Engine: Service and Repair

6-258 engine lubrication system:

1. Disconnect battery ground cable and drain cooling system.
2. Mark position of hood hinges, disconnect hood lamp if equipped, then remove hood.
3. Disconnect remaining cable and remove battery.
4. Remove air cleaner.
5. Disconnect fuel inlet pipe at pump and plug pipe and pump fitting.
6. Disconnect fuel return hose from pipe on frame or fuel filter, as equipped.
7. Disconnect heater hoses from engine and core fittings, remove fan shroud retaining screws, then disconnect hoses from radiator.
8. Disconnect electrical connectors and ground straps from engine, and remove vacuum switch and bracket from valve cover, if equipped.
9. Mark and disconnect all vacuum hoses from engine.
10. Disconnect throttle linkages and cables from throttle lever and engine mounted brackets.
11. Disconnect transmission cooler lines from radiator, if equipped, and plug lines and open fittings.
12. Remove radiator mounting bolts, radiator and fan shroud.
13. Remove fan and spacer or fan clutch, then install bolt through pulley and thread bolt into water pump hub to maintain pulley alignment.
14. On models with A/C proceed as follows:
a. Remove service valve caps and rotate service valves fully clockwise to the front seated position.
b. Slowly discharge refrigerant from compressor through service valve cores.
c. Disconnect service valve assemblies from compressor and secure hoses aside. Plug open ports in compressor and service valves.
15. On models with power steering, disconnect hoses from steering gear and plug hose and gear fittings.
16. On all models, remove nut securing right front mount cushion to bracket and the bolt securing transmission filler tube, if equipped.
17. Raise and support vehicle and remove remaining mount cushion to bracket nuts.
18. Disconnect electrical connector to oxygen sensor, if equipped, then disconnect exhaust pipe from manifold.
19. Remove starter motor.
20. On models with manual transmission, remove flywheel shield and disconnect clutch linkage.
21. On models with automatic transmission, proceed as follows:
a. Remove converter access cover and converter bolts, rotating crankshaft as needed to gain access to bolts.
b. Remove oil pan bolts securing cooler line brackets to engine.
c. Remove brace between converter housing and exhaust pipe, if equipped.
22. On all models, remove upper bellhousing to engine bolts and loosen lower bolts, then lower vehicle.
23. Remove A/C idler pulley and bracket, if equipped, then attach suitable lifting equipment to engine.
24. Raise engine off mounts, place suitable support under bellhousing, then remove lower bellhousing bolts.
25. Separate engine from bellhousing and remove from vehicle.
26. Reverse procedure to install. Prior to refilling cooling system, remove coolant temperature sending unit to allow air to escape from engine block. When system is filled, reinstall sending unit.