Engine Removal and Installation
TWO AND FOUR WHEEL DRIVE PICKUP MODELSNOTICE: If the engine is damaged Internally and a new engine assembly is installed in the vehicle, make sure all foreign material is completely flushed out of the cooling system. The oil cooler system should also be flushed out (If equipped). Failure to rid the oil or cooler system of debris can result in engine damage to the replacement engine.
Remove
Tool Required: J 41427 Universal Lift Bracket
1. Negative battery cable.
2. Hood.
- Raise the vehicle.
- Drain the engine oil.
3. Exhaust at the manifolds and loosen the hanger at the catalytic converter. This is necessary to remove the rear catalytic converter cushion mounts for removal of the exhaust assembly.
4. Under body shield.
5. Braces from the engine to the transmission, if equipped.
6. Slave cylinder or hydraulic line if cylinder is mounted inside the bellhousing.
7. Fuel line clamp at the bellhousing.
8. Starter motor.
9. Torque convertor bolts (if equipped) through the starter opening hole.
10. Oil filter.
Engine Frame Mount (2WD):
Engine Frame Mount (4WD):
Engine Mount Bracket:
11. Engine mount through-bolts.
12. Bellhousing bolts except the left upper.
- Lower the vehicle.
13. Battery ground cable at the engine.
14. Front drive axle bolts and roll axle down (4WD models only).
15. Air cleaner box and intake duct.
16. Engine cooling fan.
17. Air conditioning compressor and bracket.
18. Oil cooler, if equipped.
19. Radiator.
20. Power steering hoses at the steering gear and cap the lines.
21. Heater hoses from the intake manifold.
22. Wiring harness from the engine.
23. Vacuum lines.
24. Throttle cables.
25. Remaining bolt in the bell housing.
26. Fuel lines and bracket.
27. Ground strap from the rear of the cylinder head.
- Loosen the front body bolts (4WD models only).
- Support the transmission. Do no support under the transmission filter pan.
- Attach J 41427 to the right rear and left front bolts of the lower intake.
- Tighten retaining bolts to 15 N.m (11 lb. ft.).
28. Engine from the vehicle.
NOTE: If a new engine is to be installed, make sure any remaining components, brackets, or accessories are transferred to the new engine.
Install
1. Engine into the vehicle.
- Disconnect lifting device and J 41427.
- Tighten retaining bolts to 15 N.m (11 lb. ft.).
2. Tighten the front body bolts (4WD models only).
- Tighten fasteners to specifications.
3. Ground straps to the rear of the cylinder head.
4. Fuel lines and bracket.
5. Torque convertor bolts (if equipped) through the starter opening hole.
6. Left upper bellhousing bolt.
7. Throttle cables.
8. Vacuum lines.
9. Wiring harness to the engine.
10. Heater hoses.
11. Power steering hoses.
12. Radiator.
13. Oil cooler, if equipped.
14. Air conditioning compressor and bracket.
15. Belt.
16. Engine cooling fan assembly.
17. Air cleaner box and intake duct.
18. Front drive axle bolts and roll axle up into place (4WD models only).
- Raise the vehicle.
19. Battery ground strap to the engine block.
20. Bell housing bolts.
21. Engine mount through-bolts.
- Tighten bolts to 66 N.m (49 lb. ft.).
22. Oil filter.
23. Starter motor.
24. Fuel line clamp at the bellhousing.
25. Clutch slave cylinder and line (if equipped).
26. Braces.
27. Under body shield.
28. Catalytic converter y-pipe assembly and hangers.
29. Hood.
30. Proper quantity and grade of coolant into the cooling system.
31. Proper quantity and grade of engine oil into engine.
32. Proper quantity and grade of power steering fluid.
33. Negative battery cable.