Engine: Service and Repair

1. Remove hood, battery and fan shroud.
2. Drain radiator. Disconnect hoses and temperature sender wires. Remove lower radiator mounting bolts.
3. Disconnect rubber duct hose from mixture regulator. Remove throttle plate housing and hoses.
4. Disconnect fuel supply and return hoses, cold start injector hose and PCV hose.
5. Remove injectors, mixture regulator and air filter.
6. Unbolt air conditioning compressor and disconnect freon hose clamp from alternator bracket. Secure compressor aside.
7. Disconnect accelerator cable and engine electrical harness. Disconnect harness from engine TDC sensor diagnostic plug and separate high tension lead connectors. Disconnect evaporative canister hoses.
8. Disconnect heater hose, power steering fluid reservoir, Lambda sensor wire and air injection hose to catalytic converter.
9. Disconnect vacuum switch hoses and wires.
10. Remove starter, upper bellhousing bolts, and disconnect engine mounts.
11. Disconnect power steering pump and exhaust header pipe.
12. Remove bellhousing inspection plates. On automatic transmission models, position torque converter support plate so as not to alter TDC sensor adjustment. Mark TDC sensor notch in relation to support plate. Remove converter bolts and retain torque converter in housing.
13. On all models, unbolt and move condenser and receiver dryer assembly towards left leaving hoses attached.
14. Install lifting equipment on engine and support transmission. Remove engine.
15. Reverse procedure to install. Note the following: On automatic transmission models, lubricate torque converter centering nipple with Calysol grease F 3015 or equivalent. Position TDC sensor notch and align reference marks. Coat torque converter bolts with suitable thread locking compound and torque to 21.75 ft. lbs. On manual transmission models, lubricate main shaft splines and pilot bushing with Molykote 321 or equivalent. Torque engine mount bolts to 21.75 ft. lbs. and bellhousing bolts to 39.88 ft. lbs. Adjust new TDC sensor to bring the three nipples in contact. Adjust gap between used sensor and flywheel to .007 inch (1.7 mm).