Operation CHARM: Car repair manuals for everyone.

Engine: Service and Repair


1. Disconnect battery cables.
2. Remove upper exhaust pipe to turbocharger attaching nut.
3. Disconnect air filter hose.
4. Remove rear preheat panel assembly.
5. Raise and support vehicle.
6. Disconnect red lead electrical connector from alternator assembly, then remove engine splash guard.
7. Remove lower right and left engine mount attaching nuts.
8. On manual transmission models, disconnect clutch cable from clutch fork.
9. Disconnect exhaust pipe from turbocharger assembly, transmission crossmember and coupling support brackets.
10. Loosen starter motor attaching bolts, then suspend starter motor from control arm strut. Use a piece of wire to suspend starter motor.
11. Remove flywheel housing attaching bolts. Leave at least 2 or 3 bolts in place to keep housing in position. Different size bellhousing bolts are used. Ensure to install correct bolt into its proper location. On manual transmission models, ensure to retain the two thick washers from either end of bellhousing and note positions from which they were removed for installation. On automatic transmission models, spring washers are used on all attaching bolts except the dipstick tube attaching bolts.
12. Disconnect coolant hoses from engine and allow engine coolant to drain as follows:
a. On models without drain tap, disconnect lower hose from cold start unit.
b. Disconnect lower hose from radiator.
c. On models with drain tap, loosen drain tap and allow coolant to drain.
d. Disconnect expansion tank hoses from radiator and upper radiator hose from engine.
13. Remove grille and fan shroud.
14. Remove radiator mounts and radiator.
15. Remove power steering pump and A/C compressor, then position aside.
16. Remove air filter.
17. Disconnect upper hose from heat exchanger. Disconnect vacuum hose from pump.
18. Disconnect and cap fuel lines from fuel filter and fuel connector manifold.
19. Disconnect throttle pulley cable.
20. Disconnect kickdown cable, if equipped.
21. On vehicles with cruise control, disconnect throttle cable and vacuum hose.
22. Disconnect glow plug relay from wheel housing. Separate cable harness, then disconnect spade terminal and positive lead from relay assembly.
23. Attach suitable engine lifting equipment onto engine.
24. On automatic transmission models, remove torque converter attaching bolts.
25. On manual transmission models, remove remaining bolts from flywheel housing.
26. Remove engine from vehicle.
27. Reverse procedure to install.