Engine

REMOVAL & INSTALLATION

1. Scribe matchmarks on the hood and hinges. Remove the hood from the hinges.
2. Working from underneath the truck, remove the gravel shield then drain the cooling system.

   CAUTION
   When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

3. Drain the engine oil.
4. Disconnect the cable from the negative (–) battery terminal.

   CAUTION
   The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

5. Remove the air cleaner, bracket, and hoses.
6. Detach the accelerator cable, choke cable, and fuel lines from the carburetor.

   CAUTION
   Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

7. Remove the nuts which secure the thermostat housing. Disconnect the ground cable from the housing and install the housing again after the cable is removed.
8. Disconnect the power brake vacuum line from the intake manifold.
9. Remove the fan shroud securing bolts and then the shroud itself. Remove the bolts which secure the fan clutch to the eccentric shaft pulley. Withdraw the fan and clutch as a single unit.

   CAUTION
   Keep the fan clutch in an upright position so that its fluid does not leak out.

10. Unfasten the clamps and remove both radiator hoses.
11. Note their respective positions and remove the spark plug cables. Disconnect the primary leads from the distributor and the distributor cap.
12. Detach all of the leads from the alternator, the water temperature sender, the oil pressure sender, and the starter motor.
13. Disconnect all of the wiring from the emission control system components.
14. Detach the heater hoses at the engine.
15. Detach the oil lines from the front and the rear of the engine.
16. Disconnect the battery cable from the positive (+) battery terminal and from the engine.
17. Unfasten the clutch slave cylinder retaining nuts from the clutch housing and tie the cylinder up and out of the way.

    NOTE: Do not remove the hydraulic line from the slave cylinder.

18. Remove the exhaust pipe and the thermal reactor.

    CAUTION
    Be sure that the thermal reactor has completely cooled; severe burns could result if it has not!

19. Remove the nuts and bolts, evenly and in two or three stages, which secure the clutch housing to the engine.
20. Support the transmission with a jack.
21. Remove the nuts from each of the engine mounts.
22. Attach a lifting sling to the lifting bracket on the rear of the engine housing.
23. Use a hoist to take up the slack on the sling.
24. Pull the engine forward until it clears the transmission input shaft. Lift the engine straight up and out of the truck.
25. Remove the hat stove from the exhaust manifold.
26. Remove the thermal reactor.
27. Mount the engine on a workstand. To install:
28. Install the thermal reactor.
29. Install the hat stove on the exhaust manifold.
30. Lower the engine into the truck. Push it rearward to engage the transmission.
31. Install the nuts on the engine mounts. Torque them to 40 ft. lbs.
32. Install the nuts and bolts which secure the clutch housing to the engine. Torque them to 40 ft. lbs.
33. Remove the transmission jack.
34. Remove the shop crane.
35. Install the exhaust pipe and the thermal reactor. Torque the nuts to 40 ft. lbs.
36. Install the clutch slave cylinder.
37. Connect the battery cable.
38. Connect the oil lines at the front and the rear of the engine.
39. Connect the heater hoses at the engine.
40. Connect all of the wiring to the emission control system components.
41. Connect all of the leads to the alternator, the water temperature sender, the oil pressure sender, and the starter motor.
42. Install the spark plug cables.
43. Connect the primary leads at the distributor and the distributor cap.
44. Install both radiator hoses.
45. Install the fan and clutch.
46. Install the fan shroud.
47. Connect the power brake vacuum line at the intake manifold.
48. Install the thermostat housing and ground cable.
49. Connect the accelerator cable, choke cable, and fuel lines at the carburetor.
50. Install the air cleaner, bracket, and hoses.
51. Connect the cable to the negative (–) battery terminal.
52. Fill the cooling system.
53. Fill the engine with the proper amount of oil.
54. Install the gravel shield.
55. Install the hood.