Engine: Service and Repair

1. Disconnect battery ground cable, then drain cooling system.
2. Disconnect air cleaner outlet tube, idle speed control hose, upper and lower radiator hoses and heater hoses.
3. Disconnect lower intake manifold hose from heater hose T-fitting, then remove fan shroud attaching bolts and fan shroud.
4. Disconnect alternator electrical connectors, remove throttle linkage shield, then disconnect accelerator and cruise control (if applicable) cables from throttle body and position aside.
5. On models equipped with A/C, discharge refrigerant, then disconnect hoses and clutch electrical connector at compressor.
6. On all models, disconnect ignition coil electrical connector at lower left front of engine.
7. Working from beneath lower intake manifold, disconnect TFI module electrical connector at distributor.
8. Disconnect knock sensor electrical connector from upper intake manifold.
9. Disconnect and mark all hoses to vacuum tree of upper intake manifold.
10. Disconnect electrical connector and vacuum hose at EGR valve.
11. Working from inside cab, remove engine cover, then disconnect throttle position sensor electrical connector at rear of throttle body.
12. Disconnect oil pressure sender electrical connector, then the hoses to the fuel return and supply lines.
13. Disconnect fuel injection wiring harness electrical connector.
14. Working at lower intake manifold, disconnect electrical connectors at air charge temperature (ACT) and coolant temperature sensors.
15. Remove ground strap retaining nut and ground strap at right rear of engine.
16. On manual transmission equipped vehicles, proceed as follows:
a. Position shift lever in Neutral.
b. Remove shift lever to floor and shift lever to transmission retaining bolts.
c. Remove shift lever assembly from vehicle.
17. Raise and support vehicle, then on automatic transmission equipped vehicles, disconnect fluid lines at radiator.
18. Disconnect power steering pressure switch electrical connector from steering gear, if applicable.
19. Remove intermediate steering column shaft to steering gear retaining bolt, then disconnect shaft from gear. Prior to disconnecting shaft, ensure steering wheel and front wheels are centered in travel.
20. Disconnect starter electrical cables, then route cables out from crossmember.
21. On models equipped with manual transmission, remove hydraulic hose to slave cylinder retaining pin, then disconnect and plug hose to prevent spillage.
22. On all models, disconnect oxygen sensor electrical connector.
23. Remove retaining nuts and bolts, then the exhaust manifold, exhaust pipe and catalytic converter.
24. Disconnect speedometer cable, tachometer cable (if applicable) and back-up lamp switch electrical connector from transmission.
25. On models equipped with manual transmission, disconnect shift indicator sensor electrical connector.
26. On models equipped with automatic transmission, disconnect electrical connector from neutral start switch, and throttle and kickdown cable from transmission lever. Route kickdown cable out of engine compartment and remove from vehicle.
27. On all models, remove driveshaft. Plug opening in extension housing to prevent spillage of fluid.
28. Remove wheel assemblies, then disconnect and remove stabilizer bar from lower control arms.
29. Disconnect brake lines at frame brackets behind spindles, then position suitable jack under lower control arm. Raise jack slightly until tension is applied to coil spring, then remove spindle to upper ball joint retaining nut and bolt. Lower jack to disconnect spindle from ball joint, then position safety chains around lower control arms and spring upper seat.
30. Position suitable jack under transmission, raise transmission slightly, then remove crossmember to frame and crossmember to transmission retaining nuts and bolts. Remove crossmember from vehicle.

Fig. 4 Positioning support table under front crossmember:

31. Position engine support table 109-0002 or equivalent under front crossmember and engine assembly, Fig. 4.
32. Lower vehicle until front crossmember rests on support table. Position blocks of wood under front crossmember and transmission to keep assembly level, then install safety chains around crossmember and support table.
33. Remove engine and crossmember to frame retaining nuts and bolts from both sides of vehicle.
34. Disconnect any remaining wires or hoses that will interfere with engine removal, raise vehicle body until clear of engine/transmission assembly and support table, then lower support table and remove engine/transmission assembly from vehicle.
35. Reverse procedure to install.