Engine: Service and Repair

ENGINE REPLACEMENT

Remove or Disconnect

Figure 31:

Figure 32:

Figure 33:

Figure 34:

Notice: If the engine damaged interally and a new engine assembly is installed, 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 cooling system of debris may result in premature failure of the replacement engine.

1. Negative battery cable.
2. Underhood lamp.
3. Vacuum reservoir from hood.
4. Windshield washer line to hood.
5. Outer cowl vent grilles.
6. Hood.
- Raise the vehicle.
- Drain the engine oil.
- Drain the engine coolant.
7. Recover the air conditioning refrigerant.
8. Oxygen sensor.
9. Exhaust at manifold.
- Loosen hanger at converter.
10. Pencil braces from engine to transmission.
11. Inspection cover.
12. Wiring to starter motor.
13. Starter motor.
14. Engine mount through bolts.
15. Bell housing bolts.
- Lower the vehicle.
16. Battery.
17. Body ground.
18. Air cleaner.
19. Upper and lower fan shrouds.
20. Fan.
21. Multiple ribbed belt.
22. Coolant pump.
23. Upper radiator hose.
24. Air conditioning compressor (if equipped) from its brackets and lay aside.
25. Lower radiator hose.
26. Radiator.
27. Power steering lines at the pump.
28. Heater hoses from the intake and coolant pump.
29. Wiring harness from engine.
30. Vacuum lines.
31. Throttle cable.
32. Fuel lines.
A. Support the transmission.
B. Install engine lifting device.
C. Raise the engine.
33. Left side engine mount.
34. Engine from the vehicle.
35. Pressure plate and clutch disc (if equipped).
36. Flywheel.
- Place engine on a suitable engine stand.

Install or Connect

Notice: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

1. Lifting device and remove the engine from the stand.
2. Flywheel.
3. Pressure plate and disk (if equipped).
4. Engine into the vehicle.
- Remove engine lifting device.
5. Fuel lines and brackets.
6. Throttle cable.
7. Vacuum lines.
8. Wiring harness clips and ground straps at the rear of the engine.
9. Heater hoses.
10. Power steering hoses.
11. Radiator.
12. Lower fan shroud.
13. Air conditioning compressor.
14. Upper radiator hose.
15. Coolant pump.
16. Multiple-ribbed belt.
17. Fan assembly.
18. Upper fan shroud.
19. Air cleaner assembly and duct work.
- Raise the vehicle.
20. Ground strap to the engine block.
21. Bellhousing bolts.
22. Engine mount through bolts.

Tighten
- Bolts to specifications.

Figure 31:

- Right Engine mount
- Engine mount bolts to 53 Nm (39 lbs. ft.)
- Stud to 53 Nm (39 lbs. ft.)
- Generator brace nut to 50 Nm (37 lbs. ft.)

Figure 32:

- Left Engine mount
- Engine mount bolts to 53 Nm (39 lbs. ft.)
- Stud to 53 Nm (39 lbs. ft.)

Figure 33:

- Engine Mount to Frame bracket
- Attaching bolts to 45 Nm (33 lbs. ft.)
- Through bolts to 51 Nm (38 lbs. ft.)

Figure 34:

- Left engine mount to shield bolts to 11Nm

23. Transmission.
24. Starter motor.
25. Flywheel cover.
26. Pencil braces.
27. Converter pipe assembly and hangers.
-
28. Hood.
29. Outer cowl vent grilles.
30. Vacuum reservoir to the hood.
31. Underhood lamp.
32. Windshield washer hoses.
33. Negative battery cable.
- Fill the engine crankcase with the proper quantity and grade of oil.
- Fill cooling system with the proper quantity and grade of coolant.