Engine: Service and Repair

1. Disconnect battery ground cable and drain cooling system.
2. Remove hood and the air cleaner.
3. Remove radiator shrouds, as needed, disconnect radiator hoses and remove radiator.
4. Disconnect heater hoses, then the brake booster vacuum hose.
5. Disconnect fuel hoses, then the accelerator cable.
6. Disconnect starter motor wiring harness, then the clutch cable from transmission.
7. Disconnect alternator wiring harness, then the engine ground cable.
8. Disconnect coil wiring, then the water temperature gauge connector.
9. Remove power steering pump, if equipped, then disconnect the oil pressure switch or oil pressure gauge unit harness.
10. On models less 4WD remove under cover.
11. On 4WD models, remove engine under cover and skid plate, then the transfer case protector.
12. On all models, disconnect speedometer cable at transmission.
13. On 2WD models, disconnect back-up light switch harness. On 4WD models, disconnect back-up light switch harness and 4WD indicator light harness.
14. Remove drive shaft(s).
15. Remove gearshift lever assembly.
16. Support transmission with a suitable jack, then remove rear insulator and No. 2 crossmember.
17. On 4WD models, support transfer case with a suitable jack, then remove transfer case mounting bracket and support insulator from side frame plate. Remove side frame plate, then the transfer case mounting bracket from case.
18. On all models, remove engine mount attaching nuts from front insulators.
19. Attach suitable lifting fixture to engine, then remove engine/transmission assembly from vehicle.
20. Reverse procedure to install, noting the following:
a. Torque front insulators to engine mounting bracket attaching bolts to 22-29 ft. lbs.
b. Torque front insulators to engine support bracket attaching bolts to 10-14 ft. lbs.
c. Torque No. 2 crossmember to side frame attaching bolts to 29-36 ft. lbs. on models less 4WD and 40-54 ft. lbs. on models W/4WD.
d. Torque rear insulator to No. 2 crossmember attaching bolts to 11-14 ft. lbs. on models less 4WD and 22-30 ft. lbs. on models W/4WD.
e. Torque rear insulator to transmission attaching bolts to 15-17 ft. lbs. on models less 4WD and 14-18 ft. lbs. on models W/4WD.
f. On models W/4WD, torque plate to side frame, transfer case support insulator to mounting bracket and transfer case mounting bracket to transfer case attaching bolts to 14-18 ft. lbs.