CAUTION: Do not oil threads that require oil resistant or water resistant sealer.

When installing nuts or bolts, oil the threads with light-weight engine oil.

Engine

Removal

1. Drain coolant from radiator and oil from crankcase.

2. Mark hood hinge locations and remove hood.

3. Remove air cleaner outlet hose.

4. Disconnect battery ground cable.

5. Remove radiator upper and lower hoses.

6. Remove radiator and fan.

   On vehicles equipped with an electric cooling fan, disconnect power lead to fan motor. Remove fan and shroud assembly.

7. Disconnect the heater hose from the heater core.

8. Disconnect the wires from the generator and starter. Disconnect the accelerator cable from the throttle body (TB) 9E9260.

   On vehicles with air conditioning, remove the compressor from the mounting bracket and position it out of the way, leaving the refrigerant lines attached.

9. Disconnect the flexible fuel line at the fuel rail and plug the fuel line.

10. Disconnect the coil primary wire at the coil. Disconnect the water temperature sending unit, and the injector wiring harness connectors from the main wiring harness.

11. Remove the starter.

12. Remove engine mount bolts.

13. Raise vehicle. Refer to Section 00-02. Remove the flywheel or converter housing upper retaining bolts.

14. Disconnect the muffler inlet pipe at the exhaust manifold. Disconnect the engine RH and LH mounts at the No. 2 crossmember pedestals. Remove the flywheel or converter housing cover.

    On vehicles with a manual-shift transmission, remove the flywheel housing lower retaining bolts.

    On a vehicles with automatic transmission, disconnect the converter from the flywheel. Disconnect transmission oil cooler lines, if attached to engine at pan rail. Remove the converter housing lower retaining bolts.

15. Lower vehicle. Support the transmission and flywheel or converter housing with a jack.

16. Attach the engine lifting hooks to the existing lifting brackets. Carefully lift the engine out of the engine compartment. Install the engine on a work stand.

Installation

1. Install clutch, if removed. Refer to Section 08-00. Carefully lower the engine into the engine compartment.

2. Ensure the studs on the exhaust manifold are aligned with the holes in the muffler inlet pipe.

   On a vehicle with automatic transmission, start the converter pilot into the crankshaft.

    CAUTION: If the engine hangs up after the shaft enters, turn the crankshaft in the clockwise direction slowly (transmission in gear), until the shaft splines mesh with the clutch disc splines.

   On a vehicle with a manual transmission, start the transmission input shaft into the clutch disc. It may be necessary to adjust the position of the transmission in relation to the engine if the input shaft will not enter the clutch disc.

3. On automatic transmission vehicles, install flywheel or converter housing upper retaining bolts. Remove engine lifting sling hooks.

4. Remove jack from transmission. Raise vehicle. Refer to Section 00-02.

5. Install the flywheel or converter housing lower retaining bolts.

   On a vehicle with automatic transmission, attach the converter to the flywheel. Tighten the retaining nuts to 27-46 Nm (20-34 lb-ft).

6. Install the flywheel or converter housing dust cover.

7. Install the engine LH and RH mounts to the No. 2 crossmember pedestals. Tighten the nuts and bolts to 108-144 Nm (80-106 lb-ft).

8. Connect muffler inlet pipe to manifold.

9. Remove the plug from the fuel line and connect the flexible fuel line to the fuel rail. Refer to Section 03-04A.

10. Install the starter motor and connect the starter cable.

11. Lower vehicle. Connect the oil pressure and the engine temperature sending unit wires and the injector wiring harness. Connect the coil wires. Connect the accelerator cable. Connect the generator wires and connect the heater hoses to the water pump and the water outlet connector at the cylinder head.

12. Install the pulley, fan, and drive belt. Refer to Section 03-05. On a vehicle with air conditioning, install the compressor on the mounting bracket. Install the electric fan, shroud and the radiator. On vehicles equipped with electric cooling fan, connect electrical connector. Connect the radiator upper and lower hoses. Fill and bleed the cooling system. Refer to Section 03-03. Fill the crankcase with the proper grade and quantity of engine oil.

13. Connect battery ground cable.

14. Operate the engine at fast idle. Check all gaskets and hose connections for leaks.

15. Install hood and align. Refer to Section 01-02.

16. Install the air cleaner outlet hose and connect the positive closed-type crankcase ventilation hose.