Engine: Service and Repair
ENGINE REPLACE1. Release fuel pressure as outlined under "Precautions.
2. Remove hood and battery.
3. Remove Electronic Control Module (ECM).
4. Remove fuel supply line at fuel rail and fuel return line at pressure regulator.
5. Remove purge valve from shock tower.
6. Remove RAM housing and air flow sensor.
7. Remove air cleaner assembly.
8. Disconnect throttle cable and position aside.
9. Remove battery tray.
10. Remove bolts from fuse box and position aside. Disconnect engine harness connectors from fuse box.
11. Remove engine harness and ground cables from engine.
12. Without disconnecting pressure lines, remove A/C compressor from mounting and position aside.
13. Remove cooling fan and viscous coupling.
14. Remove front grille, hood platform support, and air deflectors.
15. Remove washer bottle filler neck.
16. Disconnect engine and transmission oil cooler lines. Plug lines and position aside.
17. Disconnect coolant hoses from thermostat housing.
18. Remove power steering fluid reservoir from radiator, then the hoses from power steering pump.
19. Remove electrical connectors from transmission oil temperature sensor.
20. Remove radiator and cooling fans.
21. On models with manual transmission, perform the following:
a. Using a suitable brake hose clamp, clamp flexible clutch hose.
b. Disconnect flexible clutch hose at transmission pipe, and position aside.
22 On all models, remove window switch pack from center console, then the console.
23. Remove sound deadener pad from transmission tunnel, then the bolts securing gear shift lever.
24. Release handbrake and remove handbrake cable clevis pin. Disconnect handbrake cable.
25. Raise vehicle and drain engine oil, transmission fluid and transfer case fluid.
26. Support transmission using a suitable transmission jack.
27. Remove exhaust front pipe.
28. Remove rear propeller shaft guard, then the mark transfer case and propeller shaft flanges to aid reassembly.
29. Raise one wheel on each axle to allow rotation of propeller shaft.
30. Remove propeller shaft from transfer case and position aside.
31. On models with automatic transmission, disconnect gear selector cable trunnion from transmission lever. Remove bolts securing selector cable abutment bracket to transmission and position aside.
32. On all models, lower transmission and disconnect electrical connectors.
33. Remove engine mount nuts and discard.
34. Remove oil filler cap to avoid damage during engine lifting.
35. Place protective cloth over plenum chamber to avoid damage.
36. Attach suitable lifting bracket and hoist.
37. Lift engine slightly upward and forward, then remove engine and transmission. Engine and transmission assembly must be tilted at a 45 degrees angle before it can be removed from engine compartment.
38. Reverse procedure to install noting:
a. Bleed clutch hydraulic system.
b. Adjust gear selector lever cable.
c. Tighten to specification.