Engine: Service and Repair

The engine is removed without the transmission as follows:
1. Drain cooling system.
2. Mark hood hinge locations, disconnect underhood lamp, if equipped, and remove hood.
3. Disconnect battery cables and remove battery.
4. Disconnect alternator wiring and the ignition coil, distributor and oil pressure sender leads.
5. Remove TCS switch bracket from cylinder block, if equipped.
6. Disconnect flexible fuel line from fuel pump and plug line and pump port.
7. Disconnect engine ground strap.
8. Remove the right front engine support cushion to bracket screw.
9. If equipped with air conditioning:
a. Remove service valve covers and front seat valves.
b. Loosen service valve to compressor attaching nuts.
c. Bleed compressor refrigerant charge.
d. Remove service valves and cap compressor ports and service valves.
e. Disconnect clutch feed wire.
10. Remove starter.
11. Remove air cleaner and disconnect purge hose from canister and TAC vacuum hose from manifold, if equipped.
12. Disconnect throttle stop solenoid lead, if equipped.
13. Disconnect fuel return hose from fuel filter and the carburetor bowl vent hose from canister.
14. Disconnect throttle cable and remove from bracket. Disconnect throttle valve rod at carburetor and the bellcrank.
15. Disconnect carburetor stepper motor and oxygen sensor electrical connectors, if equipped.
16. Disconnect heater and air conditioning system vacuum hose from intake manifold.
17. Disconnect temperature sender wire and TCS vacuum solenoid wiring harness.
18. Disconnect radiator hoses from radiator and the heater hoses from engine.
19. Disconnect transmission oil cooler lines from radiator, if equipped.
20. Remove fan shroud attaching screws, then the radiator and shroud.
21. Remove fan and spacer. Install a 5/16 x 1/2 inch capscrew through fan pulley, into water pump flange.
22. Remove power brake vacuum check valve from power brake unit, if equipped.
23. If equipped with power steering, disconnect hoses from gear and drain reservoir. Cap gear ports and hoses.
24. Remove transmission filler tube bracket screw, if equipped.
25. Raise and support vehicle on jack stands.
26. If equipped with automatic transmission:
a. Remove converter housing spacer cover.
b. Remove converter attaching screws.
c. Remove exhaust pipe support from converter housing. This also supports the inner end of the transmission linkage.
27. If equipped with manual transmission:
a. Remove clutch housing cover and clutch bellcrank inner support screws.
b. Disconnect springs and remove bellcrank.
c. Remove outer bellcrank to strut rod bracket retainer.
d. Disconnect back-up lamp switch wiring harness under hood at dash panel to gain access to clutch housing screw.
28. On all models, remove engine mount cushion to bracket screws.
29. On Eagle models proceed as follows:
a. Support axle assembly, then remove half shaft to axle flange attaching bolts.
b. Compress half shafts inward, toward wheels, and secure to frame side sills with wire.
c. Remove axle bracket attaching bolts at axle tube and righthand engine mount, then remove axle bracket.
d. Remove axle bracket attaching bolts at pinion end of axle.
e. Remove left engine mount support to front axle bracket attaching bolts.
f. Disconnect axle vent hose, then lower axle assembly and remove from vehicle.
30. Disconnect exhaust pipe from manifold.
31. Remove upper converter or clutch housing screws and loosen the bottom screws.
32. Raise vehicle and support on jack stands.
33. Remove air conditioning compressor drive belt idler pulley and the compressor mounting bracket, if equipped.
34. Install suitable engine lifting equipment and slightly raise engine. Support transmission with a suitable jack.
35. Remove remaining converter or clutch housing screws.
36. Remove engine from vehicle.
37. Reverse procedure to install.