) module
     
    Ground strap
     
    Electric cooling fan assembly
     
    A/C condenser assembly
     
    Power steering oil cooler mounting nuts and secure unit to the engine
     



    Front wheels
     
    Right front fender splash guard
     
    Windshield washer bottle-to-frame brace
     
    Separate the upper intermediate steering shaft from the center intermediate shaft
     
    Heater hoses
     
    Rear brake lines from the brake pressure modulator valve (BPMV)
     
    Transmission
     
    Clutch slave cylinder
     
    Rear brake lines from bundle clips
     
    Powertrain control module (PCM)
     
    Right and left shock module upper mounting bolts
     




  14.  
  15. Please a suitable lift table under the engine, front frame and front suspension assembly.
  16.  
  17. Raise the lift table to preload the weight of the engine, front frame and suspension assembly.
  18.  
  19. Remove the front frame bolts.
  20.  
  21. Lower the lift table and remove the engine, front frame and suspension assembly from the vehicle.
  22.  
  23. Using a suitable engine hoist, remove the engine from the front frame assembly.

    Click image to see an enlarged view

    Fig. Engine support fixture-5.7L

  24.  

To install:

  1. Lower the engine onto the front frame assembly.
  2.  
  3. Raise the engine, front frame and suspension assembly into the vehicle.
  4.  
  5. Install the frame bolts and tighten to 141 ft. lbs. (191 Nm).
  6.  
  7. Install the right and left shock module upper mounting bolts. Tighten to 83 ft. lbs. (112 Nm).
  8.  
  9. Remove the engine lift table.
  10.  
  11. Install or connect the following:

    PCM and wiring harness
     
    Rear brake lines into the bundle clips
     
    Clutch slave cylinder
     
    Transmission
     
    Rear brake lines to the BPMV
     
    Heater hoses
     
    Upper intermediate steering shaft to the center intermediate shaft
     
    Windshield washer bottle-to-frame brace
     
    Right fender splash guard
     
    Power steering hose and A/C suction hose to proper positions
     
    Power steering oil cooler. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    A/C condenser
     
    Radiator assembly
     
    Electric cooling fan assembly
     
    Ground strap
     
    Underhood fuse block wiring harness
     
    TAC module
     
    Electrical connectors to the top of the right and left shock towers
     
    Battery
     
    Engine wiring harness connect at the front of the dash
     
    Chassis-to-EVAP hose at the right rear of the engine
     
    Chassis fuel line at the right rear of the engine
     
    Brake master cylinder. Tighten the mounting nuts to 18 ft. lbs. (25 Nm).
     
    Brake fluid level switch electrical connector
     
    Brake booster vacuum line
     
    A/C liquid line
     
    A/C suction hose to the evaporator
     
    Throttle body heater outlet hose to the throttle body
     
    Air intake assembly
     
    Engine shroud
     
    Engine cross brace
     
    Shifter assembly mounting bolts. Tighten to 13 ft. lbs. (18 Nm).
     
    Battery cables
     

  12.  
  13. Remove the steering column anti-rotation pin.
  14.  
  15. Fill and bleed the power steering system.
  16.  
  17. Fill the transmission with fluid to the correct level.
  18.  
  19. Refill the engine oil.
  20.  
  21. Fill and bleed the coolant system.
  22.  
  23. Recharge the A/C system and check for leaks.
  24.  
  25. Start the vehicle and inspect for leaks.
  26.  

 
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