Engine

REMOVAL & INSTALLATION

1,586cc Engine

1. Scribe the locations of the hood hinges and remove the hood.
2. Remove the engine splash shield.
3. Drain the coolant.

   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.

4. Drain the engine oil.

   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. Disconnect the battery cables and remove the battery.
6. Disconnect the primary wire and coil wire from the distributor.
7. Disconnect the wire at the B terminal of the alternator and disconnect the plug from the rear of the alternator.
8. Disconnect the wire from the oil pressure switch.
9. Disconnect the engine ground wire.
10. Remove the air cleaner and heat insulator.
11. Disconnect the breather hose from the rocker cover.
12. Disconnect the water temperature gauge wire and solenoid valve wire.
13. Disconnect the starter wires.
14. Remove the upper and lower radiator hoses.
15. Remove the bolts attaching the radiator cowling. The cowling can only be removed after the radiator has been removed.
16. Unbolt and remove the radiator and cowling.
17. Disconnect the heater hoses from the intake manifold.
18. Disconnect the throttle cable from the carburetor and remove the throttle linkage from the rocker cover attaching point.
19. Disconnect the choke cable from the carburetor.
20. Disconnect the fuel ventilation hose from the oil separator.
21. Disconnect the fuel line at the carburetor and plug the fuel line.

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

22. Remove the starter.
23. Disconnect the exhaust pipe from the manifold.
24. Remove the clutch cover plate.
25. Support the transmission with a jack and remove the bolts attaching the engine to the transmission.
26. Unbolt the right and left engine mounts.
27. Attach a lifting sling to the engine and pull the engine forward until it clears the clutch shaft.
28. Lift the engine from the truck. To install:
29. Lower the engine into the truck.
30. Push the engine rearward until it engages the clutch shaft.
31. Install the bolts attaching the engine to the transmission. Torque the bolts to 40 ft. lbs.
32. Connect the right and left engine mounts. Torque the bolts to 45 ft. lbs.
33. Install the clutch cover plate.
34. Connect the exhaust pipe to the manifold.
35. Install the starter.
36. Connect the fuel line at the carburetor.
37. Connect the fuel ventilation hose at the oil separator.
38. Connect the choke cable at the carburetor.
39. Connect the throttle cable at the carburetor and install the throttle linkage at the rocker cover attaching point.
40. Connect the heater hoses.
41. Install the radiator and cowling.
42. Install the upper and lower radiator hoses.
43. Connect the starter wires.
44. Connect the water temperature gauge wire and solenoid valve wire.
45. Connect the breather at from the rocker cover.
46. Install the air cleaner and heat insulator.
47. Connect the engine ground wire.
48. Connect the wire at the oil pressure switch.
49. Connect the wire at the alternator.
50. Connect the primary wire and coil wire at the distributor.
51. Install the battery.
52. Connect the battery cables.
53. Fill the engine with the proper amount of oil.
54. Fill the cooling system.
55. Install the engine splash shield.
56. Install the hood.

1,796cc and 1,970cc Engines

1. Scribe the locations of the hood hinges and remove the hood.
2. Remove the engine splash shield.
3. Drain the coolant.

   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.

4. Drain the engine oil.

   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. Disconnect the battery cables and remove the battery.
6. Disconnect the primary wire and coil wire from the distributor.
7. Disconnect the wires at the alternator and disconnect the plug from the rear of the alternator. Remove the drive belts from the alternator, thermactor and air conditioning compressor. Remove each of these items from their mounting brackets and position them out of the way. It is not necessary to disconnect any refrigerant lines.
8. Disconnect the wire from the oil pressure switch.
9. Disconnect the engine ground wire.
10. Remove the air cleaner and heat insulator.
11. Disconnect the breather hose from the rocker cover.
12. Disconnect the water temperature gauge wire and solenoid valve wire.
13. Disconnect the starter wires.
14. Remove the upper and lower radiator hoses. On models with automatic transmission, disconnect the cooling lines at the radiator tank.
15. Remove the bolts attaching the radiator cowling. The cowling can only be removed after the radiator has been removed.
16. Unbolt and remove the radiator and cowling.
17. Disconnect the heater hoses from the intake manifold.
18. Disconnect the throttle cable from the carburetor and remove the throttle linkage from the rocker cover attaching point or the intake manifold clamps, on later models.
19. Disconnect the choke cable from the carburetor.
20. Disconnect the fuel ventilation hose from the oil separator.
21. Disconnect the fuel line at the carburetor and plug the fuel line.

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

22. Raise and support the truck on jackstands. Remove the starter.
23. Disconnect the exhaust pipe from the manifold.
24. Remove the engine skid plate. Remove the clutch cover plate. On trucks with automatic transmission, disconnect the vacuum line at the modulator. Remove the torque converter access cover, matchmark the converter and drive plate and remove the four converter-to-drive plate bolts.
25. Support the transmission with a jack and remove the bolts attaching the engine to the transmission.
26. Unbolt the right and left engine mounts.
27. Attach a lifting sling to the engine and pull the engine forward until it clears the clutch shaft.
28. Lift the engine from the truck. To install:
29. Lower the engine into the truck.
30. Pull the engine rearward until it engages the clutch shaft.
31. Install the bolts attaching the engine to the transmission. Torque them to 35 ft. lbs.
32. Connect the right and left engine mounts. Torque the bolts to 35 ft. lbs. Remove the shop crane.
33. Install the four converter-to-drive plate bolts. Torque them to 35 ft. lbs.
34. Install the torque converter access cover.
35. On trucks with automatic transmission, connect the vacuum line at the modulator.
36. Install the clutch cover plate.
37. Install the engine skid plate.
38. Connect the exhaust pipe at the manifold.
39. Install the starter.
40. Connect the fuel line at the carburetor.
41. Connect the fuel ventilation hose at the oil separator.
42. Connect the choke cable at the carburetor.
43. Connect the throttle cable at the carburetor.
44. Install the throttle linkage at the rocker cover attaching point or the intake manifold clamps, on later models.
45. Connect the heater hoses.
46. Install the radiator and cowling.
47. Install the upper and lower radiator hoses.
48. On models with automatic transmission, connect the cooling lines at the radiator tank.
49. Connect the starter wires.
50. Connect the water temperature gauge wire and solenoid valve wire.
51. Connect the breather hose at the rocker cover.
52. Install the air cleaner and heat insulator.
53. Connect the engine ground wire.
54. Connect the wire at the oil pressure switch.
55. Install the alternator.
56. Install the air pump.
57. Install the air conditioning compressor.
58. Connect the wires at the alternator.
59. Install the accessory drive belts.
60. Connect the primary wire and coil wire at the distributor.
61. Install the battery.
62. Connect the battery cables.
63. Fill the engine with the proper amount of oil.
64. Fill the cooling system.
65. Install the engine splash shield.
66. Install the hood.

1,998cc Engine

1. Scribe the locations of the hood hinges and remove the hood.
2. Remove the engine splash shield.
3. Drain the coolant.

   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.

4. Drain the engine oil.

   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. Disconnect the battery cables and remove the battery.
6. Remove the air cleaner and the oil dipstick.
7. Remove the radiator shroud and the engine fan. Place the fan in an upright position to avoid fluid loss from the fan clutch.
8. Disconnect and tag all wires, hoses, cables, pipes and linkage from the engine.

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

9. Remove the 3-way solenoid valves, but don't disconnect the vacuum tubes.
10. Remove the duty solenoid valves, but don't disconnect the vacuum tubes.
11. Remove the emissions canister.
12. Remove the radiator.
13. Disconnect the exhaust pipe at the manifold and remove the exhaust manifold.
14. Dismount the air conditioning compressor and position it out of the way. Don't disconnect any refrigerant lines.
15. Dismount the power steering pump and position it out of the way without disconnecting any hoses.
16. Raise and support the truck on jackstands.
17. Remove the starter.
18. Attach a lifting sling and shop crane to the engine lifting eyes and take up the weight of the engine.
19. Support the transmission with a floor jack and remove the transmission-to-engine bolts.
20. Remove the engine support plates and mounting nuts, push the engine forward to clear the transmission and lift it out of the truck. To install:
21. Lower the engine into the truck.
22. Push the engine rearward to engage the transmission.
23. Install the engine support plates and mounting nuts. Torque the nuts to 35 ft. lbs.
24. Install the transmission-to-engine bolts. Torque the bolts to 35 ft. lbs.
25. On trucks with automatic transmission, install the converter bolts. Torque them to 35 ft. lbs.
26. Remove the shop crane.
27. Install the starter.
28. Install the power steering pump.
29. Install the exhaust manifold. Torque the exhaust manifold-to-engine nuts to 16–21 ft. lbs.
30. Connect the exhaust pipe at the manifold.
31. Install the radiator.
32. Install the emissions canister.
33. Install the duty solenoid valves.
34. Install the 3-way solenoid valves.
35. Connect all wires, hoses, cables, pipes and linkage at the engine.
36. Install the radiator shroud and the engine fan.
37. Install the air cleaner and the oil dipstick.
38. Install the battery.
39. Connect the battery cables.
40. Fill the engine with the proper amount of oil.
41. Fill the cooling system.
42. Install the engine splash shield.
43. Install the hood.

2,209cc Diesel Engine

1. Scribe the locations of the hood hinges and remove the hood.
2. Remove the engine splash shield.
3. Drain the coolant.

   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.

4. Drain the engine oil.

   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. Disconnect the battery cables and remove the battery.
6. Remove the air cleaner and the oil dipstick.
7. Remove the radiator shroud and the engine fan. Place the fan in an upright position to avoid fluid loss from the fan clutch.
8. Disconnect and tag all wires, hoses, cables, pipes and linkage from the engine.

   CAUTION
   Never smoke when working around diesel fuel! Avoid all sources of sparks or ignition. Diesel fuel vapors are EXTREMELY volatile!

9. Remove the clutch release cylinder.
10. Remove the oil cooler.
11. Remove the radiator.
12. Disconnect the exhaust pipe at the manifold and remove the exhaust manifold.
13. Dismount the air conditioning compressor and position it out of the way. Don't disconnect any refrigerant lines.
14. Dismount the power steering pump and position it out of the way without disconnecting any hoses.
15. Raise and support the truck on jackstands.
16. Attach a lifting sling and shop crane to the engine lifting eyes and take up the weight of the engine.
17. Support the transmission with a floor jack and remove the transmission-to-engine bolts.
18. Remove the engine support plates and mounting nuts.
19. Push the engine forward to clear the transmission and lift it out of the truck. To install:
20. Lower the engine into the truck.
21. Push the engine rearward to engage the transmission.
22. Install the engine support plates and mounting nuts. Torque the nuts to 35 ft. lbs.
23. Install the transmission-to-engine bolts. Torque the bolts to 35 ft. lbs.
24. Remove the shop crane.
25. Install the power steering pump.
26. Install the air conditioning compressor.
27. Install the exhaust manifold.
28. Connect the exhaust pipe at the manifold.
29. Install the radiator.
30. Install the oil cooler.
31. Install the clutch release cylinder.
32. Connect all wires, hoses, cables, pipes and linkage at the engine.
33. Install the radiator shroud and the engine fan.
34. Install the air cleaner and the oil dipstick.
35. Install the battery.
36. Connect the battery cables.
37. Fill the engine with the proper amount of oil.
38. Fill the cooling system.
39. Install the engine splash shield.
40. Install the hood.