Engine: Service and Repair

1. Drain cooling system. Remove serpentine drive belt, also remove vacuum pump drive belt if equipped.
2. Remove air cleaner and install a suitable cover.
3. Disconnect battery ground cable at battery (on vehicles equipped with heavy duty system there will be two batteries), ground wires at inner fender and engine ground strap.
4. Raise vehicle. Remove flywheel cover.
5. Remove flywheel to torque converter attaching bolts.
6. Disconnect exhaust pipe from rear exhaust manifold.
7. Remove engine to transaxle brace.
8. Remove engine mount to cradle retaining nuts and washers.
9. Disconnect leads to starter motor, No. 2 cylinder glow plug and battery ground cable at transaxle to engine bolt.
10. Disconnect lower oil cooler hose and plug openings.
11. Remove accessible power steering pump bracket fasteners and lower vehicle.
12. Remove remaining power steering pump bracket/brace.
13. Remove heater outlet pipe.
14. Disconnect all remaining glow plug leads at glow plugs.
15. Disconnect all other leads at engine, disconnect engine harness at cowl connector and body mounted relays and position engine harness aside.
16. If equipped with A/C, disconnect compressor with brackets and lines attached and position aside.
17. Disconnect fuel and vacuum hoses, plug all fuel line openings.
18. Disconnect throttle and T.V. cables at injection pump and cable bracket. Position cables aside.
19. Disconnect upper oil cooler hose and plug openings. Remove exhaust crossover pipe heat shield.
20. Disconnect and position aside transaxle filler tube.
21. Remove exhaust crossover pipe.
22. Remove engine mounting strut and strut brackets.
23. Install a suitable engine lifting device. When installing lifting chains to cylinder heads, ensure that washers are used under the chains and bolt heads and the bolts are torqued to 20 ft. lbs.
24. Position a suitable support under transaxle rear extension. As engine is being removed it may be necessary to raise support. Remove engine to transaxle bolts, then engine.
25. Reverse procedure to install. Before installing the flex plate to converter bolts, ensure the weld nuts on the converter are flush with the flex plate and converter rotates freely by hand in this position. Hand start the three bolts and finger tighten, then torque converter bolts to 35 ft. lbs. This ensures proper alignment of converter.