Rendezvous 2006-2007

Engine

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Removal & Installation



3.4L & 3.5L Enginess
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    Failure to remove the intermediate shaft from the steering gear may result in damage to the gear or intermediate shaft and may cause a loss of steering control.



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



    Intermediate shaft from the steering gear
     

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

    Frame bolts

    Click image to see an enlarged view

    Fig. Use a engine stand to support the assembly during frame removal-3.4L and 3.5L Engines

     

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

    Starter
     
    Flywheel-to-torque converter bolts
     

  14.  
  15. Install a suitable engine hoist

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

  16.  

To install:

  1. Install or connect the following:

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

  2.  
  3. Remove the engine hoist.

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

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


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



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



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



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

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

3.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the throttle body air inlet duct.
    NOTE
    Do not disconnect the battery negative cable from the vehicle.

  6.  
  7. Disconnect the battery negative cable from the engine block.
    NOTE
    Do not disconnect the battery positive cable from the vehicle, underhood electrical center or the battery.

  8.  
  9. Disconnect the battery positive cable from the alternator and the starter.
  10.  
  11. Drain the cooling system.
  12.  
  13. Disconnect the radiator hoses from the engine.
  14.  
  15. Disconnect the heater hoses from the engine.
  16.  
  17. Remove the engine mount struts.
    WARNING
    Relieve the fuel pressure.

  18.  
  19. Disconnect the fuel pressure and evaporative emission (EVAP) pipes from the engine.
  20.  
  21. Remove the ECM chassis (outboard) side electrical connector from the ECM.
  22.  
  23. Remove the wiring harness ground from the transmission.
  24.  
  25. Remove the vacuum brake booster hose from the intake manifold.
  26.  
  27. Properly evacuate the air conditioning system.
  28.  
  29. Disconnect the discharge hose from the condenser.
  30.  
  31. Disconnect the suction hose from the evaporator outlet tube.
  32.  
  33. Secure the discharge and suction hoses to the powertrain.
  34.  
  35. Remove the transmission electrical connector.
  36.  
  37. Raise and support the vehicle.
  38.  
  39. If you will be separating the engine from the transmission, remove the torque converter bolts.
  40.  
  41. Drain the engine oil.
  42.  
  43. If the vehicle is equipped with all wheel drive (AWD), remove rear propeller shaft.
  44.  
  45. Remove the catalytic converter.
  46.  
  47. Remove the front tires and wheels.
  48.  
  49. Remove lower radiator air baffle.
  50.  
  51. Remove the engine splash shields.
  52.  
  53. Disconnect the vehicle speed sensor (VSS) electrical connector and secure the wiring harness to the vehicle.
  54.  
  55. Remove the front wheel speed sensor wiring harnesses from the lower control arms and the frame.
  56.  
  57. Remove the tie rod ends from the steering knuckles.
  58.  
  59. Remove the lower ball joints from the knuckles.
  60.  
  61. Disconnect the drive axles from the transaxle.
  62.  
  63. Rotate the struts and reposition the drive axles toward the rear of the vehicle in order to provide clearance for the powertrain to be removed.
    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. This damage may cause loss of steering control which could result in an accident and possible personal injury

  64.  
  65. Separate the intermediate steering shaft from the steering gear.
  66.  
  67. Remove the engine mount lower nuts.
  68.  
  69. Remove the transmission mount lower nuts.
  70.  
  71. Position a powertrain lift table below the powertrain.
  72.  
  73. Lower the vehicle until the powertrain is supported by the powertrain lift table.
  74.  
  75. Remove the frame bolts.
  76.  
  77. Carefully raise the vehicle or lower the powertrain table in order to remove the powertrain from the vehicle.
  78.  
  79. Remove the exhaust crossover pipe.
  80.  
  81. Remove the coolant inlet pipe.
  82.  
  83. Perform the following steps if it is necessary to separate the engine from the transmission.
    NOTE
    Do not disconnect the power steering pipes or drain the power steering fluid.

  84.  
  85. Remove the power steering pressure pipe/hose from the water outlet.
  86.  
  87. Remove the accessory drive belt.
  88.  
  89. Remove the power steering reservoir and reposition to provide access.
  90.  
  91. Remove and reposition the power steering pump with the power steering pipe/hose.
  92.  
  93. Remove the transfer case brace.
  94.  
  95. Remove the transmission lower brace.
  96.  
  97. Remove the transmission upper brace nut located behind the power steering pump.
  98.  
  99. Remove the engine to transmission (bell housing) bolts.
  100.  
  101. Use 4 M1 0x1.5x40 GM P/N 11519182, or equivalent bolts to install the EN 46114 engine lift brackets to the left rear and right front cylinder heads.
  102.  
  103. Tighten the lift bracket bolts to 48 ft. lbs. (65 Nm).
  104.  
  105. Use an engine hoist in order to separate the engine from the transmission and the frame.
  106.  
  107. Install the engine to a suitable engine stand.
  108.  

To install:


NOTE
Use an engine hoist in order to remove the engine from the engine stand.

  1. Install the engine to the transmission and the frame at the powertrain lift table.
  2.  
  3. Remove the EN 46114 engine lift brackets.
  4.  
  5. Install the engine to transmission (bell housing) bolts.
  6.  
  7. Install the transmission upper brace nut located behind the power steering pump.
  8.  
  9. Tighten the transmission upper brace nut to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the transmission lower brace.
  12.  
  13. Install the transfer case brace.
  14.  
  15. Install the power steering pump with the power steering pipe/hose.
  16.  
  17. Install the power steering reservoir and reposition to provide access.
  18.  
  19. Install the accessory drive belt.
  20.  
  21. Install the power steering pressure pipe/hose to the water outlet.
  22.  
  23. Install the coolant inlet pipe.
  24.  
  25. Install the exhaust crossover pipe.
  26.  
  27. Carefully lower the vehicle or raise the powertrain table in order to install the powertrain to the vehicle.
  28.  
  29. Install the frame bolts.
  30.  
  31. Raise the vehicle and remove the powertrain lift table.
  32.  
  33. Install the transmission mount lower nuts. Torque the bolt to 35 ft. lbs. (48 Nm).
  34.  
  35. Install the engine mount lower nuts.
    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. This damage may cause loss of steering control which could result in an accident and possible personal injury

  36.  
  37. Install the intermediate steering shaft to the steering gear.
  38.  
  39. Rotate the struts and install the drive axles to the transaxle.
  40.  
  41. Install the lower ball joints to the knuckles.
  42.  
  43. Install the tie rod ends to the steering knuckles.
  44.  
  45. Install the front wheel speed sensor wiring harnesses to the lower control arms and the frame.
  46.  
  47. Connect the VSS electrical connector and secure the wiring harness to the vehicle.
  48.  
  49. Install the engine splash shields.
  50.  
  51. Install lower radiator air baffle.
  52.  
  53. Install the front tires and wheels.
  54.  
  55. Install the catalytic converter.
  56.  
  57. If the vehicle is equipped with AWD, install rear propeller shaft.
  58.  
  59. Install the torque converter bolts as necessary.
  60.  
  61. Lower the vehicle.
  62.  
  63. Fill the engine oil as necessary.
  64.  
  65. Install the transmission electrical connector.
  66.  
  67. Connect the suction hose to the evaporator outlet pipe.
  68.  
  69. Connect the discharge hose to the condenser.
  70.  
  71. Recharge the air conditioning system.
  72.  
  73. Install the brake booster vacuum hose to the intake manifold.
  74.  
  75. Install the transmission ground wire and the bolt.
  76.  
  77. Tighten the transmission ground bolt 55 ft. lbs. (75 Nm).
  78.  
  79. Install the ECM chassis (outboard) side electrical connector to the ECM.
  80.  
  81. Connect the fuel pressure and EVAP pipes to the engine.
  82.  
  83. Install the engine mount struts.
  84.  
  85. Connect the heater hoses to the engine.
  86.  
  87. Connect the radiator hoses to the engine.
  88.  
  89. Fill the cooling system.
  90.  
  91. Connect the battery positive cable to the alternator and the starter.
  92.  
  93. Connect the battery negative cable to the engine block.
  94.  
  95. Install the throttle body air inlet duct.
  96.  
  97. Connect the battery negative cable to the battery.
  98.  

 
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