With Manual Transmission

WARNING: Residual pressure remains in fuel system after engine is shut off. This could result in injury when fuel lines are disconnected. Disconnect inertia fuel shutoff switch and crank engine until fuel in lines is used up.

NOTE: It is not necessary to remove upper intake manifold for engine removal.

REMOVAL
1. Disconnect the battery ground cable and drain the cooling system.
2. Using Rotunda 023-0100 Refrigerant Reclaim System or equivalent, drain air conditioning system.
3. Remove the hood.
4. Remove the accelerator control splash shield and air cleaner outlet tube.
5. Remove the upper radiator hose and lower radiator hose.
6. Remove the fan shroud attaching bolts and position the shroud over the fan blade. Disconnect radiator overflow hose. Remove radiator bolts and remove radiator. Lift fan shroud off of fan blade.
7. Using Fan Clutch Nut Wrench T84T-6312-D and Fan Clutch Holding Tool T84T-6312-C, remove fan blade. Using wrench, lift drive belt tensioner pulley and remove drive belt.
8. Recover refrigerant from air conditioning system.

NOTE: Determine which type of air conditioning refrigerant is used in the vehicle to be serviced and follow the procedure for that specific refrigerant.

9. Disconnect air conditioning manifold tube assembly from A/C compressor. Disconnect compressor electrical connector.
10. Remove A/C compressor mounting bracket and brace and set aside. It is not necessary to disconnect power steering return hose and power steering pressure hose.
11. Using door trim tool, remove connector from alternator mounting bracket. Remove clip from engine control sensor wiring and alternator mounting bracket.
12. Disconnect alternator. Remove bolts and alternator mounting bracket with attached alternator and set aside.
13. Disconnect the manifold tube assembly at the intake manifold and water pump.
14. Remove the ground wires from the cylinder block and wire from air conditioning pressure switch.
15. Disconnect accelerator cable and remove throttle cable bracket.
16. Tag and disconnect vacuum lines from rear of engine, throttle body, and intake manifold.
17. Remove air conditioning manifold tube assembly bolt from upper intake manifold, disconnect lines from suction accumulator/drier and A/C condenser core, and remove.
18. Disconnect the fuel tank-to-fuel rail fuel lines at the fuel rail.
19. Tag and disconnect remaining vacuum line and electrical connectors.
20. Disconnect heated oxygen sensor.
21. Remove two top transmission-to-engine bolts and oil filler tube.
22. Raise the vehicle and secure with safety stands.
23. Disconnect the exhaust inlet pipes at the exhaust manifolds.
24. Disconnect the battery to starter relay cable and remove the starter motor.
25. It is not necessary to disconnect the clutch hydraulic line for engine removal.
26. Remove the bellhousing-to-cylinder block bolts.
27. Partially lower the vehicle.
28. Remove battery cable bracket bolt and wire harness-to-engine clip.
29. Install lifting brackets on the exhaust manifolds. Attach Rotunda Engine Lifting Sling 014-00036 or equivalent.
30. Position a jack under the transmission.
31. Raise the engine slightly and carefully pull it from the transmission. Carefully lift the engine out of the engine compartment so that the rear cover plate is not bent, or components damaged. Install the engine on a work stand.

INSTALLATION

NOTE: To facilitate engine-to-transmission installation and prevent clutch hub damage, make two guide studs by cutting the heads off two M10 x 70 mm bolts and grinding a screwdriver slot in each bolt on the un-threaded end.

1. Install two studs into opposite engine-to-transmission bolt holes in engine to simplify installation.
2. Attach Rotunda Engine Lifting Sling 014-00036 or equivalent and hoist to lifting brackets at exhaust manifolds. Remove engine from work stand.
3. Lower the engine carefully into the engine compartment. Make sure exhaust manifolds are properly aligned with the exhaust inlet pipes.
4. Remove transmission jack and lifting equipment from engine.
5. Install transmission-to-engine bolts finger-tight and remove guide studs and install those two bolts finger-tight.
6. Position transmission-to-engine bracket and finish installing transmission-to-engine bolts and tighten to 38-51 Nm (28-38 ft lb).
7. Install starter motor and tighten bolts to 20-27 Nm (15-20 ft lb).
8. Route and connect battery cable.
9. Connect the muffler inlet pipes at the exhaust manifolds. Tighten bolts to 37-50 Nm (27-37 ft lb).
10. Install battery cable bracket bolt and tighten.
11. Install the engine front support nuts and washer to the crossmember or through-bolts.
12. Lower the vehicle.
13. Install ground wires to cylinder block.
14. Route wiring harness through intake manifold.
15. Connect air conditioner manifold tube assembly to condenser A/C condenser core and suction accumulator/drier and install bolt attaching it to upper intake manifold.
16. Install vacuum hoses, PCV hose, and tie strap.
17. Uncap and connect fuel lines.
18. Install accelerator shaft bracket and tighten bolts to 21-27 Nm (15.4-19.9 ft lb).
19. Install A/C compressor mounting bracket and brace with assembled power steering pump and A/C compressor. Tighten screws to 40-55 Nm (30-40 ft lb).
20. Plug in compressor electrical connections.
21. Install warm air duct.
22. Connect heater water hose to water pump and other electrical and vacuum connections.
23. Install alternator mounting bracket with assembled alternator. Tighten bolts to 40-55 Nm (30-40 ft lb).
24. Connect heater water hose to engine. Clip engine control sensor wiring to side of generator mounting bracket.
25. Install drive belt over pulleys. Make sure that all V-grooves make proper contact with pulleys.
26. Lift tensioner and slide belt under tensioner pulley. Release drive belt tensioner to rest on belt.
27. Install air cleaner outlet tube, accelerator control splash shield, and radiator overflow hose.
28. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of oil.
29. Connect battery ground cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

30. Charge air conditioning system.
31. Operate the engine at fast idle until it reaches normal operating temperature and check all gaskets and hose connections for leaks.
32. Install and adjust the hood.