With Manual Transmission

WITH MANUAL 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 transmission fluid Procedures.
21. Drain the engine oil Service and Repair.





22. Remove the four bolts (1) and the tunnel support brace (2). Reinstall the four bolts (1) to maintain alignment of the frame extensions. Tighten the bolts (1) to 90 Nm (60 ft. lb.).





23. Remove both front tire and wheel assemblies Tires And Wheels - Removal.
24. Remove both front inner wheel well splash shields Splash Shield - Removal.
25. Remove the front fascia (1) Front Bumper Fascia - Removal.





26. Remove the right and left headlamp units (2) Headlamp Unit - Removal.





27. Disconnect the upper coolant hose from the radiator.
28. Disconnect the electrical connector from the cooling fan resistor (1).





29. Disconnect the lower coolant hose from the radiator.
30. Disconnect the cooling fan electrical connector (3).





31. Remove the bolt (4) and disconnect the A/C liquid line (1) and the A/C discharge line (2) from the A/C condenser tapping block (3).
32. Separate the A/C liquid line from the A/C discharge line. Remove and discard the dual plain seals.
33. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.





34. Press down the latch release (3) and remove the hood latch cable (2) from the latch.





35. Disconnect the wire harness connector (1) from the right and left front impact sensors (3) Front.





36. Disconnect the wire harness connector (2) from the horn (1).





37. Disengage the wire harness connector (1) from the bumper reinforcement.





38. Disengage the wire harness retainer (1) from the bottom of the bumper reinforcement.





39. Remove the four bolts (1), eight bolts and washers (2), eight bolts and washers (3) and the cooling module assembly (4) from the vehicle.





40. Remove the exhaust flange nuts (1).
41. Remove the maniverter pipe extension support bolt (2).





42. Remove the two nuts (1), four bolts (3) and the maniverter heat shield (2).





43. Disconnect the electrical connectors from the upstream (2) and downstream (3) oxygen sensors.

CAUTION: The maniverter studs are installed in the cylinder head with a thread sealant. If the studs rotate during service this indicates that the seal is broken and the stud must be replaced. Failure to replace the studs can result in engine oil leaking onto the exhaust manifold.

44. Mark the end of the nine maniverter mounting studs with a paint pen or equivalent to indicate possible stud rotation.
45. Remove nine nuts (1) and remove the maniverter (4) from the cylinder head.
46. Check the markings on the studs for indication of rotation. If there is evidence of stud rotation, replace the stud Exhaust Manifold Stud Replacement.
47. Remove and discard the maniverter gasket.





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





49. Remove the rear engine mount bracket bolt (3) and nut (6).
50. Remove the two bolts (2 and 4) and remove the rear engine mount bracket (5).
51. Loosen the isolator bolt (1) and reposition the rear engine mount isolator (7).





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





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





56. Remove the two bolts (1) from the hydraulic clutch line support bracket (2).





57. Remove the two bolts (1) from the hydraulic clutch slave cylinder and reposition the slave cylinder.





58. Disconnect the electrical connector (1) from the reverse lamp switch.





59. Remove the ground strap (1) from the transmission.





60. Disconnect the shift selector cable (1) from the lever.





61. Remove the retainer (1) from the shift selector cable and reposition the cable.





62. Disconnect the shift cable (1) from lever.





63. Remove the retainer (1) from the shift cable and reposition the cable.





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





65. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
66. 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.





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





69. 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.

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





71. 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.).





72. Reposition the main wire harness over the left frame extension.
73. 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).






NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

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






NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

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






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

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





78. Remove the two bolts (1) from the flywheel dust cover.






NOTE: The flywheel dust cover is bolted to the oil pan and cannot be removed at this time.

79. Remove the lower transmission bell housing bolts (3) and nut (1).





80. Position a transmission jack under the transmission. Secure the transmission to the jack.
81. Remove the upper bell housing 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.

82. Remove the clutch pressure plate and disc Clutch Disc - Removal.





83. Remove the flywheel Removal.





84. Remove the bolt (1) and the flywheel dust cover (2).





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





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





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





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





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





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






NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

92. 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.
93. Remove six bolts (2) and the RH engine mount bracket (1).