G6 2005-2007

Engine

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Removal & Installation



2.4L Engine
  1. Place the wheels in the straight ahead position.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air inlet duct and resonator.
  6.  
  7. Secure the cooling module to the upper body structure.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Disconnect the fuel line from the fuel rail.
  12.  
  13. Drain the cooling system.
  14.  
  15. Remove the radiator inlet hose.
  16.  
  17. Remove the surge tank to cylinder head hose.
  18.  
  19. Remove the radiator outlet hose.
  20.  
  21. Remove the heater hoses.
  22.  
  23. Disconnect the following harness connectors:

    Electronic throttle control
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Oil pressure sensor
     
    Purge solenoid
     
    Ignition coils
     
    Heated oxygen sensor
     
    Vehicle Speed Sensor (VSS)
     
    Engine Coolant Temperature (ECT) sensor
     
    Back-up light switch
     
    Camshaft position actuator solenoid control valves
     
    Fuel rail
     

  24.  
  25. Raise and support the vehicle.
  26.  
  27. Remove the drive belt.
  28.  
  29. Remove the AC compressor bolts and set the compressor aside.
  30.  
  31. Disconnect the starter and alternator connectors.
  32.  
  33. Disconnect the front exhaust pipe from the exhaust manifold.
  34.  
  35. Lower the vehicle.
  36.  
  37. Disconnect the transmission harness connectors.
  38.  
  39. Disconnect the transmission shift cable from the transmission.
  40.  
  41. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  42.  
  43. Remove the engine mount.
  44.  
  45. Remove the side transmission mount bracket bolts.
  46.  
  47. Raise the vehicle.
  48.  
  49. Disconnect the stabilizer links from the stabilizer bar.
  50.  
  51. Disconnect the outer tie rod ends from the steering knuckles.
  52.  
  53. Disconnect the intermediate shaft from the steering gear.
  54.  
  55. Disconnect the lower control arms from the steering knuckles.
  56.  
  57. Disconnect the drive axles from the transaxle and support with wire or bungee cords.
  58.  
  59. Use a paint pen or magic marker in order to mark the frame to body position.
  60.  
  61. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
  62.  
  63. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  64.  
  65. Remove the front frame bolts and then the rear frame bolts.
  66.  
  67. Slowly raise the vehicle off of the frame and powertrain.
  68.  
  69. Attach an engine lift hoist to the engine lift hooks.
  70.  
  71. Remove the starter.
  72.  
  73. Remove the torque converter-to-flywheel bolts.
  74.  
  75. Remove the transaxle to engine bolts.
  76.  
  77. Separate the engine from the transaxle.
  78.  
  79. Remove the following components:

    Exhaust manifold
     
    Engine mount bracket.
     
    Engine block heater
     
    Thermostat housing and feed pipe
     
    Alternator
     
    Fuel rail
     
    Drive belt tensioner.
     

  80.  
  81. Install the engine to a suitable engine stand.
  82.  

To install:

  1. Attach a lifting device to the lifting hooks.
  2.  
  3. Install the following components:

    Exhaust manifold
     
    Engine mount bracket.
     
    Engine block heater
     
    Thermostat housing and feed pipe
     
    Alternator
     
    Fuel rail
     
    Drive belt tensioner.
     

  4.  
  5. Lower the engine into the vehicle and install the engine to the transaxle bolts and tighten to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the torque converter bolts and tighten to 46 ft. lbs. (62 Nm).
  8.  
  9. Install the starter.
  10.  
  11. Remove the engine lift from the engine.
  12.  
  13. Lower vehicle slowly over frame and powertrain.
  14.  
  15. Hand start all the frame bolts while aligning the frame to the paint marks.
  16.  
  17. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus an additional 180 degrees.
  18.  
  19. Remove the lift table.
  20.  
  21. Connect the drive axles to the transaxle.
  22.  
  23. Connect the lower control arm to the steering knuckle.
  24.  
  25. Connect the intermediate steering shaft to the steering gear.
  26.  
  27. Connect the outer tie rod ends to the steering knuckles.
  28.  
  29. Connect the stabilizer links to the stabilizer bar.
  30.  
  31. Install the side transmission mount bracket bolts and tighten to 37 ft. lbs. (50 Nm).
  32.  
  33. Install the engine mounts and tighten to 37 ft. lbs. (50 Nm).
  34.  
  35. Remove the wood blocks between the powertrain and frame.
  36.  
  37. Connect the transmission shift cable to the transmission.
  38.  
  39. Connect the transmission harness connector.
  40.  
  41. Install the catalytic converter to the exhaust manifold and tighten to 22 ft. lbs. (30 Nm).
  42.  
  43. Lower the vehicle.
  44.  
  45. Install the alternator and starter connections.
  46.  
  47. Install the AC compressor to the engine.
  48.  
  49. Install the engine drive belt.
  50.  
  51. Connect all electrical connectors disconnect previously.
  52.  
  53. Install the heater hoses.
  54.  
  55. Install the radiator outlet hose.
  56.  
  57. Connect the fuel line to the fuel rail.
  58.  
  59. Release the cooling module from the upper body structure.
  60.  
  61. Install the air inlet duct and resonator.
  62.  
  63. Connect the negative battery cable.
  64.  
  65. Fill and bleed the cooling system.
  66.  
  67. Fill the engine with clean oil.
  68.  
  69. Fill the transaxle to the proper level.
  70.  
  71. Start the vehicle, check for leaks and repair if necessary.
  72.  

3.5L Engine
  1. Drain the cooling system.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove the intake manifold cover.
  10.  
  11. Remove the air cleaner assembly.
  12.  
  13. Remove the hood.
  14.  
  15. Remove the engine mount strut.
  16.  
  17. Remove the drive belt.
  18.  
  19. Disconnect the following electrical connectors:

    Knock Sensor (KS)
     
    Camshaft Position Sensor (CPS)
     
    Crankshaft Position (CKP) sensor
     
    Heated oxygen sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EGR valve
     
    EVAP canister purge solenoid
     
    Electronic throttle control
     
    Ignition coils
     
    Body wiring harness-to-engine harness
     

  20.  
  21. Raise and support the vehicle.
  22.  
  23. Remove the catalytic converters.
  24.  
  25. Remove the engine wiring harness grounds from the transaxle.
  26.  
  27. Remove the engine mount lower nuts.
  28.  
  29. Remove the torque converter covers.
  30.  
  31. Remove the starter.
  32.  
  33. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor.
  34.  
  35. Remove the torque converter bolts.
  36.  
  37. Remove the transaxle brace.
  38.  
  39. Remove the 6 lower transaxle-to-engine bolts and the stud.
  40.  
  41. Remove the radiator outlet hose from the engine.
  42.  
  43. Lower the vehicle and support the transaxle.
  44.  
  45. Remove the heater outlet and inlet hoses from the engine.
  46.  
  47. Remove the vacuum hoses from the upper intake manifold.
  48.  
  49. Remove the brake booster vacuum hose from the upper intake manifold.
  50.  
  51. Remove the fuel lines from the fuel rail.
  52.  
  53. Remove the radiator inlet hose from the engine.
  54.  
  55. Install an engine lifting device to the engine.
  56.  
  57. Remove the upper transaxle-to-engine bolts and the stud.
  58.  
  59. Remove the engine from the vehicle.
  60.  
  61. Remove the flywheel.
  62.  
  63. Install the engine to the engine stand.
  64.  

To install:

  1. Remove the engine from the engine stand.
  2.  
  3. Install the flywheel.
  4.  
  5. Install the engine to the vehicle.
  6.  
  7. Install the upper transaxle-to-engine bolts and the stud and tighten to 55 ft. lbs. (75 Nm).
  8.  
  9. Remove the engine lifting device.
  10.  
  11. Install the radiator inlet hose to the engine.
  12.  
  13. Install the fuel lines to the fuel rail.
  14.  
  15. Install the brake booster vacuum hose to the upper intake manifold.
  16.  
  17. Install the vacuum hoses to the upper intake manifold.
  18.  
  19. Install the heater inlet and outlet hoses to the engine.
  20.  
  21. Raise the vehicle and remove the transaxle support.
  22.  
  23. Install the radiator outlet hose to the engine.
  24.  
  25. Install the lower transaxle-to-engine bolt and the stud and tighten to 55 ft. lbs. (75 Nm).
  26.  
  27. Install the transaxle brace and tighten to 53 ft. lbs. (72 Nm).
  28.  
  29. Install the torque converter bolts.
  30.  
  31. Install the A/C compressor.
  32.  
  33. Install the starter motor.
  34.  
  35. Install the torque converter covers.
  36.  
  37. Install the engine mount lower nuts and tighten to 32 ft. lbs.
  38.  
  39. Install the engine wiring harness grounds to the transaxle.
  40.  
  41. Install the engine wiring harness ground nut to the transaxle stud.
  42.  
  43. Install the catalytic converters.
  44.  
  45. Lower the vehicle.
  46.  
  47. Connect the electrical connectors disconnected previously.
  48.  
  49. Install the engine mount lower nuts and tighten to 32 ft. lbs. (43 Nm).
  50.  
  51. Install the engine wiring harness grounds to the transaxle.
  52.  
  53. Install the engine wiring harness ground nut to the transaxle stud.
  54.  
  55. Install the catalytic converters.
  56.  
  57. Lower the vehicle.
  58.  
  59. Connect the negative battery cable.
  60.  
  61. Fill and bleed the cooling system.
  62.  
  63. Fill the engine with clean oil.
  64.  
  65. Fill the transaxle to the proper level.
  66.  
  67. Start the vehicle, check for leaks and repair if necessary.
  68.  

3.6L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Remove the hood.
  12.  
  13. Remove the engine mount strut.
  14.  
  15. Remove the drive belt.
  16.  
  17. Disconnect the front knock sensor (KS).
  18.  
  19. Disconnect the rear KS (1) and the crank sensor.
  20.  
  21. Re-position the plastic wire loom/shield on each valve cover, then disconnect the camshaft position (CMP) sensors.
  22.  
  23. Disconnect the manifold absolute pressure (MAP) sensor.
  24.  
  25. Disconnect the evaporative emission (EVAP) canister purge solenoid.
  26.  
  27. Disconnect the front and rear ignition coils.
  28.  
  29. Disconnect the A/C compressor.
  30.  
  31. Disconnect the coolant temperature sensor.
  32.  
  33. Disconnect the following electrical connectors:

    The heated oxygen sensor (HO2S)
     
    The exhaust gas recirculation (EGR) valve
     
    The electronic throttle control
     
    The body wiring harness-to-engine harness
     

  34.  
  35. Raise and support the vehicle.
  36.  
  37. Remove the catalytic converters.
  38.  
  39. Remove the engine wiring harness grounds from the transaxle.
  40.  
  41. Remove the engine mount lower bolts .
  42.  
  43. Remove the torque converter covers.
  44.  
  45. Remove the starter motor.
  46.  
  47. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor and set aside.
  48.  
  49. Remove the power steering pump and position aside.
  50.  
  51. Remove the torque converter bolts.
  52.  
  53. Remove the engine mount bracket.
  54.  
  55. Remove the transaxle to oil pan brace bolts and brace.
  56.  
  57. Remove the lower transaxle-to-engine bolt and the stud.
  58.  
  59. Remove the radiator outlet hose from the engine.
  60.  
  61. Lower the vehicle and support the transaxle.
  62.  
  63. Remove the engine coolant thermostat housing from the engine.
  64.  
  65. Remove the vacuum hoses from the upper intake manifold.
  66.  
  67. Remove the brake booster vacuum hose from the upper intake manifold.
  68.  
  69. Remove the fuel lines from the fuel rail.
  70.  
  71. Remove the battery ground from the rear of engine.
  72.  
  73. Remove the radiator inlet hose from the engine
  74.  
  75. Install the engine lifting device to the engine.
  76.  
  77. Remove the upper transaxle-to-engine bolts and the stud.
  78.  
  79. Remove the engine from the vehicle.
  80.  
  81. Remove the flywheel.
  82.  
  83. Install the engine to the engine stand.
  84.  

To install:

  1. Remove the engine from the engine stand.
  2.  
  3. Install the flywheel and tighten the bolts in a star pattern to 52 ft. lbs (71 Nm).
  4.  
  5. Install the engine to the vehicle
  6.  
  7. Install the upper transaxle-to-engine bolts and the stud. Tighten to 55ft. lbs. (75 Nm).
  8.  
  9. Remove the engine lifting device.
  10.  
  11. Install the radiator inlet hose to the engine.
  12.  
  13. Install the battery ground to the rear of engine.
  14.  
  15. Install the fuel lines to the fuel rail.
  16.  
  17. Install the brake booster vacuum hose to the upper intake manifold.
  18.  
  19. Install the vacuum hoses to the upper intake manifold.
  20.  
  21. Install the engine coolant thermostat housing to the engine. Tighten mounting bolts to 18 ft. lbs. (25 Nm).
  22.  
  23. Raise the vehicle and remove the transaxle support.
  24.  
  25. Install the radiator outlet hose to the engine.
  26.  
  27. Install the lower transaxle-to-engine bolt and the stud. Tighten to 55ft. lbs. (75 Nm).
  28.  
  29. Position the transaxle to oil pan brace, install and tighten the bolts to 37 ft. lbs. (50 Nm).
  30.  
  31. Install the engine mount bracket. Tighten the Upper and lower bracket bolts to 37 ft. lbs. (50 Nm).
  32.  
  33. Install the torque converter bolts.
  34.  
  35. Install the power steering pump. Tighten engine mount adapter bolt to 43 ft. lbs. (58 Nm). Tighten pump bolt to 37 ft. lbs. (50 Nm).
  36.  
  37. Install the A/C compressor. Tighten A/C mounting bolts to 37 ft. lbs. (50 Nm).
  38.  
  39. Install starter motor, tighten mounting bolts to 37 ft. lbs. (50 Nm).
  40.  
  41. Install the torque converter covers.
  42.  
  43. Install the engine mount lower bolts and tighten to 37 ft. lbs. (50 Nm).
  44.  
  45. Install the engine wiring harness grounds to the transaxle.
  46.  
  47. Install the engine wiring harness ground nut to the transaxle stud. Tighten to 26 ft. lbs. (35 Nm).
  48.  
  49. Install the catalytic converters. Tighten converter to manifold bolts to 33ft. lbs. (45 Nm). Tighten left and right converter joining bolts to 18 ft. lbs. (25 Nm).
  50.  
  51. Lower the vehicle.
  52.  
  53. Connect the following electrical connectors:

    The body wiring harness-to-engine harness
     
    The electronic throttle control
     
    The EGR valve
     
    The HO2S
     
    Coolant temperature sensor 
     
    A/C compressor
     
    Front and rear ignition coils 
     
    EVAP canister purge solenoid 
     
    MAP sensor
     

  54.  
  55. Connect the CMP sensors, then re-position the plastic wire loom/shield on each valve cover.
  56.  
  57. Connect the rear KS
  58.  
  59. Connect the front KS and the crank sensor.
  60.  
  61. Install the drive belt.
  62.  
  63. Install the engine mount strut. Tighten the bolt to 81 ft. lbs. (110 Nm).
  64.  
  65. Install the hood and mounting bolts, tighten to 89 inch. lbs. (10 Nm).
  66.  
  67. Install the air cleaner assembly.
  68.  
  69. Connect the negative battery cable.
  70.  
  71. Fill the crankcase with engine oil.
  72.  
  73. Fill and bleed cooling system.
  74.  
  75. Perform a CKP system variation learn procedure.
  76.  
  77. Install the intake manifold cover
  78.  
  79. Start the vehicle, check for leaks and repair if necessary.
  80.  

3.9L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the hood.
  10.  
  11. Remove the intake manifold cover.
  12.  
  13. Remove the engine mount strut.
  14.  
  15. Remove the drive belt.
  16.  
  17. Remove the power steering pump and disconnect the power steering lines, if equipped.
  18.  
  19. Remove the oil pressure sensor heat shield nuts and shield.
  20.  
  21. Disconnect the oil pressure sensor connector.
  22.  
  23. Disconnect the knock sensor connector.
  24.  
  25. Disconnect the air conditioning compressor electrical connector.
  26.  
  27. Lower the vehicle.
  28.  
  29. Disconnect the EVAP canister purge solenoid connector.
  30.  
  31. Disconnect the electronic throttle control connector.
  32.  
  33. Remove the connector position assurance retainer.
  34.  
  35. Disconnect the heated oxygen sensor electrical connector.
  36.  
  37. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  38.  
  39. Disconnect the ignition control module connector.
  40.  
  41. Disconnect the inlet manifold valve connector.
  42.  
  43. Disconnect the fuel injector inline connector.
  44.  
  45. Disconnect the camshaft phaser sensor connector.
  46.  
  47. Disconnect the rear upper HO2S electrical connector.
  48.  
  49. Disconnect the Crankshaft Position (CKP) sensor connector.
  50.  
  51. Disconnect the engine harness connector from the body harness connector.
  52.  
  53. Disconnect the body harness electrical connector from the powertrain control module (PCM).
  54.  
  55. Disconnect the engine harness electrical connectors from the PCM.
  56.  
  57. Disconnect the engine harness electrical connector from the transmission control module (TCM).
  58.  
  59. Remove the engine harness attachments from the transmission stud.
  60.  
  61. Remove the catalytic converters.
  62.  
  63. Remove the engine mount.
  64.  
  65. Remove the torque converter cover.
  66.  
  67. Remove the starter.
  68.  
  69. Remove the torque converter bolts.
  70.  
  71. Unbolt and reposition the A/C compressor of to the side. DO NOT discharge the A/C system.
  72.  
  73. Remove the transaxle brace.
  74.  
  75. Remove the lower transaxle-to-engine bolt and stud.
  76.  
  77. Reposition the radiator outlet hose clamp at the thermostat housing.
  78.  
  79. Remove the radiator outlet hose from the thermostat housing.
  80.  
  81. Lower the vehicle and support the transaxle.
  82.  
  83. Reposition the radiator surge tank hose clamp at the surge tank pipe.
  84.  
  85. Remove the radiator surge tank hose from the surge tank pipe.
  86.  
  87. Reposition the brake booster vacuum hose clamp at the intake manifold.
  88.  
  89. Remove the brake booster vacuum hose from the intake manifold.
  90.  
  91. Reposition the heater inlet and outlet hose clamps at the engine.
  92.  
  93. Remove the heater hoses.
  94.  
  95. Disconnect the fuel feed line from the fuel rail.
  96.  
  97. Disconnect the EVAP purge line from the canister purge solenoid.
  98.  
  99. Reposition the radiator inlet hose clamp at the engine.
  100.  
  101. Remove the radiator inlet hose from the engine.
  102.  
  103. Install a engine lifting device to the engine.
  104.  
  105. Remove the remaining transaxle-to-engine bolts/studs.
  106.  
  107. Remove the engine from the vehicle.
  108.  
  109. Remove the flywheel.
  110.  
  111. Install the engine to the engine stand.
  112.  

To install:

  1. Remove the engine from the engine stand.
  2.  
  3. Install the flywheel and tighten the bolts to 52 ft. lbs .(70 Nm).
  4.  
  5. Install the engine to the vehicle.
  6.  
  7. Install the transaxle-to-engine bolts/studs and tighten to 55 ft. lbs. (75 Nm).
  8.  
  9. Remove the engine lifting device from the engine.
  10.  
  11. Install the radiator inlet hose to the engine.
  12.  
  13. Position the radiator inlet hose clamp at the engine.
  14.  
  15. Connect the EVAP purge line to the canister purge solenoid.
  16.  
  17. Connect the fuel feed line to the fuel rail.
  18.  
  19. Install the heater hoses.
  20.  
  21. Install the brake booster vacuum hose to the intake manifold.
  22.  
  23. Install the radiator surge tank hose to the surge tank pipe.
  24.  
  25. Raise and support the vehicle.
  26.  
  27. Install the radiator outlet hose to the thermostat housing.
  28.  
  29. Install the lower transaxle-to-engine bolt and stud and tighten to 55 ft. lbs. (75 Nm).
  30.  
  31. Install the transaxle brace and tighten to 53 ft. lbs. (72 Nm).
  32.  
  33. Position the A/C compressor and tighten to 37 ft. lbs. (50 Nm).
  34.  
  35. Install the torque converter bolts and tighten to 37 ft. lbs. (50 Nm).
  36.  
  37. Install the starter.
  38.  
  39. Install the torque converter cover.
  40.  
  41. Install the engine mount and tighten to 37 ft. lbs. (50 Nm).
  42.  
  43. Install the catalytic converters.
  44.  
  45. Install the engine harness attachments to the transmission stud.
  46.  
  47. Connect the engine harness electrical connector to the TCM and PCM.
  48.  
  49. Connect the engine harness connector to the body harness connector and PCM.
  50.  
  51. Connect the CKP sensor connector.
  52.  
  53. Connect the knock sensor connector.
  54.  
  55. Connect the rear upper HO2S connector.
  56.  
  57. Install the CPA retainer.
  58.  
  59. Connect the camshaft phaser sensor connector.
  60.  
  61. Connect the fuel injector inline connector.
  62.  
  63. Connect the inlet manifold valve connector.
  64.  
  65. Connect the ignition control module connector.
  66.  
  67. Connect the MAP sensor connector.
  68.  
  69. Connect the HO2S connector.
  70.  
  71. Install the CPA retainer.
  72.  
  73. Connect the ETC connector.
  74.  
  75. Connect the EVAP canister purge solenoid connector.
  76.  
  77. Raise and support the vehicle.
  78.  
  79. Connect the A/C compressor electrical connector.
  80.  
  81. Connect the knock sensor connector.
  82.  
  83. Connect the oil pressure sensor connector.
  84.  
  85. Install the oil pressure sensor heat shield and nuts.
  86.  
  87. Lower the vehicle.
  88.  
  89. Connect the power steering lines and install the power steering pump, if equipped.
  90.  
  91. Install the drive belt.
  92.  
  93. Install the engine mount strut.
  94.  
  95. Install the intake manifold cover.
  96.  
  97. Install the hood.
  98.  
  99. Install the air cleaner assembly.
  100.  
  101. Fill the engine with oil.
  102.  
  103. Fill the cooling system.
  104.  
  105. Connect the negative battery cable.
  106.  
  107. Start the engine and check for leaks.
  108.  

 
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