Engine: Service and Repair

ENGINE REMOVAL AND INSTALLATION

Removal

1. Disconnect battery negative cable.
2. Drain cooling system.
3. Remove air cleaner.
4. Disconnect left AIR hose at check valve.
5. Disconnect right AIR hose at check valve.
6. Disconnect AIR management hose at check valve.
7. Remove belt.
8. Remove A/C Compressor rear braces: one at intake and one at exhaust.
9. Disconnect A/C compressor wires.
10. Remove AIR pulley.
11. Remove AIR management valve adaptor at AIR pump.
12. Remove AIR pump bolts.
13. Remove AIR pump.
14. Remove radiator upper hose at thermostat outlet and power steering reservoir brace.
15. Disconnect alternator wires.
16. Remove alternator brace.
17. Remove alternator.
18. Remove AIR pipe at intake and power steering reservoir brace.
19. Remove power steering reservoir brace.
20. Remove power steering' pump lower bracket.
21. Move reservoir and brace, power steering pump and A/C wire loom to front.
22. Remove fuel inlet and return lines.
23. Remove A/C compressor and idler pulley bracket nuts at water pump.
24. Remove A/C lower mounting bolt.
25. Move bracket forward and remove A/C compressor upper bolt.
26. Remove compressor and lay aside.
27. Remove fuel lines lower bracket at former fuel pump cover plate.
28. Remove idler pulley bracket.
29. Remove lower radiator hose at water pump.
30. Remove heater hose at water pump.
31. Move hoses and fuel lines aside.
32. Disconnect accelerator, TV and cruise control cables from brackets and from TBI.
33. Disconnect brake vacuum and PCV at intake cover.
34. Disconnect electrical connections at TBI, front ground stud, coolant sensor and EGR solenoid.
35. Disconnect vacuum lines.
36. Remove wiring harness from valve cover clip. Move air management valve, AIR pipe and wiring harness to back right of engine.
37. Remove tach filter and ground wires from intake cover stud. Disconnect connections and wire from distributor cap.
38. Disconnect spark plug wires and remove distributor cap.
39. Remove heater hose from intake.
40. Mark distributor and remove distributor.
41. Remove oil sending unit.
42. Remove rear intake bolt and remove wire bracket.
43. Remove crankshaft pulley for clearance.
44. Raise vehicle.
45. Remove crossover pipe at manifold.
46. Remove crossover pipe at converter.
47. Remove hanger from crossover.
48. Remove converter air management pipe from right exhaust manifold.
49. Remove starter wires and sensor wire.
50. Disconnect coolant sensor wire at head and bracket on block.
51. Disconnect wire harness from oil pan, front of block, temperature sensor, oil temperature and oxygen sensor.
52. Disconnect battery ground and engine ground from rear of block above oil filter.
53. Remove flywheel cover.
54. Remove torque converter bolts.
55. Remove bellhousing bolts on right side. Remove lower bolt, then upper in order to gain access to center bolt. Remove bolts on left side including ground wire.
56. Support engine.
57. Remove right motor mount to block bolts.
58. Remove left motor mount to block bolts.
59. Lower vehicle.
60. Support transmission.
61. Attach lifting device and remove engine.
62. Disconnect wires at rear left head.

Installation

For installation, reverse removal procedures.