Previous Next

Engine Assembly

Removal & Installation

To Remove:

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Relieve the fuel system pressure.
  3. Drain the cooling system and the engine oil.
  4. Disconnect the negative battery cable.
  5. Properly discharge the A/C system and remove radiator hoses.
  6. Remove the hood and the air cleaner outlet tube.
  7. Disconnect the upper and lower radiator hoses.

    CAUTION
    There are left-hand threads on the fan clutch.

  8. Use the fan clutch holding tool (303-239) to remove the fan clutch and fan blade as an assembly.
  9. Remove the drive belt, fan shroud, and radiator.
  10. Disconnect the heater hoses.
  11. Recover the A/C system.
  12. Disconnect the A/C manifold and tube and remove the nut then disconnect the A/C manifold and tube at the accumulator.
  13. Disconnect the electrical connectors for the A/C cut-out switch.
  14. Remove the nut and move the line to the side.
  15. Disconnect the A/C compressor wiring.
  16. Remove the fasteners and as an assembly, place the power steering pump, mounting bracket, and A/C compressor to the side.
  17. Disconnect the heater water hoses.
  18. Remove the nut and place the ground cable to the side.
  19. Relieve the fuel system pressure.
  20. Disconnect the fuel lines.
  21. Remove the accelerator control splash shield.
  22. Disconnect the accelerator cable and the speed control actuator cable then disconnect the vacuum line from the vacuum tee.
  23. Disconnect the vacuum lines and electrical connectors from the engine.
  24. Disconnect the PCM connector.
  25. Remove the nut from the PCM harness then remove the stud bolt and the PCM ground strap.
  26. Disconnect the generator wiring and place it to the side.
  27. Disconnect both heated oxygen sensors and the connectors for the transmission harness.
  28. Disconnect the vacuum line to the vacuum reservoir and the mass air flow (MAF) sensor.
  29. Safely raise and support the vehicle.
  30. Drain the engine oil.
  31. Remove the left-hand heated oxygen sensor.
  32. Disconnect the dual converter Y pipe from both exhaust manifolds.
  33. Remove the starter motor and the torque converter nuts.
  34. Disconnect the ground cable.
  35. Remove the transmission-to-engine bolts.
  36. Lower the vehicle.
  37. Install the engine lifting eyes (303-D030).
  38. Remove the 4 nuts and support the transmission then remove the engine from the vehicle then remove the flywheel.
  39. Mount the engine on an appropriate work stand.

To Install:

NOTE: In vehicles with automatic transmission, make sure the torque converter stud and flexplate marks made during removal are aligned.

  1. Attach the lifting eyes (303-D030) then remove the engine from the engine stand.
  2. Place the engine-to-transmission spacer plate.

    NOTE: Tighten the bolts in a star pattern.

  3. Install the flywheel. Torque to 54-64 ft-lb (73-87 Nm).
  4. Place the engine into the vehicle.
  5. Remove the support jack for the transmission.
  6. Install the 4 nuts. Torque to 65-95 ft-lb (88-130 Nm).
  7. Remove the lifting eyes.
  8. Safely raise and support the vehicle.
  9. Install the transmission-to-engine bolts. Torque to 23-39 ft-lb (38-51 Nm).
  10. Install the transmission cooler line bracket and bolt. Torque to 80-106 in-lb (9-12 Nm).
  11. Install the torque converter nuts. Torque to 26-ft-lb (35 Nm).
  12. Install the ground cable. Torque to 15 ft-lb (20 Nm).
  13. Install the starter motor.
  14. Connect the dual converter Y pipe.
  15. Install the left-hand HO2S.
  16. Lower the vehicle.
  17. Connect the engine sensor control wiring to the MAF sensor then connect the vacuum line to the vacuum reservoir.
  18. Connect the connectors for the transmission wiring harness then connect the engine sensor control wiring to both heated oxygen sensors.
  19. Place and connect the generator wiring harness.
  20. Install the PCM ground strap. Torque to 80-106 in-lb (9-12 Nm).
  21. Install the PCM wiring bracket.
  22. Connect the engine control wiring harness to the PCM. Torque to 45-61 in-lb (5-7 Nm).
  23. Connect the vacuum line to the evaporative emissions solenoid.
  24. Connect the connector for the engine control sensor wiring. Torque to 71-106 in-lb (8-12 Nm).
  25. Connect the vacuum lines.
  26. Install the accelerator cable and the speed control actuator cable. Torque to 71-106 in-lb (8-12 Nm).
  27. Install the accelerator control splash shield.
  28. Connect the fuel lines.
  29. Install the ground cable. Torque to 71-106 in-lb (8-12 Nm).
  30. Connect the heater water hoses.
  31. As an assembly, install the power steering pump, mounting bracket, and A/C compressor.
  32. Install the fuel line bracket. Torque to 71-106 in-lb (8-12 Nm).
  33. Connect the A/C compressor wiring.
  34. Position the A/C suction/discharge line and install the nut. Torque to 89-106 in-lb (10-12 Nm).
  35. Connect the A/C line at the accumulator.
  36. Install the suction/discharge manifold on the A/C compressor.
  37. Connect the engine sensor control wiring to the A/C cut-out switch.
  38. Install the radiator.
  39. Install the fan shroud. Torque to 54-70 in-lb (6-8 Nm).
  40. Install the drive belt.

    CAUTION
    There are left-hand threads on the fan clutch.

  41. Use the fan pulley holding wrench (303-239) to install the fan clutch and fan blade.
  42. Connect the upper and lower radiator hoses to the radiator.
  43. Install the air cleaner outlet tube and the hood.
  44. Connect the negative battery cable.
  45. Fill the engine with the correct type and amount of clean engine oil.
  46. Fill and bleed the engine cooling system.
  47. Charge the A/C system.
  48. Examine the engine and cooling system for leaks.

Previous Next