With Automatic Transmission

WITH AUTOMATIC TRANSMISSION

Special Tools:











NOTE: The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler Engine Oil Cooler - Removal .

1. Perform the fuel pressure release procedure Service and Repair.
2. Recover the refrigerant from the refrigerant system Refrigerant System Recovery.
3. Remove the engine cover (1).





4. Remove the air cleaner body (6) Air Cleaner Body - Removal.





5. Disconnect the PCV hose (1) from the intake manifold.
6. Disconnect the vent hose (3) from the oil filler neck.
7. Remove the three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.






CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

8. Disconnect and remove the battery Battery - Removal.
9. Disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).





10. Disengage two starter wire harness retainers (6) from the battery tray (3).
11. Disengage two engine wire harness retainers (4) from the battery tray (3).
12. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
13. Remove the nut (5) and two bolts (1).





14. Open the two wire harness retainers (3) and reposition the wire harness.
15. Remove the nut (1) and the ground strap (4).
16. Remove the battery tray with the PCM (2) attached.





17. Raise and support the vehicle Maintenance.
18. Remove the belly pan Belly Pan - Removal.
19. Drain the cooling system Service and Repair.
20. Drain the engine oil Service and Repair.





21. Remove the maniverter (4) Exhaust Manifold - Removal.





22. Remove both axle shafts (1) Half Shaft - Removal.





23. Remove two bolts (4) from the rear engine mount bracket (3), loosen the bolt (1) and reposition the rear engine mount link (5) away from the bracket (3).





24. Remove the upper radiator hose (2) from the engine.
25. Disengage the hose retainer (4) and remove the windshield washer fluid reservoir Windshield Washer Reservoir - Removal.
26. Remove the lower radiator hose (3) from the engine.





27. Remove the pressurized coolant bottle (5) Coolant Recovery Bottle - Removal.





28. Disconnect the wire harness connector (5) from the transmission range selector switch.
29. Disconnect the gearshift cable (2) from the transmission manual valve lever (4).
30. Remove the gearshift cable (2) from the bracket (1).
31. Remove the bolt (2) and the ground strap from the transmission.





32. Remove the nut (2) and the battery cable (1) from the battery terminal.





33. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
34. Remove the nut (2) and disconnect the A/C suction line (1) from the A/C expansion valve. Install plugs in, or tape over all the opened refrigerant line fittings and expansion valve ports.





35. Disconnect the fuel vapor purge hose (3) from the intake manifold.
36. Open the hose retainer (1). Disconnect the fuel line (2) from the fuel rail Service and Repair.





37. Disconnect the main wire harness connector (2) from the engine harness.

CAUTION: The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. If removing both hoses, it is recommended that the hoses be marked at disassembly to avoid an incorrect installation. Failure to properly install the hoses can result in engine damage.

38. Remove the vacuum pump (1) Vacuum Pump - Removal.





39. Install the (10299) (1) on the vacuum pump mounting surface with three bolts (2) provided with the engine lifting bracket. Tighten the bolts to 20 Nm (15 ft. lbs.).





40. Reposition the main wire harness over the left frame extension.
41. Attach a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the front engine mounting bracket, the engine lifting bracket and an engine hoist (1).





42. Remove the three bolts (2 and 3) and the LH engine mount isolator (1).





43. Remove the three bolts (3) from the RH engine mount isolator (1).
44. Remove the engine and transmission from the vehicle.






NOTE: Perform the following steps to remove the transmission from the engine if required.

45. Remove the torque converter access cover (1).





46. Remove the six torque converter bolts (1).





47. Remove the four lower transmission mounting bolts (1) and the oxygen sensor harness bracket (2).





48. Position a transmission jack under the transmission. Secure the transmission to the transmission jack.
49. Remove the two upper transmission mounting bolts (1) and separate the transmission from the engine.






NOTE: Perform the following steps to remove components for installation on a replacement engine if required.

50. Remove the starter assembly (5) Starter - Removal.





51. Remove the flexplate (1) Flexplate - Removal.





52. Remove three bolts (3 and 4), one bolt and nut (2) and the transmission adapter plate (1).





53. Remove the accessory drive belt (4) Serpentine Accessory Drive Belt - Removal.





54. Remove the generator (3) Generator - Removal.





55. Remove the A/C compressor (1) A/C Compressor - Removal.





56. Remove the bolt (2) and the oil level indicator tube (1).





57. Remove the bolt (5) and the ground wire.
58. Remove three bolts (3), two nuts (2 and 3) and the accessory mounting bracket (1).





59. Remove the block heater (3) (if equipped) Engine Block Heater - Removal.





60. Install the engine on an engine stand such as OTC(R) 1726A 1,000 LB. Capacity Engine Stand or equivalent, and remove the lifting sling.
61. Remove six bolts (2) and the RH engine mount bracket (1).