Engine: Service and Repair

FOUR 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.
- Raise the vehicle and support with safety stands.
3. Body mounts.
4. Front air dam end bolts.
5. Starter motor. Refer to SECTION 6D2.
6. Torque convertor bolts (if equipped) through the starter opening hole.
7. Top transmission to engine bolts.
- Raise the body.
- Support transmission with a suitable fixture.
8. Remaining transmission to engine bolts.
9. Second crossmember.
10. Exhaust pipes at manifolds.
11. Catalytic converter hanger.
12. Front propeller shaft at the front differential.
13. Transmission cooler lines at engine clips.
14. Braces from frame to engine.

Engine Frame Mount (2WD):

Engine Frame Mount (4WD):

Engine Mount Bracket:

15. Engine mount bolts.
16. Front splash shield.
- Lower the vehicle.
17. Oil filter pipe at the remote oil filter.
18. Radiator.
19. Engine cooling fan.
20. Air cleaner box and intake duct.
21. Air conditioning compressor and bracket (if equipped).
22. Power steering pump and bracket.
23. 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.
24. Necessary wires, vacuum lines, and emission hoses.
25. Accelerator cable and cruise control cable (if equipped).
26. Engine wiring harness.







27. Heater hoses at the engine.
- 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.)
28. 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.)
- Raise the vehicle.
2. Engine mount through-bolt.
- Tighten fasteners to specifications. Refer to mountings. 3 Torque convertor bolts (if equipped) through the starter opening hole.
4. Lower transmission to engine bolts.
- Raise the body.
5. Upper transmission to engine bolts.
- Lower the body.
6. Body mount bolts.
7. Starter motor.
8. Front propeller shaft.
9. Catalytic converter hanger.
10. Exhaust pipe to the manifolds.
11. Crossmember.
12. Braces from frame to engine.
13. Front splash shield.
14. Transmission cooler lines at the engine clips (if equipped).
15. Front air dam bolts.
- Lower the vehicle.
16. Engine wiring harness.
17. Accelerator cable and cruise control cable (if equipped).
18. Heater hoses.
19. Wires, vacuum lines, and emission hoses.
20. Fuel lines and all clamps.
21. Power steering pump and bracket.
22. Air conditioning compressor and bracket (if equipped).
23. Engine cooling fan.
24. Radiator.
25. Oil filter pipe at the remote oil filter. Use new 0-rings.
26. Belt.
27. Air cleaner box and intake duct.
28. Hood.
29. Proper quantity and grade of coolant into the cooling system.
30. Proper quantity and grade of engine oil into engine.
31. Proper quantity and grade of power steering fluid.
32. Negative battery cable.