Montana SV6 (2006), Relay, Terraza, Uplander (2005-2007)

Engine

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery cables and properly relieve the fuel system pressure.
  4.  
  5. Drain the engine cooling system and the engine oil into separate drain pans.
  6.  
  7. Remove the wheel, marking the location of the wheel to the hub prior to removal. Mark the individual location of all retainers as they are removed.
  8.  
  9. Remove or disconnect the following:
    NOTE
    DO NOT discharge the A/C system


    CAUTION
    Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft.



    Negative battery cable
     
    Radiator and heater hoses
     
    Vacuum hoses from upper intake manifold
     
    Fuel lines from the fuel rail
     
    Electrical connectors
     
    Engine wiring harness grounds from the transaxle
     
    Engine mount strut
     
    Raise and support the vehicle
     
    Rear driveshaft (AWD only)
     
    Catalytic converter
     
    Lower radiator baffle assembly
     
    Engine splash shields
     
    Stabilizer shaft links from the lower control arms
     
    Tie rod ends from the steering knuckles
     
    Lower ball joints from the steering knuckles
     
    A/C compressor bolts and position compressor aside, support the compressor
     



    Drive axles from the transaxle, secure the drive axles
     
    Intermediate shaft pinch bolt from the steering gear
     

  10.  
  11. Lower the vehicle until the frame contacts the transaxle table J39580.

    Click image to see an enlarged view

    Fig. Showing the transaxle table J39580

  12.  
  13. Remove the frame bolts.
  14.  
  15. Raise the vehicle to separate the powertrain/frame assembly from the vehicle.
  16.  
  17. Remove or disconnect the following:

    Starter motor
     
    Torque converter covers
     
    Torque converter bolts
     
    Engine mount lower nuts
     
    Transaxle brace
     
    Exhaust crossover pipe
     

  18.  
  19. Install engine hoist to engine.

    Click image to see an enlarged view

    Fig. Transaxle to engine mounting bolts

  20.  
  21. Remove the transaxle to engine bolts (3, 4, 5, 6) and the studs (1, 2)
  22.  
  23. Separate and remove the engine from the transaxle/frame
  24.  
  25. Remove the flywheel.
  26.  
  27. Remove the drive belt.
  28.  

To install:

  1. Install or connect the following:

    Drive belt
     
    Flywheel
     
    Engine to the transaxle/frame
     
    Transaxle to engine bolts and tighten the bolts to 55 ft. lbs. (75 Nm)
     

  2.  
  3. Remove the engine hoist from engine.
  4.  
  5. Install or connect the following:

    Exhaust crossover pipe
     
    Transaxle brace
     
    Engine mount lower nuts and tighten to 32 ft. lbs. (43 Nm)
     
    Torque converter bolts
     
    Torque converter covers
     
    Starter motor
     

  6.  
  7. Position the transaxle table with the powertrain/frame under the vehicle.
  8.  
  9. Lower the vehicle until the frame contacts the transaxle table.
  10.  
  11. Install NEW frame bolts.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the transaxle table.
  16.  
  17. Install or connect the following:

    Intermediate shaft pinch bolt to the steering gear
     
    Drive axles to transaxle
     
    A/C compressor to engine and install bolts
     
    Lower ball joints to steering knuckles
     
    Stabilizer shaft links to lower control arms
     
    Engine splash shields
     
    Lower radiator baffle assembly
     
    Catalytic converter
     
    Rear driveshaft (AWD only)
     
    Lower vehicle
     
    Fill engine with oil
     
    Engine mount strut
     
    Electrical connectors
     
    Engine wiring harness ground nut to transaxle stud and tighten to 18 ft. lbs. (2 Nm)
     
    Fuels lines to fuel rail
     
    Vacuum hoses to upper intake manifold
     
    Radiator and heater hoses
     

  18.  
  19. Install the tire and wheel assembly. Tighten the lug nuts to 100 ft. lbs. (140 Nm) in a criss-cross pattern, after aligning the wheel hub with the reference mark and holes as shown in appropriate illustration.
  20.  
  21. Check all powertrain fluid levels and add, as necessary. Be sure to properly fill the engine crankcase with clean engine oil.
  22.  
  23. Connect the battery cables and properly fill the engine cooling system.
  24.  
  25. Start and run the engine, then check for leaks.
  26.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Lock the steering column by installing the J 42640 into the underside of the steering column.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Pull up on the intake manifold cover in order to disengage it from the studs.
  10.  
  11. Disconnect the battery cables.
  12.  
  13. Disconnect the battery current sensor, auxiliary ground cable on the inner fender and positive battery feed at the junction box.
  14.  
  15. Remove the lower radiator air baffle.
  16.  
  17. Remove the coolant recovery reservoir hose from the crossover.
  18.  
  19. Remove the coolant reservoir.
  20.  
  21. Remove the left side diagonal brace.
  22.  
  23. Unsnap and remove the junction block cover.
  24.  
  25. Remove the air intake assembly.
  26.  
  27. Remove the engine control module (ECM) from the air cleaner cover.

    Click image to see an enlarged view

    Fig. Disconnect the various engine wiring harness connectors-3.9L engine

  28.  
  29. Disconnect the engine harness electrical connector (1) from the transaxle control module (TCM).
  30.  
  31. Disconnect the engine harness electrical connector (3) from the instrument panel (I/P) harness electrical connector (2).
  32.  
  33. Disconnect the engine harness electrical connector (5) from the I/P harness electrical connector (4).
  34.  
  35. Disconnect the engine harness electrical connector (6) from the ABS module.
  36.  
  37. Disconnect the engine harness clip from the air conditioning (A/C) line.
  38.  
  39. Remove the underhood junction box.
  40.  
  41. Disconnect the engine harness electrical connector from the mass air flow (MAF)/intake air temperature (IAT) sensor.
  42.  
  43. Disconnect the positive crankcase ventilation (PCV) fresh air tube quick connect fitting from the air cleaner outlet duct.
  44.  
  45. Remove the air cleaner outlet duct from the throttle body and MAF/IAT sensor.
  46.  
  47. Gather the outer branches of the engine harness and lay them on top of the engine.
  48.  
  49. Disconnect the radiator hoses.
  50.  
  51. Disconnect the heater hoses from the inlet and outlet pipes.
  52.  
  53. Remove the brake booster vacuum hose from the upper intake manifold fitting.
  54.  
  55. Disconnect the fuel supply hose and evaporative emission (EVAP) line.
  56.  
  57. Remove the engine mount struts.
  58.  
  59. Raise and safely support the vehicle. Remove the front wheels and tires.
  60.  
  61. If equipped with AWD, remove rear propeller shaft.
  62.  
  63. Disconnect the left and right wheel speed sensor electrical connectors.
  64.  
  65. Remove the drive belt.
  66.  
  67. Disconnect the engine harness electrical connectors from the A/C compressor.
  68.  
  69. Remove the A/C compressor and reposition and support the A/C compressor out of the way.
    NOTE
    Leave the refrigerant lines connected and it is not necessary to evacuate the A/C system prior to repositioning the A/C compressor.

  70.  
  71. Remove the catalytic converter.
  72.  
  73. Remove the engine splash shield.
  74.  
  75. If equipped with FWD, remove the stabilizer shaft link lower nuts.
  76.  
  77. Remove the stabilizer shaft links from the stabilizer shaft.
  78.  
  79. Remove the tie rod end nuts at the steering knuckles.
  80.  
  81. Using Special Tool J 24319-B, separate the outer tie rod ends from the steering knuckle.
    WARNING
    Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints.


    CAUTION
    Use only the recommended tools for separating the ball joint from the knuckle. Do NOT hammer or pry the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal.

  82.  
  83. Using the J 33008-A , J 29794 , and the J 2619-O1 disengage the halfshafts from the transaxle. Secure the halfshafts to the steering knuckle/struts.
  84.  
  85. Reposition the intermediate steering shaft seal in order to provide access to the intermediate steering shaft pinch bolt. Remove the intermediate steering shaft pinch bolt.
  86.  
  87. Disconnect the intermediate steering shaft from the power steering gear.
  88.  
  89. Place transaxle table J 39580 under the frame and lower the vehicle until the frame contacts transaxle table.
  90.  
  91. Remove the front and rear frame bolts, frame rear strap bolts and frame rear straps.
  92.  
  93. Raise the vehicle in order to separate the drivetrain/frame assembly from the vehicle.
  94.  
  95. Remove or disconnect the following:

    Starter motor
     
    Torque converter covers
     
    Torque converter bolts
     
    Engine mount lower nuts
     
    Transaxle brace
     
    Exhaust crossover pipe
     

  96.  
  97. Install a suitable engine hoist to the engine.
  98.  
  99. Remove the transaxle to engine bolts.
  100.  
  101. Separate and remove the engine from the transaxle/frame
  102.  
  103. Installation is the reverse order of removal.
  104.  

 
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