Engine Replace

Fig. 1 Disconnecting engine harness:

1. Disconnect battery ground cable and remove battery.
2. Remove hood.
3. Drain cooling system and remove coolant overflow container.
4. Disconnect the following:
a. Ground cable (2) from cylinder head, Fig 1.
b. All connectors (3) from power supply cable, Fig. 1.

Fig. 2 Disconnecting body harness:

c. All engine harness electrical connectors at body multiple connectors, Fig. 2.

Fig. 3 Disconnecting transmission oil cooler hoses:

d. Transmission oil cooler lines at radiator (1), Fig 3. Support lines in an elevated position to prevent loss of fluid.
e. Left exhaust pipe.

Fig. 4 Disconnecting accelerator control and kickdown cable assembly:

f. Accelerator (8) and kickdown (10) cables, Fig 4. Do not disconnect cruise control cable.
5. Remove power steering reservoir without disconnecting lines, and set reservoir aside.
6. Remove air conditioning compressor (5) without disconnecting lines, and set compressor aside.

Fig. 5 Radiator removal:

7. Remove fan (2) and fan shrould (3), Fig 5.
8. Remove air filter, air flow sensor assembly and air preheat system.
9. Remove electronic idle regulation electrovalve from right valve cover.

Fig. 6 Disconnecting fuel feed hoses:

10. Disconnect fuel feed hose (1), injector ramp return hose (2) and cruise control vacuum hose (3), Fig. 6.

Fig. 7 Ignition sensor connection:

11. Disconnect heater hoses from front of right cylinder head, then disconnect hose (5) and ignition sensor connector (6) from rear of left cylinder head, Fig. 7.

Fig. 8 Steering column coupling and front crossmember:

12. Disconnect steering column at coupling (1), Fig. 8. Using special bolts 1511C, lower front crossmember about 2 inches (dimension a), Fig. 8.
13. Remove the two right exhaust pipe nuts, the starter motor bolts (do not remove starter), the left exhaust pipe and the bellhousing inspection plates.

Fig. 9 Locking the flywheel:

14. Lock flywheel using special tool .0134Q, Fig. 9, and remove the torque converter bolts using special socket KM-J36301.
15. Remove flywheel locking pawl installed previously, then hold torque in place using clamp .0318, using care not to distort referenced section of flywheel.
16. Remove upper transmission assembly bolts, and transmission dipstick tube bolt from cylinder head.

Fig. 10 Transmission supporting tool:

17. Remove the two engine mount to crossmember nuts. Lift engine using a suitable hoist until transmission contacts floorpan. Install brace .0125 and pad .0156 to upport transmission, Fig. 10.
18. Remove the two lower transmission to engine bolts.
19. Carefully remove engine from vehicle and place on engine stand.
20. Reverse procedure to install. Torque bolts to the following specifications:
a. Engine to transmission bolts, 37 ft. lbs.
b. Exhaust pipe bolts, 26 ft. lbs.
c. Engine to crossmember nuts, 26 ft. lbs.
d. Starter motor bolts, 15 ft. lbs.
e. Torque converter bolts, 44 ft. lbs.
f. Crossmember attachments, 31 ft. lbs.
g. Steering column coupling nuts, 18 ft. lbs.