ENGINE 3.8L
DESCRIPTION
The 3.8 Liter (231 cu. in.) engine is 60° V-6 engines with cast iron cylinder blocks and aluminum cylinder heads. The engine uses a single, block mounted camshaft, roller lifters with pushrods to actuate the valves and either cracked cap, or standard cap, forged connecting rods. The engine does not have provisions for a free wheeling valve train.
The firing order is 1–2–3–4–5–6. The left cylinder bank is numbered 2, 4, and 6. The right cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the rear of the cylinder block just below the cylinder head.
REMOVAL - ENGINE ASSEMBLY
1. Perform fuel pressure release procedure. (Refer to 14 - FUEL SYSTEM - STANDARD PROCEDURE).
2. Disconnect negative battery cable.
3. Disconnect the Inlet Air Temp Sensor (IAT) (2), and remove air cleaner hose (1) and housing.
4. Evacuate and recover the air conditioning.
5. Disconnect the throttle control connectors (3) from the throttle body.
6. Disconnect the PCV hose (1) at the left cylinder head cover.
7. Remove the front splash shield (1).
8. Drain the cooling system.
9. Disconnect the upper radiator hose from the thermostat housing and the lower radiator hose from the radiator.
10. Disconnect the heater hoses and coolant reservoir hose.
11. Disconnect the generator electrical connectors (1,2).
12. Disconnect the throttle position (TP), idle air control (IAC) motor, oxygen (HO2), cam position (CMP), manifold absolute pressure (MAP) (2) and the two engine wiring harness connectors. Free the harness from the cover studs and set harness aside.
13. Disconnect the purge solenoid harness connector.
14. Disconnect the EVAP hose from the throttle body.
15. Remove the EGR tube (1) (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - REMOVAL).
16. Remove the drive belts.
17. Remove the generator (3).
18. Disconnect the fuel line from fuel rail (4).
19. Remove engine wiring harness retainer from left cylinder head cover and oil level indicator tube.
20. Disconnect the knock sensor wiring harness connector.
21. Remove the upper intake manifold (3).
22. Disconnect the A/C electrical connector.
23. Disconnect the A/C discharge line (2) from the compressor. Cover and seal all openings of hoses and compressor.
24. Disconnect the A/C suction line (2) from the compressor. Cover and seal all openings of hoses and compressor.
25. Disconnect the oil pressure sending unit (OPS).
26. Disconnect the coolant hose at the engine oil cooler.
27. Remove the crankshaft sensor (2), (CKP).
28. Disconnect the in block heater (if equipped).
29. Disconnect the starter wiring (1) and remove starter.
30. Remove the starter (1).
31. Remove the flex plate inspection cover. (If equipped).
32. Rotate the engine at the crankshaft pulley bolt and remove the torque converter bolts. (If equipped).
33. Disconnect the left side oxygen sensors (1,2).
34. Disconnect the right side oxygen sensors (1,2).
35. Disconnect the exhaust pipes from the manifolds.
36. Remove the left and right exhaust manifolds.
37. Remove the power steering pump mounting bolts (2) and pump, with hoses attached.
38. Remove the engine mount thru bolts.
39. Remove the structural cover mounting bolts (1,2), and cover. (If equipped).
40. Support the transmission using a suitable jack.
41. Connect engine lifting chain to engine, and lift the engine using a suitable hoist.
42. Lift the engine using a suitable hoist.
43. Separate the transmission from the engine.
INSTALLATION - ENGINE ASSEMBLY
1. Position the engine in the vehicle.
2. Install the transmission bellhousing to engine mounting bolts (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 42RLE - INSTALLATION).
3. Tighten the engine mount thru bolts (Refer to 9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT - INSTALLATION).
4. Install the torque converter bolts. (If equipped) (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 42RLE - INSTALLATION).
5. Install the structural cover (1) (Refer to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION).
6. Install the crank position sensor (2) (CKP).
7. Install the starter (1) (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION).
8. Install the flex plate inspection cover. (If equipped).
9. Connect the starter wiring (1) (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION).
10. Connect the knock sensor electrical connector.
11. Install the left and right exhaust manifolds.
12. Connect the exhaust system and connect the right side O2 sensors (1,2).
13. Connect the left side O2 sensors (1,2).
14. Connect the in block heater (if equipped).
15. Connect the coolant hose at the engine oil cooler.
16. Connect the oil pressure sending unit (OPS) wiring harness connector.
17. Install the upper intake manifold (3) (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
18. Install the EGR tube (1) (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - INSTALLATION).
19. Connect the engine vacuum harnesses.
20. Route the engine harness to the left cylinder head and attach the purge solenoid.
21. Connect the throttle position (TP), idle air control (IAC) motor, oxygen (H02), cam position (CMP), manifold absolute pressure (MAP) (2), and the engine wiring harness connectors.
22. Connect the A/C discharge line (2) at the compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).
23. Connect the A/C suction line (2) at the compressor and compressor electrical connector (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).
24. Install the power steering pump (1) (Refer to 19 - STEERING/PUMP - INSTALLATION).
25. Connect the fuel line (4) to the fuel rail.
26. Install the generator (3) (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
27. Reconnect the generator wiring. (1,2) (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
28. Install the drive belt.
29. Connect the radiator, coolant reservoir and heater hoses.
30. Connect the throttle wiring harness (ETC) (3).
31. Install the PCV hose (1).
32. Fill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
33. Install the air cleaner housing, inlet hose (1) and inlet air temp sensor (IAT) (2) (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - INSTALLATION).
34. Evacuate and recharge A/C system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE).
35. Install new oil filter. Fill engine crankcase with proper oil to correct level (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - SPECIFICATIONS).
36. Install the front splash shield (1).
37. Connect negative cable to battery.
38. Start engine and run until operating temperature is reached.