Engine: Service and Repair

REMOVAL

1. Disconnect battery ground cable, then drain cooling system.
2. Disconnect engine compartment lamp electrical connector on inboard side of battery.
3. Disconnect windshield washer hose from reservoir and plug reservoir outlet.
4. Disconnect hood ground strap, mark hood hinge locations, then remove hood.
5. Disconnect inlet air hoses from throttle body.
6. Remove air cleaner cover, air box and inlet air hoses.
7. Remove radiator upper shroud and cooling fan assembly.
8. Unfasten power steering pump and alternator and position components aside.
9. On models equipped with Thermactor, remove Thermactor retaining bolts, hose and air pump and position aside.
10. On all models, disconnect hoses from heater valve.
11. Disconnect coolant hoses from water pump and thermostat housing.
12. Disconnect throttle cable from throttle body linkage. Remove throttle cable bracket attaching bolts position aside.
13. Release fuel system pressure as follows:
a. Connect fuel pressure gauge (part No. T80L-9974-B) with extension hose (part No. D85L-9974-B) to Schrader valve on fuel supply manifold.
b. Position drain hose in a container and depress drain valve.
14. Disconnect fuel supply and return lines.
15. Remove distributor cap, rotor, distributor electrical connector and spark plug wires.
16. Label and disconnect ignition coil electrical connectors.
17. Label and disconnect vacuum hoses from front and rear of upper intake manifold and EGR fitting.
18. Remove carbon canister with bracket and vacuum line.
19. Disconnect the following electrical connectors and position aside: air charge temperature sensor, idle speed control valve, oil pressure switch, engine coolant temperature sensor, throttle position sensor, A/C compressor clutch and fuel injectors.
20. Disconnect ground wire from spade terminal on LH fender apron.
21. Disconnect manifold absolute pressure sensor under cowl weatherstrip and position aside.
22. Raise and support vehicle.
23. Remove exhaust manifold-to-exhaust pipe retaining nuts.
24. On models equipped with automatic transmission, disconnect transmission oil cooler lines from radiator.
25. On all models, remove two radiator attaching bolts, then disengage upper retaining clips and lower radiator from vehicle.
26. Disconnect starter wiring, then remove starter attaching bolts and the starter.
27. Remove engine insulator lower retaining nuts and washers.
28. Remove side and lower converter housing or clutch-to-engine attaching bolts.
29. On models equipped with automatic transmission, remove inspection plate, then the converter-to-flywheel attaching nuts.
30. On all models, loosen A/C compressor retaining bolt and pivot bolts, then lower vehicle.
31. Install engine lifting device on engine lifting attachments.
32. Support transmission with a jack, then remove two upper converter housing or clutch attaching bolts.
33. Raise engine enough to allow A/C compressor to be removed, then unfasten the compressor and wire aside.
34. Raise engine until insulators are cleared, then pull engine forward to separate it from transmission and carefully raise engine out of engine compartment.

INSTALLATION

Reverse procedure to install, noting the following:
1. Torque transmission-to-engine attaching bolts to specification.
2. Temporarily install A/C compressor prior to lowering engine into vehicle.
3. Torque left side engine support bracket attaching bolts to specification.
4. On models equipped with automatic transmission, torque converter-to-flywheel retaining nuts to specification.
5. On all models, torque exhaust manifold-to-exhaust pipe attaching bolts to specification.
6. Torque throttle cable bracket attaching bolts to 11-15 ft. lbs.