Engine: Service and Repair

Engine and transmission should be removed as an assembly.

1. Disconnect battery ground cable, then mark position of hood hinges and remove hood.
2. Remove engine undercover, under skid plate, transfer case protector, cross shaft protector, then the snow protector.
3. Drain transmission fluid, then the transfer case oil.
4. Drain power steering fluid, then the A/C refrigerant.
5. Remove air filter, then disconnect accelerator cable.
6. Disconnect coolant hoses, then remove shrouds and radiator.
7. Disconnect brake booster vacuum hoses, then the heater hoses.
8. Disconnect oxygen sensor, then the control harness.
9. Disconnect battery positive cable, then the starter motor.
10. Disconnect A/C harness, then the alternator connector.
11. Disconnect water temperature gauge, switch and sensor.
12. Disconnect oil pressure gauge.
13. Disconnect power steering pressure and return hoses, then the throttle cable.
14. Disconnect fuel main and return hoses, then the A/C compressor and discharge hoses and ground strap.
15. Remove front exhaust pipe attaching nuts, then disconnect front exhaust pipe and gasket.
16. Remove control lever assembly, then the rear propeller shaft.
17. Remove front propeller shaft, then the O.D. solenoid valve connector.
18. Disconnect oil cooler feed and return tubes, then the speedometer cable.
19. Disconnect 4WD indicator lamp switch, then on models with manual transmission, remove clutch release cylinder.
20. On all models, disconnect select cross shaft, then the transmission control rod.
21. Remove insulator mounting plate attaching nuts and bolts, then the mounting plate.
22. Remove transfer mounting insulator and brackets, then the No. 2 crossmember.
23. Attach a suitable lifting device, then remove engine and transmission.
24. Remove engine to transmission attaching bolts.
25. On models with automatic transmission, remove bolts attaching driveplate to torque converter then on all models, separate transmission from engine.
26. On all models, reverse procedure to install, noting the following:
a. On models with automatic transmission, tighten driveplate to torque converter bolts to specification.
b. On all models, tighten engine to transmission bolts to specification.
c. On models with manual transmission, tighten engine to transmission bolts to specification.
d. On all models, tighten transfer mount insulator and bracket bolts to specification.
e. Tighten No. 2 crossmember to body bolts to specification.
f. Tighten front exhaust pipe nuts to specification.
g. Tighten engine front mount insulator bolts to specification.
h. Tighten propeller shaft flange yoke attaching bolts to specification.