Engine: Service and Repair

1. On models with airbag, disable airbag system, refer to MAINTENANCE PROCEDURES/AIRBAG ARMING & DISARMING.
2. On all models, disconnect battery ground cable. Battery is located in righthand side plenum chamber.
3. Remove upper radiator cover, then the expansion tank cap.
4. Drain cooling system, then remove rear mounting bolt for coolant tube.
5. Remove ground strap from left engine mount, then disconnect warm-up regulator.
6. Remove upper radiator hose, then the windshield washer fluid reservoir.
7. Disconnect coolant hose from heater at rear of engine block, then remove power steering pump belt.
8. Remove power steering pump, leaving hoses attached.
9. Remove A/C compressor belt, then the compressor with hoses attached. Secure compressor aside.
10. Disconnect warm-up regulator and thermoswitch, then remove hoses.
11. Remove vacuum hoses from thermo-pneumatic valve (slanted green connector, straight connector to T-piece), then the thermo-pneumatic valve.
12. Disconnect oil pressure switches, then tower wire from ignition coil.
13. Remove distributor cap, then disconnect Hall sending unit by pressing securing clip on connector.
14. Remove vacuum hose from ignition distributor, then the air cleaner cover.
15. Remove injectors from cylinder head, then disconnect control valve for idle stabilizer.
16. Disconnect and remove accelerator cable from throttle valve, then pull through support. Remove safety clip on cam disc.
17. On models with automatic transmission, disconnect cold start valve, throttle switch, Lambda sensor and full-load switch.
18. On models with automatic transmission, disconnect accelerator linkage, remove vacuum hose on throttle valve, then the air shroud.
19. On all models, remove crankcase ventilation hose from cylinder head cover, then the hoses from idle stabilizer control valve.
20. Remove cold start valve, but do not disconnect.
21. Disconnect thermo-time switch and temperature sensor.
22. Remove upper engine to transmission connecting bolts.
23. Remove upper starter bolt, then the righthand side engine mount cover.
24. On models with automatic transmission, remove hoses from transmission oil cooler.
25. On all models, remove alternator belt, then the alternator. Tie alternator aside, leaving wires connected.
26. Remove the starter and tie aside, leaving wires attached.
27. Remove front exhaust pipe from manifold and transmission mount.
28. Remove the lower and upper left engine to transmission bolts.
29. Place engine supports 10-222-A and 3147 or equivalents into position, being careful not to damage ignition wires.
30. Raise or lower transmission to desired height, then disconnect left and right engine mounts.
31. Remove any remaining engine to transmission connecting bolts.
32. Attach engine sling 2024-A or equivalent and crane. Attach sling on pulley side in second hole in vertical bar, (position 3). On flywheel side, attach sling in fourth hole in vertical bar, (position 8). Positions marked 1 through 4 on bar must be toward pulley side. Holes in hooks are counted upwards from hook.
33. Lift engine slowly, until load is taken off of mounts, then remove left engine mount.
34. Pry engine from transmission, then remove from vehicle.
35. Reverse procedure to install, noting the following:
a. Ensure dowels for centering engine to the transmission are in the engine block.
b. Replace all self-locking nuts.
c. Adjust accelerator cable.
d. Refill cooling system.
e. Lubricate clutch release bearing and shaft splines with Mos.2 grease.
f. Tighten all nuts and bolts to specifications.