Engine: Service and Repair

REMOVAL AND INSTALLATION
1. Drain cooling system and engine oil, then disconnect battery negative and positive cables from battery.
2. Mark hood hinge locations and remove hood.
3. Disconnect battery and ground cables from engine block.
4. Label, then disconnect all EFI related component electrical connectors, vacuum lines and fuel lines that may interfere with engine removal.
5. Relieve system pressure as outlined under, Fuel Delivery Air Induction/ Service And Repair/ Fuel Pressure Relief Procedure.
6. Remove air intake duct assembly with crankcase hose and carbon canister hose.
7. Disconnect radiator upper and lower hoses and transmission oil cooler lines (if equipped) from radiator.
8. Disconnect and cap power steering hoses, then disconnect thermactor air pump hose.
9. On models equipped with A/C, discharge refrigerant from system, then remove A/C condenser and disconnect lines from compressor.
10. Remove fan shroud attaching bolts and position shroud over fan.
11. Remove radiator, fan shroud, fan spacer, belts and pulley.
12. Remove alternator attaching bolts and swing alternator aside.
13. Disconnect alternator electrical connector, remove air pump, alternator, power steering pump and A/C compressor bracket, then disconnect and cap power steering lines.
14. Disconnect electrical connector from oil pressure sending unit.
15. Disconnect vacuum hoses from evaporative canister.
16. Disconnect chassis fuel line quick disconnects at fuel rail.
17. Disconnect accelerator and speed control (if equipped) cable from the throttle body.
18. Disconnect power brake booster vacuum hose.
19. Disconnect heater hoses from water pump and intake manifold.
20. Disconnect electrical connector from coolant temperature sending unit.
21. Remove flywheel housing-to-engine upper attaching bolts.
22. Disconnect wire harness from ignition coil, then remove wiring harness from left rocker arm cover and position aside.
23. Disconnect ground strap from cylinder head.
24. Raise and support vehicle.
25. Remove starter motor.
26. Disconnect exhaust pipes and exhaust from exhaust manifolds.
27. Disconnect engine motor mounts from frame brackets.
28. On models equipped with automatic transmission remove converter inspection plate and the converter-to-flywheel attaching bolts.
29. Remove remaining flywheel housing-to-engine attaching bolts.
30. On models equipped with A/C, disconnect A/C compressor clutch electrical connector.
31. Lower vehicle and support transmission with a suitable jack.
32. Install lifting brackets to intake manifold and attach suitable lifting equipment to engine.
33. Raise engine slightly and carefully separate from transmission, then lift engine from vehicle.
34. Reverse procedure to install. Tighten engine to transmission bolts to 40-50 ft lb