Front Frame Replacement 4.6L

Tools Required

1. Install the J 28467-A in order to support the engine. Refer to Engine Support Fixture .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
4. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement .
5. Remove the bolts retaining the steering gear to the engine frame.
6. Remove the ball joints from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
7. Remove the front air deflector. Refer to Front Air Deflector Replacement .
8. Remove the brake pressure modulator valve and bracket from the frame. Refer to Brake Pressure Modulator Valve Replacement .
9. Disconnect the ESC sensor links from the lower control arm ball studs.
10. Remove the secondary air injection pump assembly. Refer to Secondary Air Injection Pump Replacement .



11. Remove the steering gear heat shield fasteners (1) in order to remove the steering gear heat shield (2) and disconnect the electrical harness retainer that is mounted on the heat shield.
12. Disconnect the electrical harness from the heat shield.



13. Remove the brackets (2) retaining the power steering line (1) to the frame.
14. Remove the retainer (3), retaining the power steering line (4) along the left side of the engine frame.
15. Using mechanics wire, retain the steering gear to the body.



16. Lower vehicle until the engine frame rests on the J 39580 or suitable jack stands .



17. Remove the fastener retaining the front engine mount to the engine frame.



18. Remove the fasteners retaining the rear transaxle mount (1) to the engine frame.



19. Remove the engine frame insulator bolts (3) retaining the engine frame (2) to the vehicle.
20. Raise vehicle away from engine frame.
21. Remove the control arms. Refer to Lower Control Arm Replacement .

1. Install the control arms. Refer to Lower Control Arm Replacement .
2. Lower the vehicle onto the engine frame.



3. Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the engine frame insulator retainer bolts in order to retain the engine frame to the vehicle.

Tighten
Tighten the retainers to 181 N·m (133 lb ft).

5. Check the front wheel alignment. Refer to Wheel Alignment Specifications .



6. Raise the vehicle away from the jack stands supporting the engine frame.



7. Install the fasteners in order to retain the rear transaxle mount (1) to the bracket.

Tighten
Tighten the retainers to 50 N·m (37 lb ft).




8. Install the fastener in order to retain the front engine mount to the engine frame.

Tighten
Tighten the fastener to 70 N·m (52 lb ft).

9. Install the fasteners in order to retain the steering gear to the engine frame.

Tighten
Tighten the fastener to 95 N·m (70 lb ft).




10. Install the bracket (2) to retain the power steering line (1) to the engine frame.
11. Install the clips (3) retaining power steering line (4) along engine frame rail.
12. Connect the wiring harness to the heat shield.



13. Install the steering gear heat shield (2) to the vehicle.

Tighten
Tighten the retainers to 9 N·m (80 lb in).

14. Install the secondary air injection pump to the vehicle. Refer to Secondary Air Injection Pump Replacement .
15. Install the brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement .
16. Install the ESC sensor links to the lower control arm ball studs.
17. Install the front air deflector. Refer to Front Air Deflector Replacement .
18. Install the ball joints to the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement .
19. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
20. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement .



21. Lower the vehicle.
22. Remove the J 28467-A , supporting the engine.
23. Check the front wheel alignment. Refer to Wheel Alignment Specifications .

Front Frame Replacement 3.8L

Tools Required

J 39580 Universal Engine Support Table

1. Install the engine support fixture. Refer to Engine Support Fixture .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



3. Remove the fasteners retaining the rack and pinion at the left side of the vehicle.
4. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation .
5. Separate the ball joints from the steering knuckle. Refer to Lower Control Arm Replacement .
6. Remove the front air deflector. Refer to Front Air Deflector Replacement .
7. Remove the brackets (2) securing the power steering lines at the engine frame by lifting the push pin (1).
8. Remove the brackets retaining the transmissions cooler lines to the engine frame.
9. Remove the fastener retaining the rack and pinion at the right side of the vehicle.
10. Support the rack and pinion with a wire to the body.
11. Remove the nut securing the front engine mount to the frame. Refer to Engine Front Mount Replacement .



12. Remove the fasteners securing the left transmission mount to the frame. Refer to Transmission Mount Replacement - Left Side .
13. Remove the fastener securing the rear transmission mount to the frame. Refer to Transmission Rear Mount Replacement .



14. Support the engine frame near the frame insulators using J 39580 or suitable jackstands.



15. Remove the engine frame insulator fasteners (3) retaining the engine frame (2) to the vehicle.
16. Lower the engine frame (2) from the vehicle.



17. Separate the engine frame insulators (3-6) from the engine frame. Refer to Frame Cushion or Insulator Replacement .
18. If the engine frame is to be replaced, remove the lower control arms. Refer to Lower Control Arm Replacement .

1. Install the lower control arms. Refer to Lower Control Arm Replacement .



2. Assemble the engine frame insulators (3-6) to the engine frame. Refer to Frame Cushion or Insulator Replacement .



3. Using 16 mm (0.630 in) dowel pins in the alignment holes (1), align the engine frame (2) with the body.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the engine frame insulator fasteners (3) to retain the engine frame (2) to the vehicle.

Tighten
Tighten the fasteners to 191 N·m (141 lb ft).




5. Remove the jack stands supporting the engine frame.
6. Install the fasteners securing the left transmission mount to the frame. Refer to Transmission Mount Replacement - Left Side .



7. Install the fastener in order to secure the rear transmission mount to the bracket. Refer to Transmission Rear Mount Replacement .
8. Install the nut in order to retain the front engine mount to the frame. Refer to Engine Front Mount Replacement .



9. Install the fasteners in order to retain the rack and pinion to the engine frame. Refer to Steering Gear Replacement .
10. Install the brackets in order to retain the transmission cooler lines to the engine frame.
11. Install the brackets in order to retain the power steering lines (1, 2) at the engine frame.
12. Install the front air deflector. Refer to Front Air Deflector Replacement .
13. Install the ball joints to the steering knuckle. Refer to Lower Control Arm Replacement .
14. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation .



15. Remove the engine support fixture. Refer to Engine Support Fixture .
16. Lower the vehicle.
17. Check the front wheel alignment. Refer to Wheel Alignment Specifications .
18. Test drive the vehicle in order to ensure there are no performance issues.