Engine: Service and Repair

1. Relieve fuel system pressure as described under POWERTRAIN MANAGEMENT/ FUEL DELIVERY AND AIR INDUCTION/ SERVICE PRECAUTIONS/ FUEL SYSTEM PRESSURE RELIEF.
2. Disconnect battery ground cable and remove hood insulation pad.
3. Apply masking tape to forward edge of hood to protect paint.
4. Remove hood, then drain cooling system.
5. Remove air cleaner cover assembly and spoiler/under tray to inner wheel arch cover.
6. Remove nuts securing fan clutch unit to water pump and the clips securing the fan cowl.
7. Remove cowl and fan clutch unit as an assembly.
8. Disconnect all hoses and lines from radiator, then remove top radiator rail.
9. Cut and remove thermostatic switch connector securing strap.
10. Remove radiator, then cut and remove harness to hydraulic pump hose securing straps.
11. Remove coil mounting bracket. Disconnect coil leads, super heat switch and connector from compressor.
12. Disconnect engine harness and crank sensor block connectors, then cut and remove harness to cylinder head bracket ratchet strap. Reposition harness over manifold.
13. Remove power steering hose. Plug reservoir and hose.
14. Disconnect and plug steering hose from steering rack.
15. Remove hydraulic pump and pump drive coupling, then disconnect injector and throttle potentiometer connectors.
16. Disconnect air flow meter, auxiliary air valve, coolant temperature and oil pressure connectors.
17. Reposition ground leads and harnesses away from intake manifold and engine.
18. Remove fuel supply line to injector clips, then disconnect and plug fuel line from injector rail.
19. Disconnect and plug return hose from pressure regulator.
20. Reposition feed and return hoses away from manifold.

Fig. 2 Inner Throttle Cable Linkage Removal:

21. Disconnect heater vacuum hoses from manifold and inner throttle cable from linkage. Fig. 2.
22. Loosen throttle cable adjusting nuts, then disconnect cable and reposition away from bracket.
23. Disconnect intake elbow hose from throttle housing and breather line.
24. Disconnect auxiliary air valve hose from intake elbow.
25. Remove nut securing intake elbow, then remove air flow meter from air cleaner box.
26. Disconnect expansion tank hoses and alternator connections.
27. Disconnect water valve vacuum hose and feed hose from heater.
28. Disconnect return hose from heater line. Disconnect starter solenoid connectors, then remove starter solenoid & alternator link harness.
29. Remove oil cooler lines to oil filter head clamp nut, then disconnect lines.

Fig. 1 Engine Support Tools:

30. Install engine support tools No. 18G-1465 and MS-53B or equivalents, to manifold. Align to rear lifting eye on engine, Fig. 1.
31. Tighten hook on tool to relieve weight from engine.
32. Raise and support front of vehicle, then remove A/C compressor belt and move compressor away from bracket and secure to body.
33. Disconnect exhaust intermediate pipe to transmission support cable, then remove exhaust system.

Fig. 3 Selector Cable & Switch Removal:

34. Remove selector cable from securing clamp and rotary transmission switch/cable assembly harness, (1, 2) Fig. 3.
35. Support rear of transmission with a suitable jack.
36. Remove rear mounting to body bracket bolts.
37. Lower jack and remove mounting assembly.
38. Remove mounting spring, mounting spring to transmission rubber bushing and spacers.
39. Remove driveshaft to transmission flange securing nuts.
40. Reposition driveshaft away from flange, then loosen engine support hook to lower rear of transmission for access. Be sure engine does not rest on steering rack.
41. Lower front of vehicle and remove front pulley using removal tool No. 18G-1437 or equivalent.
42. Remove A/C dryer to rubber mounting nuts. Carefully remove condenser from mounted position, ensuring all lines and hoses are not damaged or stressed.
43. Place condenser/dryer assembly over side of engine compartment and support.
44. Remove exhaust manifold heat shield.
45. Align remaining engine lifting eyes to manifolds and tighten bolts.
46. Remove remaining manifold securing nut/bolt and front engine mounting upper securing nuts.
47. Support transmission with a suitable jack. Remove engine support hook tool No. 53B or equivalent.
48. Install an ``H'' sling to engine hoist and connect to engine lifting eyes.
49. Using a hoist and jack, remove engine from vehicle using caution not to damage steering rack.
50. Reverse procedure to install. Tighten to specifications.