Engine: Service and Repair
REMOVAL1. Drain engine cooling system.
2. Disconnect battery ground cable, then underhood lamp wiring connector.
3. Mark position of hood hinge, then remove hood.
4. Disconnect generator to voltage regulator wiring assembly, then remove radiator upper sight shield.
5. Release drive belt tensioner and remove drive belt.
6. Remove air cleaner outlet tube as follows:
a. Disconnect wire harness from intake air temperature sensor, then crankcase ventilation tube from air cleaner outlet tube.
b. Loosen air cleaner tube clamps on outlet tube, then disconnect outlet tube from throttle body.
c. Disconnect outlet tube from mass airflow sensor, then remove tube.
7. Disconnect electric fan motor.
8. Disconnect constant control relay module at wiring connector, then remove radiator coolant recovery reservoir.
9. Remove radiator electric motor, fan blade, and fan shroud as an assembly.
10. Remove upper radiator hose.
11. On models equipped with automatic transmission, disconnect transmission oil cooler inlet and outlet tubes.
12. Disconnect heater inlet and heater return tube hoses.
13. Disconnect lower radiator hose at water pump, then remove radiator bolts and radiator.
14. Disconnect power steering pressure hose, then remove power steering pump and bracket and position aside.
15. Remove mass airflow sensor, then disconnect power steering pressure switch at wiring connector.
16. On models equipped with air conditioning, proceed as follows:
a. Disconnect A/C clutch from fuel charging wiring.
b. Discharge A/C system.
c. Disconnect A/C compressor lines. Cap or plug open lines.
d. Remove A/C compressor bolts, then compressor.
17. Remove wiring shield, then disconnect accelerator cable and speed control actuator from throttle body.
18. Remove accelerator cable bracket and position aside with cables.
19. Relieve fuel system pressure.
20. Disconnect fuel supply hose, then fuel return hose.
21. Disconnect fuel charging wiring from engine control sensor wiring at 40-pin connector.
22. Disconnect main vacuum source hose, then direct ignition control module at wiring connector.
23. Disconnect fuel vapor hose.
24. On models equipped with air conditioning, remove A/C compressor mounting bracket with drive belt tensioner attached.
25. Raise and support vehicle, then position drain pan beneath engine oil pan.
26. Drain engine oil, then remove oil filter and move drain pan away from vehicle.
27. Disconnect heated oxygen sensors.
28. Remove dual converter and pipe.
29. Remove inspection plug from engine rear plate.
30. On models equipped with automatic transmission, remove torque converter bolts.
31. Remove engine to transmission bolts.
32. On models equipped with automatic transmission, remove transmission oil cooler line retainers from righthand front engine support insulator.
33. Remove front engine support insulator to crossmember nuts.
34. Remove starter motor.
35. Remove ground cable, then starter motor wire harness retainers on both lefthand and righthand sides.
36. Partially lower vehicle, then position floor jack under transmission.
37. Position suitable engine lifting equipment, then remove engine assembly from vehicle and place on work stand.
INSTALLATION
NOTE: Lightly oil all bolt and stud threads before installation, except those specifying special sealant.
1. Install suitable engine lifting equipment and remove engine assembly from work stand.
2. Position engine in engine compartment, then install two engine to transmission bolts.
3. Lower engine onto front engine support insulators, then remove lifting equipment.
NOTE: Seat lefthand side front engine support insulator locating pin before righthand side front engine support insulator.
4. Remove floor jack from under transmission, then tighten two engine to transmission bolts.
5. Raise and support vehicle, then install remaining engine to transmission bolts and tighten all engine to transmission bolts.
6. On models equipped with automatic transmission, install torque converter bolts.
7. Install inspection plug to engine rear plate and front engine support insulator nuts.
8. Install starter motor.
9. On models equipped with automatic transmission, install transmission oil cooler line bracket.
10. On all models, install dual converter and pipe.
11. Connect heated oxygen sensors.
12. Install new oil filter, then lower vehicle.
13. On models equipped with air conditioning, install A/C compressor mounting bracket with drive belt tensioner attached.
14. Connect fuel vapor hose.
15. Install radiator coolant recovery reservoir, then connect constant control relay module at wiring connector.
16. Connect main vacuum source hose, then fuel charging wiring to engine control sensor wiring at 40-pin connector.
17. Connect ignition control module at wiring connector.
18. Remove plugs from fuel supply and return lines, then connect lines.
19. Install accelerator cable bracket, then connect accelerator cable and speed control actuator to throttle body.
20. Install wiring shield.
21. On models equipped with air conditioning, proceed as follows:
a. Install A/C compressor.
b. Remove caps or plugs on A/C compressor lines, then connect lines to compressor.
c. Connect A/C clutch to fuel charging wiring.
22. Connect power steering pressure switch at wiring connector, then install mass airflow sensor.
23. Install power steering pump and bracket, then connect power steering hoses.
24. Install radiator, then connect lower radiator hose to water pump.
25. Install heater inlet and heater return tube hoses.
26. On models equipped with automatic transmission, install transmission cooler lines.
27. On all models, install upper radiator hose.
28. Install radiator electric motor, fan blade and fan shroud as an assembly.
29. Connect electric fan motor to engine control sensor wiring.
30. Install radiator coolant recovery reservoir, then connect constant control relay module at wiring connector.
31. Position drive belt, then install radiator upper sight shield.
32. Install air cleaner outlet tube to throttle body as follows:
a. Position air cleaner outlet tube to vehicle, then connect air cleaner outlet tube to mass air flow sensor.
b. Connect air cleaner outlet tube to throttle body and install tube clamps to tube.
c. Connect crankcase ventilation tube to air cleaner outlet tube.
d. Connect wire harness to intake air temperature sensor.
33. Install hood to original marked position.
34. Connect underhood lamp wiring, then battery ground cable.
35. Refill crankcase to proper level with specified engine oil.
36. Refill engine cooling system.
37. On models equipped with air conditioning, evacuate, pressure test and recharge A/C system.
38. Start engine and check for leaks.