Engine: Service and Repair

TWO WHEEL DRIVE UTILITY MODELS


NOTICE: If the engine is damaged internally and a new engine assembly is installed in the vehicle, make sure all foreign material is completely flushed out of the cooling system. The oil cooler system should also be flushed out (if equipped). Failure to rid the oil or cooler system of debris can result in engine damage to the replacement engine..


Remove

Tool Required: J 41427 Universal Lift Hooks

1. Negative battery cable.
2. Hood.
- Drain the engine oil.
3. Transmission and engine oil cooler lines (if equipped).
4. Radiator.
5. Engine cooling fan.
6. Heater hoses.
7. Air cleaner box and intake duct.
8. Vacuum hoses.
9. Wiring harness.
10. Throttle cable and cruise control cable (if equipped).
- Raise the vehicle.
11. Catalytic converter to exhaust pipe bolts.
12. Exhaust pipes at the manifolds.
13. Strut rods at the bellhousing.
14. Starter motor.
15. Torque convertor bolts (if equipped) through the starter opening hole.
16. Shield at rear of catalytic converter.
17. Converter hanger at exhaust pipe.
18. Fuel lines.
- Loosen all fuel line clamps and fasteners from the central (SF1) unit to the rear of the transmission. Without damaging them, move them to the rear of the engine compartment and tie them in place with a suitable strap.
19. Front air dam end bolts.
20. Left body mount bolts.
- Install jackstands.
- Raise the body.
21. Bellhousing bolts.
- Lower the body.

Engine Frame Mount (2WD):

Engine Frame Mount (4WD):

Engine Mount Bracket:

22. Engine mount through bolts.
23. Jackstands.
- Lower the vehicle.
24. Air conditioning compressor (if equipped).







25. Power steering pump (if equipped)
- Support the transmission. Do not support under the transmission filter pan.
- Attach J 41427 to the right rear and left front bolts of the lower intake.
- Tighten Retaining bolts to 15 Nm (11 lb. ft.)
26. Engine.


Important: If a new engine is to be installed, make sure any remaining components, brackets, or accessories are transferred to the new engine.

Install


1. Engine into the vehicle.
- Disconnect lifting device and J 41427.
- Tighten retaining bolts to 15 Nm (11 lb. ft.)
2. Remove the transmission support.
- Raise the vehicle.
3. Engine mount through bolts.
- Tighten fasteners to specifications.
4. Torque convertor bolts (if equipped) through the starter opening hole.
5. Lower bell housing bolts.
- Raise the body.
6. Upper bell housing bolts.
- Lower the body.
7. Remaining bell housing bolts.
8. Body mount bolts.
9. Front air dam end bolts.
10. Power steering pump and bracket.
11. Air conditioning compressor and bracket (if equipped).
12. Fuel lines and all clamps.
13. Converter hanger at exhaust pipe.
14. Shield at the rear of catalytic converter.
15. Starter motor.
16. Strut rods at the bell housing (if equipped)
17. Exhaust pipes to the manifolds.
18. Converter to exhaust pipe bolts.
- Lower the vehicle.
19. Throttle cable and cruise control cable (if equipped).
20. Wiring harness.
21. Vacuum hoses.
22. Air cleaner box and intake duct.
23. Heater hoses.
24. Engine cooling fan.
25. Radiator.
26. Transmission oil cooler lines (if equipped).
27. Hood.
28. Proper quantity and grade of coolant into the cooling system.
29. Proper quantity and grade of engine oil into engine.
30. Proper quantity and grade of power steering fluid.
31. Negative battery cable.