Engine Assembly

The engine removal and installation procedures are for the engine only without the transmission attached. Remove or disconnect parts of the secondary air injection system that will interfere with the removal or installation of the engine.

Removal

1. Drain the cooling system and the crankcase.

2. Remove the hood. Disconnect the battery ground cables from the cylinder block.

3. Remove the air intake duct assembly.

4. Disconnect the radiator upper hose from the coolant outlet housing and the radiator lower hose at the water pump.

5. Disconnect the transmission oil cooler lines from the radiator (automatic transmission vehicles only).

6. Remove the bolts attaching the fan shroud to the radiator.

7. Remove the radiator. Remove the fan, clutch, belt, water pump pulley and shroud.

8. Remove the generator/air pump assembly bracket bolts and position generator/air pump assembly out of the way.

   NOTE: Relieve pressure in fuel lines before disconnecting.

9. Disconnect the oil pressure sending unit wire from the sending unit. Disconnect low oil level sensor wire at middle of rear oil pan on LH side of oil pan, and the flexible fuel line at the fuel tank line. Plug the fuel tank line.

10. Disconnect the accelerator cable from the throttle body. Disconnect TV rod on AOD transmissions. Disconnect the speed control cable, if so equipped.

11. Disconnect the transmission filler tube bracket from the cylinder block (AOD transmission).

12. On a vehicle with an air conditioner, isolate and remove the compressor. Refer to Group 12.

13. Disconnect the power steering pump bracket from the cylinder head. Position the power steering pump out of the way and in a position that will prevent the fluid from draining out.

14. Disconnect the brake vacuum line from the intake manifold.

15. Disconnect the heater hoses from heater tubes. Disconnect the coolant temperature sending unit wire from the sending unit.

16. Remove the flywheel or converter housing-to-engine upper bolts.

17. Disconnect the wiring harness at the two 10-pin connectors.

18. Raise the front of the vehicle. Disconnect the starter cable from the starter. Remove the starter.

19. Disconnect the muffler inlet pipes from the exhaust manifolds. Disconnect the engine support insulators from the chassis. Disconnect down-stream secondary air injection tubing and check valve from RH exhaust manifold stud.

20. AOD only: Disconnect transmission cooler lines from retainer and remove the converter housing inspection cover. Disconnect the flywheel from the converter. Secure the converter assembly in the housing. Remove the remaining housing-to-engine bolts.

21. Lower the vehicle, and then support the transmission. Attach the engine lifting sling, and hoist to lifting brackets on exhaust manifolds.

22. Raise the engine slightly and carefully pull it from the transmission. Carefully lift the engine out of the engine compartment (avoid bending or damaging the rear cover plate or other components). Install the engine on a work stand.

Installation

1. Attach the engine lifting sling, and lifting brackets to exhaust manifold. Hoist the engine from the work stand.

2. Lower the engine carefully into the engine compartment. Ensure the exhaust manifolds are properly aligned with the muffler inlet pipes.

3. Start the converter, or manual transmission input shaft, pilot into the crankshaft. Align paint mark on flywheel to paint mark on torque converter (AOD transmission).

4. Install the flywheel or converter housing upper bolts. Ensure that the dowels in the cylinder block engage the housing.

5. Install the engine support insulator to chassis attaching fasteners.

6. Raise the front of the vehicle. Connect both muffler inlet pipes to the exhaust manifolds. Refer to Section 09-00.

7. Install the starter and the starter cable.

8. Remove the retainer holding the converter in the housing.

9. Attach the converter to the flywheel. Install the converter housing inspection cover (AOD transmission). Install the remaining housing attaching bolts.

10. Remove the support from the transmission and lower vehicle.

11. Connect the wiring harness at the two 10-pin connectors.

12. Connect the coolant temperature sending unit wire. Connect the heater hose to the heater. Connect the low oil level sensor wire. Connect the wiring to the sensors.

13. Connect the transmission filler tube bracket (AOD transmission).

14. Connect the accelerator cable and TV cable. Connect the speed control cable, if so equipped.

15. Remove the plug from the fuel tank line and connect the fuel line and the oil pressure sending unit wire.

16. Install the water pump pulley, and fan clutch.

17. Position the generator/air pump assembly bracket and install the generator/air pump assembly bolts. Connect the generator/air pump assembly and the battery ground cables.

18. On a vehicle with an air conditioner, install the compressor. Refer to Group 12.

19. Install the drive belt and power steering pump bracket. Install the bracket attaching bolts.

20. Connect the brake vacuum line.

21. Place the radiator shroud over the fan. Install the radiator. Connect the radiator upper and lower hoses. On a vehicle with an automatic transmission, connect the transmission fluid cooler lines. Install the shroud bolts. Tighten the bolts to 3-5 Nm (24-48 lb-in).

22. Connect heater hoses to heater tubes. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of oil.

23. Adjust the transmission throttle linkage (AOD transmission).

24. Install the air intake duct assembly.

25. Operate the engine at fast idle and check all gaskets and hose connections for leaks.

26. Install and adjust the hood.