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 engine cooling system and the crankcase.

2. Remove the hood (16612) . Disconnect the battery ground cable (14301) from the cylinder block (6010) .

3. Remove the air cleaner outlet tube (9B659) .

4. Disconnect the upper radiator hose (8260) from the water outlet connection (8592) and the lower radiator hose (8286) at the water pump (8501) .

5. Disconnect the lines from the transmission oil cooler (7A095) (automatic transmission vehicles only).

6. Remove the radiator electric motor (8K621) , fan blade (8600) and fan shroud (8146) as an assembly as outlined in Section 03-03.

7. Remove the radiator (8005) and drive belt (8620) .

8. Remove the generator (GEN) (10346) / secondary air injection pump (9A486) and generator bracket (10A313) as an assembly and position out of the way.

9. Disconnect engine control sensor wiring (12A581) from the oil pressure sender (9278) . Disconnect low oil level sensor (6C624) located on LH side of oil pan (6675) .

   NOTE: Relieve pressure in fuel lines before disconnecting as outlined in Section 10-01.

10. Disconnect fuel supply and return lines as outlined in Section 10-01.

11. Disconnect the accelerator cable (9A758) from the throttle body (9E926) . Disconnect throttle valve control actuating cable (7F042) (automatic transmissions). Disconnect the speed control linkage, if equipped.

12. Disconnect the transmission filler tube bracket from the tube support bracket (7G353) (automatic transmission).

13. On a vehicle with an air conditioner, isolate and remove the A/C compressor (19703) . Refer to Group 12.

14. Disconnect the power steering pump bracket from the cylinder block . Position the power steering pump (3A674) out of the way and in a position that will prevent the fluid from draining out.

15. Disconnect the brake booster vacuum line from the intake manifold (9424) .

16. Disconnect the heater water hose (18472) from intake manifold heater inlet tube (9D424) . Disconnect engine control sensor wiring from water temperature indicator sender unit (10884) .

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

18. Disconnect the fuel charging wiring (9D930) at the two 10-pin connectors.

19. Raise the front of the vehicle. Disconnect the starter cable from the starter motor (11002) . Remove the starter motor .

20. Disconnect the dual converter and pipe from the exhaust manifolds (9430) . Disconnect the front engine support insulators (6038) from the front sub-frame (5C145) . Disconnect down-stream secondary air injection tubing and check valve from RH exhaust manifold stud.

21. Automatic transmission only: Disconnect transmission cooler lines from retainer and remove the converter housing inspection cover. Disconnect the flywheel (6375) from the torque converter (7902) . Secure the torque converter in the case (7005) . Remove the remaining case-to-engine bolts.

22. Lower the vehicle and support the transmission. Attach the engine lifting sling and hoist to engine lifting eyes (17A084) on exhaust manifolds .

23. 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 engine rear plate (7007) or other components). Install the engine on a work stand.

Installation

1. Attach the engine lifting sling and engine lifting eyes 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 dual converter and pipe.

3. Start the torque converter , or manual transmission input shaft, pilot into the crankshaft (6303) . Align paint mark on flywheel to paint mark on torque converter (automatic transmission).

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

5. Install the front engine support insulators to front sub-frame attaching fasteners as outlined in Section 02-03.

6. Raise the front of the vehicle. Connect dual converter and pipe to the exhaust manifolds . Refer to Section 09-00.

7. Install the starter motor and starter wiring.

8. Remove the retainer holding the torque converter in the case .

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

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

11. Connect the fuel charging wiring at the two 10-pin connectors.

12. Connect the engine control sensor wiring to the water temperature indicator sender unit . Connect the heater water hoses to the intake manifold heater inlet tube . Connect the engine control sensor wiring to the low oil level sensor .

13. Connect the transmission filler tube support bracket (automatic transmission).

14. Connect the accelerator cable and throttle valve control actuating cable . Connect the speed control actuator (9A825) , if equipped.

15. Connect the fuel supply and return line as outlined in Section 10-01.

16. Connect engine control sensor wiring to oil pressure sender .

17. Install the generator /air pump bracket and generator bracket as an assembly and install the retaining bolts.

18. Connect engine control sensor wiring .

19. On a vehicle with an air conditioner, install the A/C compressor . Refer to Group 12.

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

21. Connect the brake booster vacuum line.

22. Install the radiator . Connect the upper radiator hose and lower radiator hose . On a vehicle with an automatic transmission, connect the lines to the transmission oil cooler . Tighten the bolts to 3-5 Nm (24-48 lb-in).

23. Install the radiator electric motor , fan blade and fan shroud as an assembly as outlined in Section 03-03.

24. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of oil.

25. Adjust the throttle valve control actuating cable (automatic transmission).

26. Install the air cleaner outlet tube .

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

28. Install and adjust the hood .