Removal and Replacement
ENGINEREMOVAL
1. Disconnect the battery negative cable.
2. Remove the air cleaner resonator and duct work as an assembly.
3. Drain cooling system.
4. Remove the accessory drive belt.
5. Remove the viscous fan/drive.
6. Remove radiator.
7. Remove the upper crossmember and top core support.
NOTE: It is not necessary to drain A/C system for engine removal.
8. Remove the A/C compressor with the lines attached. Secure compressor out of the way.
9. Remove generator assembly.
10. Perform the Fuel System Pressure Release procedure.
11. Remove the intake manifold and IAFM as an assembly.
12. Disconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.
13. Remove the power steering pump and set aside.
14. Disconnect the fuel supply line.
15. Raise and support the vehicle on a hoist and drain the engine oil.
16. Remove engine front mount thru-bolt nuts.
17. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
18. Disconnect exhaust pipe at manifolds.
19. Disconnect the starter wires. Remove starter motor.
20. Remove the structural dust cover and transmission inspection cover.
21. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
22. Remove transmission bell housing to engine block bolts.
23. Lower the vehicle.
24. Install engine lift fixture, special tool # 8984.
25. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
INSTALLATION
1. Install engine lift fixture Special tool # 8984.
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine with transmission:
- Manual Transmission: Align clutch disc assembly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmission surfaces. Install two transmission to engine block mounting bolts finger tight.
- Automatic Transmission: Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
4. Position the thru-bolt into the support cushion brackets.
5. Lower engine assembly until engine mount through bolts rest in mount perches.
6. Install remaining transmission to engine block mounting bolts and tighten.
7. Tighten engine mount through bolts.
8. Install drive plate to torque converter bolts. (Automatic transmission models)
9. Install the structural dust cover and transmission dust cover.
10. Install the starter and connect the starter wires.
11. Install exhaust pipe to manifold.
12. Lower the vehicle.
13. Remove engine lift fixture, special tool # 8984.
14. Connect the fuel supply line.
15. Reinstall the power steering pump.
16. Connect the heater hoses.
17. Install the intake manifold.
18. Using a new gasket, install throttle body.
19. Install the generator and wire connections.
20. Install a/c compressor and lines.
21. Install the accessory drive belt.
22. Install upper radiator support crossmember.
23. Install radiator.
24. Connect the radiator lower hose.
25. Connect the transmission oil cooler lines to the radiator.
26. Install the fan shroud.
27. Install the fan.
28. Connect the radiator upper hose.
29. Install the washer bottle.
30. Connect the transmission cooler lines.
31. Install the air cleaner resonator and duct work.
32. Add engine oil to crankcase.
33. Fill cooling system.
34. Connect battery negative cable.
35. Start engine and inspect for leaks.
36. Road test vehicle.