Engine — Manual Transmission

Install Fuel/Oil/Turbo Protector Cap Set T94T-9395-AH as required for any fittings, lines or ports left exposed to prevent the entry of contaminants.

Protector Cap Locations

Removal

1. Disconnect the battery ground cable. On vehicles equipped with dual batteries, refer to Section 14-01.

2. Drain the cooling system. Refer to Section 03-03.

3. Discharge and recover the refrigerant from the A/C system, if so equipped. Refer to Section 12-00 in the Body, Chassis Manual.

4. Remove the upper radiator hose clamps and upper radiator hose (8260).

5. Disconnect the radiator coolant reservoir hose at radiator (8005).

6.  CAUTION: Fan clutch has right-hand thread. Remove by turning nut counterclockwise.

   Remove the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH. Set the fan and clutch assembly in fan shroud (8146).

   

7. Remove the fan shroud screws.

8. Remove the fan shroud and fan and clutch assembly.

9. Disconnect the lower radiator hose (8286) from radiator.

10. Remove the radiator retaining bolts.

11. Disconnect the heater hose from radiator.

12. Remove the radiator.

13. Remove the drive belt (8620). Refer to Section 03-05.

14. Disconnect the generator electrical connectors.

15. Remove the generator retaining bolt and lay the heater hose aside.

16. Remove the generator bracket retaining bolts and generator bracket (10A313) (with generator (GEN) (10300) attached).

17. Disconnect the electrical connectors from A/C compressor (19703), if so equipped.

18. Disconnect the air conditioning manifold lines from the A/C compressor.

19. Disconnect the vacuum pump hose from the vacuum pump (2A451).

20. Disconnect the power steering pump lines from the power steering pump (3A674).

21. Disconnect the A/C lines at the condenser and position the A/C lines aside.

22. Disconnect the heater hoses at the water pump and the right cylinder head.

23. Disconnect the lower radiator hose from the water pump.

24. Remove the right-side battery cable clamp and bolts from engine.

25. Disconnect the MAP sensor vacuum hose from the intake manifold cover (9E434)

26. Disconnect the engine control sensor wiring (12A581) from the left side of the engine compartment and lay on top of the engine.

    

27. Remove the jack handle.

28. Remove air cleaner cover.

29. Remove engine charge exhaust pipe-to-turbocharger clamp.

30. Disconnect the wiring harness from the starter solenoid and lay across engine.

31. Raise vehicle.

32. Remove transmission. Refer to Section 07-03A or Section 07-03B.

33. Remove the right and left turbocharger exhaust inlet pipe bolts and nuts.

    

34. Remove the left battery ground cable (14301) and bolt from the cylinder block (6010).

35. Relieve fuel system pressure. Disconnect the fuel lines at the fuel line quick connects.

36. Disconnect the engine block heater (6A051).

37. Remove the oil filter.

38. Disconnect the starter motor electrical connectors.

39. Remove the starter bolts and starter motor (11002).

40. Remove the right and left engine mount nuts.

41. Lower vehicle.

    

42. Use suitable jack to support transmission.

43. Remove the front lamp harness plastic fasteners and lay the harness forward.

44. Remove the engine with the help of an assistant. Turn engine 45 degrees to the left and lift engine from compartment. Mount the engine on a work stand using Rotunda Engine Mounting Bracket 014-00939 or equivalent.

    

Installation

1. Install the engine assembly.

2. Install the engine mount nuts. Tighten nuts to 96-127 Nm (71-94 lb-ft).

3. Start the two upper transmission retaining bolts.

4. Raise vehicle.

5. Start the lower transmission bolts.

6. Install transmission. Refer to Section 07-03A or Section 07-03B.

7. Tighten the transmission attaching bolts to 53-72 Nm (39-53 lb-ft).

8. Install the starter motor and retaining bolts. Refer to Section 03-06B.

9. Install the oil filter (6731).

10. Connect the engine block heater electrical connector to the block heater.

11. Connect the fuel line quick connectors and install retaining clips.

12. Install the left battery ground cable and bolt to cylinder block.

13. Lower vehicle.

14. Install the front lamp harness and install retainers.

15. Install the ground strap and bolt to the right cylinder head (6049).

16. Connect the wiring harness to starter solenoid.

17. Connect the engine control sensor wiring

18. Connect the lower radiator hose to water pump inlet and install hose clamp.

19. Connect the heater hoses at the water pump and right cylinder head.

20. Connect the air conditioning line at condenser.

21. Install the battery terminal clamp and bolts to the engine.

22. Connect the power steering pump lines to the power steering pump. Tighten the power steering pressure line to 30-40 Nm (22-29 lb-ft).

23. Connect the vacuum pump hose to the brake vacuum pump.

24. Connect the air conditioning manifold lines to A/C compressor, if so equipped. Tighten the A/C manifold lines to 18-23 Nm (13-17 lb-ft).

25. Install generator bracket and bolts. Tighten bolts to 40-55 Nm (30-40 lb-ft).

26. Reposition heater hose and install generator retaining bolt. Tighten bolt to 40-55 Nm (30-40 lb-ft).

27. Connect electrical connectors to generator and A/C compressor.

28. Install the drive belt.

29. Install radiator.

30. Install the radiator retaining bolts and tighten to 24-34 Nm (18-25 lb-ft).

31. Connect the heater hose to radiator.

32. Connect the lower radiator hose to radiator and install the radiator hose clamp.

33. Position fan and clutch assembly inside fan shroud and position in vehicle.

34. Position fan shroud on the radiator.

35. Install fan shroud retaining screws and tighten to 5-8 Nm (44-71 lb-in).

36.  CAUTION: Fan clutch has right-hand thread. Install by turning nut clockwise.

    Install the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH or equivalent.

    

37. Connect the radiator coolant recovery reservoir hose at radiator.

38. Install the upper radiator hose and hose clamps.

39. Evacuate and recharge the refrigerant to the A/C system. Refer to Section 12-00 in the Body, Chassis Manual.

40. Refill the power steering system. Refer to Section 11-00 in the Body, Chassis Manual.

41. NOTE: When the battery (10655) has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

    Reconnect the battery ground cable. On vehicles equipped with dual batteries, refer to Section 14-01.

42. Refill the engine cooling system. Refer to Section 03-03.

43. Refill the crankcase and high-pressure oil pump supply reservoir with the proper grade and quantity of oil.